The belt conveyor has revolutionized mining by replacing labour-intensive, time-consuming methods of transporting bulk materials. However, anywhere there is product in motion, there will be challenges.
One key concern in conveyor systems is belt damage in the loading zone. Jagged lumps of material can tear or abrade the belt, while foreign objects such as scrap metal and roof bolts may puncture the belt, causing extensive rips and jams. Additionally, the impact of loaded materials can damage idlers and conveyor structures, leading to costly downtime.
Over two decades ago, Richwood Inc., headquartered in Huntington, WV, USA, introduced a groundbreaking innovation to address these challenges: the original, full belt width, Impact Saddle®. This innovation revolutionized conveyor belt support technology by replacing conventional impact idlers with a design that offers continuous support across the entire belt width. Today, Richwood remains at the forefront of conveyor solutions, leading the way in belt protection and dust containment for mining and industrial operations worldwide.
A stable foundation for dust and material containment
In addition to preventing belt damage, Richwood’s solutions have evolved to meet the growing importance of environmental compliance and operational efficiency, particularly in the mining sector. A trustworthy foundation at transfer points is now critical not just for belt longevity but also for controlling dust and material spillage. The Impact Saddle® is a key component to a well-designed impact area. It minimizes belt sag and ensures proper alignment, reducing the risk of dust emissions and material loss. By keeping material securely on the belt, operators can improve productivity and meet stringent environmental and safety standards.
From innovation to industry standard: Replacing impact idlers
Traditional impact idlers, which use rubber-coated rolls to absorb energy, were initially designed to protect idler rolls rather than conveyor belts. These systems leave belts unsupported between rolls, making them vulnerable to punctures, tears, and premature failure due to flexing at junction points. Impact Saddles® eliminated these vulnerabilities with their fully supportive design, which features a seamless surface across the belt’s width. This advancement has since become an industry benchmark for effective belt protection.
Impact Saddles® provide continuous support that protects the belt from tramp materials that can penetrate and rip the belt. The smooth, curved trough design supports the belt over the entire surface, preventing punctures and tears caused by sharp or heavy debris. This unique design eliminates the hazards commonly seen in alternative systems, such as bar slider beds or typical impact idlers:
Bar Slider Beds: Typical issues include pinch points and support gaps between slide surfaces that create belt hazards that can lead to wear and failure. This is seen in Image 1.
Impact Idlers: Unsupported areas between rollers result in idler junction points where stress concentrates, increasing the risk of belt damage and early failure, as seen in Image 2.
Full belt support: Preventing compression and elongation damage
Belts typically fail when their compression or elongation limits are exceeded. When an unsupported conveyor belt stretches under the impact of falling material, it becomes more susceptible to punctures and tears.
The Impact Saddle® eliminates this issue by providing continuous support, controlling both compression and elongation stresses to preserve the belt’s integrity.
Managing impact energy
A three-pronged approach in the design of the saddle allows it to manage impact energy:
Distribution: Impact on one segment is spread evenly across the entire segment’s area, reducing localized stress.
Isolation: Each segment is supported by rubber cushions, isolating impacts to specific zones and preventing energy transfer to other parts of the belt.
Absorption: The system uses materials like UHMW segments and rubber cushions to absorb and dissipate impact energy over time, as seen in Image 3.
More than two decades after its introduction, the Impact Saddle® continues to set the standard for conveyor belt support systems. Richwood’s commitment to innovation ensures that its solutions evolve to address the most pressing challenges in mining, including belt protection, dust containment, and environmental compliance. By choosing technologies like the Impact Saddle®, operators can extend belt life, reduce maintenance costs, and maintain environmental and safety goals.
With its proven track record and continued innovation, Richwood remains the leader in transforming conveyor load zones with systems that are reliable, efficient, and useful for compliance—even in the most demanding conditions.
For more information, contact info@richwood.com.
