Requisitos especiales
Condiciones climáticas extremas, polvo fino o fuertes vibraciones de máquinas e instalaciones: los retos de la técnica de transporte como, por ejemplo, en la minería a cielo abierto, son enormes. En ocasiones, las cintas transportadoras empleadas deben transportar de forma fiable materias primas y materiales polvorientos o húmedos por recorridos de varios kilómetros. Si las cintas transportadoras se cargan de forma desigual dejan de desplazarse de forma centrada entre los rodillos transportadores, deberá corregirse el recorrido de la cinta o detenerse inmediatamente el sistema de cintas.
La tecnología de transporte es también un componente esencial de los procesos de fabricación y carga en muchos otros sectores, por lo que desempeña un papel decisivo en la eficacia de diversas aplicaciones. Debido al rápido crecimiento de la competencia internacional, especialmente en el campo de la tecnología de automatización, la mayoría de los procesos de producción están sometidos a una enorme presión para su optimización. Por eso es tan importante la fiabilidad de las cintas transportadoras y la capacidad de detenerlas de forma inmediata y segura en cualquier momento en caso de problemas de transporte o situaciones peligrosas.
Aparatos de conmutación para la protección en la tecnología de transporte.
Dependiendo del ámbito de uso y la industria, los conmutadores deben poder utilizarse en diferentes cintas transportadoras en entornos muy duros y, al mismo tiempo, cumplir los requisitos de seguridad, resistencia a la corrosión y robustez. Por ejemplo, el interruptor de emergencia accionado por cable de steute implementa la función de parada de emergencia fiable y el control de rotura de cable en sistemas más grandes. El interruptor de desplazamiento espontáneo de cinta controla el correcto funcionamiento de las cintas transportadoras y asegura así el proceso de transporte de material pesado a granel.
Además de productos relacionados con la seguridad, steute ofrece una amplia gama de aparatos de conmutación y sensores que contribuyen especialmente a la automatización y optimización de los procesos de fabricación. Los sensores y los interruptores de posición inalámbricos permiten, por ejemplo, un uso flexible para el recuento automatizado y la supervisión de cargas unitarias en procesos de producción.
Los robustos aparatos de conmutación y sensores también están disponibles con alto grado de protección IP o en diseño a prueba de explosión.
Conveyor belt set-up
- Emergency stop function
- Emergency pull-wire switches guarantee a reliable emergency stop function including wire-break monitoring on conveyor systems
- One-side actuation up to 100 m and two-side actuation up to 200 m
- Belt position monitoring
- Staggered contacts allow for a warning signal to initiate a belt correction
- Switch-off after further actuation of the belt alignment lever
- “Advance warning contacts” reduce standstill time of the conveyor-belt system
- Belt-rip detection
- Automatic switch-off of the equipment with overload or ripped conveyor-belt
- Extensive range of accessories
- Resorte compensador ZS 90/91/92 S
- Cable de tracción Ø 5 mm
- Tornillo de armella M 10 x 150 con 2 tuercas
- Dispositivo tensor de cable TS 65
- Rodillo de desvío Multiflex 4R
Emergency-stop function with robust emergency pull-wire switches
The emergency pull-wire switches in our ZS 92 S series were developed especially for extreme environments and applications. They are optionally available with a very robust die-cast aluminium enclosure with multiple coatings (passivation, primer, powder coating) or alternatively a high-quality thermoset enclosure. Our range includes 2G/D variants for Ex zones 1 and 21, as well as 3D variants for Ex zone 22.
The ZS 92 S emergency pull-wire switch assumes the emergency-stop function along conveyors, can be actuated at any point along the wire and contributes significantly to personal and machine safety.
Opción de montaje posterior e inferior
The ZS 92 S series can be mounted both from the rear and from below. The mounting dimensions are compatible with other emergency pull-wire switches on the market, simplifying retrofitting or replacement within existing conveyor systems.
Optionally available as a Dupline safe variant
The ZS 92 S emergency pull-wire switch is optionally available with an integrated 8-pole Phoenix multi-way connector and bracket for safety bus module. The safety bus module is available as an accessory in different versions and facilitates connection to the “Dupline safe” protocol.
Extremely flexible thanks to various settings
The ZS 92 S emergency pull-wire switches are available with different settings for the release lever and unlocking mechanism. They can therefore be installed more or less anywhere.
Avisador luminoso LED
The ZS 92 S emergency pull-wire switch is optionally available with an LED indicator lamp. This lamp lights up red when the emergency pull-wire switch is actuated, making it possible to see immediately where along the conveyor belt the stop was initiated and intervention is required.
Comprehensive and innovative accessories for emergency pull-wire switches
Emergency pull-wire switches are crucial to safety in plants with industrial conveyors. They facilitate the triggering of an emergency stop anywhere along the belt. But in order to exploit the full potential of these switches and adapt them to individual requirements, it is vital to have the correct accessories. In the following, we will present a few tried and tested accessories which can increase the functionality and flexibility of emergency pull-wire switches.
Comparativa de instalación: Tensor y sujetacables vs. arrollador de cable TS 65
TS 65 wire tensioner - quick, easy, efficient!
Fewer steps, more efficiency! Our expert Matthias Schara challenged himself at the Rhein-Umschlag gravel works to perform an installation contest: the widespread conventional method of pull-wire installation using turnbuckles, cable clamps and thimbles against state-of-the-art installation using the innovative TS 65 wire tensioner from steute. The result: the complete pull-wire installation took over 9 minutes versus just 42 seconds! The TS 65 wire tensioner not only saves a considerable amount of time, but also significantly reduces the number of necessary steps and tools.
Perfect team
Particularly in plants where many switching devices are installed, the factors time and ease are very much a focal point. Holding on to conventional methods can hinder efficiency. For simplifying installation and saving not only time and money, but also manpower, the combination of a ZS 92 S pull-wire switch and a TS 65 wire tensioner is unbeatable. See for yourself in our new video.
Additional accessories for emergency pull-wire switches
Resorte compensador ZS 90/91/92 S
- Con limitación de carrera
- Para la compensación de variaciones de longitud en caso de fluctuaciones de temperatura
- Versión formada por: cadena de acero inoxidable, 2 mosquetones galvanizados y resorte de tracción
Tornillo de armella
- 150 mm de longitud, 70 mm de longitud de rosca
- Rosca M10
- Acero cincado
- 2 tuercas hexagonales incluidas en el suministro
Rodillo de desvío Multiflex 4R
- Desviación del cable de tracción hasta 90°
- Fricción reducida
- Montaje flexible
- Adaptación automática de la guía de cable mediante cabeza giratoria (360°) también para el cable de tracción
- Rodillos móviles dentro de la abertura de la polea de inversión
Cable de tracción Ø 5 mm
- Alma de acero o alma de acero inoxidable Ø 3 mm funda roja de PVC
- Diámetro total 5 mm
- Unidad de pedido: por metro
Here you will find a comprehensive overview of our versatile accessories for emergency pull-wire switches.
Position monitoring of conveyor belts using freely adjustable belt alignment switches
The belt alignment switches in our ZS 92 SR series are true specialists when it comes to extreme environments. All products in this series feature outstanding mechanical robustness and come either in a die-cast aluminium enclosure or a thermoset plastic enclosure (-KST). Also available are the Ex ZS 92 SR-2D (for dust Ex zone 21) and the Ex ZS 92 SR-3D (for dust Ex zone 22), both in a die-cast aluminium enclosure.
Our belt alignment switches monitor the straight course of conveyor belts. A large stainless steel roller lever swings to one side if the belt is no longer aligned between the rollers, for example because it is unevenly loaded. Depending on the control settings, this can either enable a correction of the belt or stop the entire conveyor. Its robust construction and special design for extreme environments make the ZS 92 SR series a reliable solution for complex applications.
Staggered contacts facilitate advance warning to enable timely belt correction
A truly outstanding feature is staggered contacts with individually adjustable switching points. The switching points for advance warning and for shutting off the conveyor can each be set within a range of 5°-35°. All that is necessary is a simple unlatching, shifting and relatching of the switch inserts. The switch can then first send an advance warning, and only if the lever swings out further will the conveyor shut down. These "advance warning contacts“ reduce standstills: the operator has a chance to intervene before the belt stops.
Different variants for roller lever adjustment
Some variants have a self-locking shaft (positive engagement), enabling the shaft to be changed quickly, while others have a continuously adjustable shaft, enabling the the default position of the roller lever to be adjusted to the individual application case.
Avisador luminoso LED
The ZS 92 SR belt alignment switch is optionally available with an LED indicator lamp which displays the switching state. This makes it possible to see along the conveyor from a distance where exactly the belt is no longer aligned.
Innovative wireless solution for belt alignment monitoring
Combining our tried-and-tested ZS 92 SR belt alignment switch with a separate RF I/O radio module has opened up new possibilities for efficient and interference-free conveyor control. Using sWave technology, a transmitter unit sends the signals coming from the switch to a wireless relay component which functions as a receiver. The transmission functions reliably and without cables over distances of up to 400 metres in the field. Additional repeaters can be installed for greater distances.
This robust wireless switching system has considerable benefits, especially in adverse environments, and unites the core steute competences switchgear and wireless technology.
Innovative belt-rip detection system
Do not let a simple rip in your conveyor belt lead to catastrophic failure and costly downtime. The ZS 71 belt rip detection switch and wire system can safeguard your operations by providing early detection and swift action. With its belt-rip features, robust construction, and user-friendly design, the ZS 71 belt-rip detection switch offers peace of mind and uninterrupted productivity. The ZS 71, combined with the comprehensive wire kit, offers a complete solution for belt-rip detection. When a rip occurs in the belt, any material or ripped section of conveyor belt caught by the wire activates the switch, halting the conveyor operation.
With its quick detection and immediate action upon belt rip occurrence, the switch significantly minimises conveyor system downtime, saving you valuable time and resources. The ZS 71 belt-rip detection switch is compact and designed to fit perpendicular to the conveyor belt, even in restrictive spaces.
Belt-rip detection system set-up
- ZS 71 belt-rip detection switch ZS 71
- 1 x mosquetón (acero inoxidable)
- 1 x llavero (acero inoxidable)
- 1 x acoplamiento de seguridad
- 2 x abrazaderas de plástico
- 5 m cable metálico, Ø 3-5mm PVC rojo
- 1 x tensor de cable TS 65
- 2 x armellas BM 8x70 (acero inoxidable) con 2 tuercas
- 2 x guía de cable (acero inoxidable) con 2 x tuercas M10 y arandelas
Conveyor belts can be safeguarded with either one or two belt-rip detection switches.
Wire system
El acoplamiento de seguridad integrado desconecta de forma segura el interruptor de control de rotura de cinta del sistema de cable en caso de sobrecarga mecánica (> 250 N). A continuación, puede volver a conectarse fácilmente.
References
Our solutions are used all over the world in a wide variety of projects and fields throughout many different branches of industry. Here you can find a selection of renowned companies which successfully deploy steute products:
- Herrenknecht / H+E Logistik GmbH, Germany
(tunnel boring machines and tunnelling) - STM Industriale S.P.A., Italy
(conveyor systems) - Rhein-Umschlag GmbH, Germany
(gravel and sand works) - Mineraria Ligure S.r.l., Italy
(manufacturing of powders, pebble stones and marble granulates) - VHV Anlagenbau, Germany
(conveyor technology) - alco energy, Netherlands
(biorefinery) - ABB, Germany
(automation) - AMAGGI Exportacao e Importacao Ltda, Brazil
(processing of grain and fertilisers) - CENIBRA Celulose Nipo-Brasileira S.A., Brazil
(pulp & paper industry)
- COPI - Companhia Operadora Portuária do Itaqui, Brazil
(Itaqi port operator, unloading, transporting and storing of fertilisers and other mass imports) - RUMO MALHA NORTE SA, Brazil
(logistics for grain, fertilisers, soya and sugar) - TERMINAL MARITIMO DO GUARUJA SA TERMAG, Brazil
(port terminal, unloading of fertilisers) - VALE SA, Brazil
(mining) - VLI MULTIMODAL SA, Brazil
(logistics for grain and mining) - YARA BRASIL FERTILIZANTES SA, Brazil
(fertiliser production) - Rio Tinto, Guinea
(mining)
Productos para la técnica de transporte
Tiradores de emergencia por cable
Interruptores de alineamiento de correas
Interruptores de control de rotura de cinta
Interruptores de posición
