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Conveyor Protection

Protecting

Conveyor Protection

Stop the conveyor early and avoid major damage.

Reduce unplanned downtime and prevent conveyor belt damage with a practical conveyor fault detection system designed for harsh Australian conditions, including mining operations.

Pacific Automation's Smart Series devices detect critical conveyor failure points: belt rip events, belt slip, belt tear and spillage, and blocked chutes, allowing you to stop the conveyor early and avoid major damage.

Applies to
Mining & Mineral Processing Bulk Handling Overland Conveyors Transfer Points
✓ Five layered protection devices ✓ Staged pre-warn and trip contacts ✓ Built for dust, wet and corrosive duty
Smart Series conveyor protection on a mine site conveyor

Key benefits

Four failure modes caught before they become a belt replacement.

Belt rip detection

Detect belt rip events before damage spreads

Under-speed and drive pulley slip detection

Detect under-speed and drive pulley slip conditions

Belt tear and spillage detection

Detect belt tear and spillage on feed and return belts

Blocked chute detection

Detect blocked chute build-up to prevent chute blockage shutdown

It starts before the order

Three questions we ask alongside the part number, so the devices you fit catch the failures your conveyor actually has.

Question one

Where does it run?

Conveyor length, transfer points, dust load, wet or corrosive conditions, and whether it is an overland run or a plant conveyor.

Question two

What is it doing?

Which failure modes you have seen: drift, rip, spillage, slip or chute blockage. Whether you want a pre-warn stage before the trip.

Question three

What if it is wrong?

A belt replaced instead of repaired, a blocked chute dug out by hand, nuisance trips, unplanned downtime.

Conveyor protection devices

Five Smart Series devices, each covering one failure mode. Layer them for full coverage.

Smart Drift belt misalignment switch

Smart Drift

Belt misalignment switch

Function: detects conveyor belt misalignment

Purpose: prevents belt edge damage and structural wear

Smart Drift detects when the belt tracks off-centre. Pre-warn and trip contacts allow staged shutdown response.

Key features
Dual-stage contacts: pre-warn at 10° and final trip at 20°
Adjustable settings
Designed for harsh industrial environments
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Smart Rip belt rip detection system

Smart Rip

Belt rip detection system

Function: belt rip detection

Purpose: stops the conveyor when a longitudinal rip occurs

Smart Rip detects belt rip events using a mechanical activation system that triggers shutdown when a rip pulls the detection pin.

Key features
IP67 sealed construction
Chemical resistant and corrosion-proof design
Designed for harsh mining environments
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Smart Spill belt tear and spillage detection

Smart Spill

Belt tear & spillage detection

Function: detects material spillage or belt tear

Purpose: prevents escalation of belt tear events

Smart Spill detects spillage caused by a torn conveyor belt. When material collects and activates the device, the conveyor trips before major belt damage occurs.

Key features
Triggers alert before damage escalates
Designed for feed and return belt installations
Adjustable sensitivity
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Smart Slip belt speed and slip detection

Smart Slip

Belt speed / slip detection

Function: detects drive pulley slip or under-speed

Purpose: prevents belt damage caused by slipping or overloading

Smart Slip monitors conveyor speed and trips if belt speed drops below operating threshold.

Key features
Tilt basket or magnetic proximity switching options (model dependent)
Trips on slip detection
Start-up bypass to avoid nuisance trips
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Smart Block blocked chute detector

Smart Block

Blocked chute detector

Function: detects blocked chutes

Purpose: prevents chute blockage shutdown and belt damage

Smart Block detects material build-up inside transfer chutes and trips the conveyor before severe blockages occur.

Key features
Trips when tilted beyond 35° in either direction
Stainless steel construction
IP68 rated
Recommended short PLC delay to prevent nuisance trips
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Layer them for full coverage

No single device prevents all failure modes. Tell us the conveyor and we will scope the combination that suits the risks you actually carry.

Get in Touch

Ask about Smart Series

Let us help you find the right conveyor safety solution for your site.

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A layered system

No single device prevents all failure modes

A properly engineered conveyor belt protection system should include belt misalignment detection, belt rip detection, belt tear and spillage monitoring, slip and speed monitoring, blocked chute detection, and emergency stop coverage.

Together, these layers help
Prevent conveyor belt damage
Avoid belt rip failure
Prevent chute blockage shutdown
Reduce unplanned downtime
Improve site safety compliance
Smart Series conveyor safety system whitepaper

Learn more about the whole system

Check out our whitepaper to read about how these protection devices come together to make the complete Smart Series conveyor safety system.

Download the Whitepaper

Designed for Australian mining and heavy industry

The Smart Series is engineered for harsh environments including:

Dust-heavy applications

Wet and corrosive conditions

High-load mining conveyors

Long overland conveyor systems

Whether you need a belt misalignment switch, belt rip detection or a blocked chute sensor, Pacific Automation can help specify the correct combination.

Tell us your conveyor and we will recommend a layered protection solution

Send us the conveyor length, the transfer points, the known failure risks and the operating environment. Our team will recommend a practical, layered conveyor belt protection solution tailored to your site.

We supply and support the product. Your team or your integrator installs and commissions it. We make sure it is the right one.