Cross-Belt Sweeper

The Cross-Belt Sweeper (CBSw) is an automated tramp metal removal system engineered to detect and extract unwanted metal contaminants from bulk materials transported on conveyor belts, without stopping the belt or interrupting the material flow. Using a high-precision metal detection system, the CBSw identifies and removes tramp metal efficiently while minimising the loss of usable material during the extraction process.

The system is designed for broad compatibility, capable of integration with conveyor belts of any size, speed, or construction. This versatility makes it a practical solution across a wide range of industrial bulk material handling applications where metal contamination poses a risk to downstream equipment, product quality, or operational safety. By removing tramp metal automatically and continuously from the conveyor stream, the CBSw reduces the risk of equipment damage caused by metal passing through crushers, mills, and other processing equipment, and minimises the unplanned downtime and repair costs that metal contamination incidents can cause.

For mining, minerals processing, aggregates, recycling, and other bulk material handling industries in Australia where conveyor belt throughput and operational continuity are ongoing priorities, the CBSw provides a cost-effective and reliable tramp metal removal solution that enhances both safety and productivity without requiring manual monitoring or intervention during normal operation.

The Cross-Belt Sweeper (CBSw) is a rugged, cost-effective solution engineered for the demanding conditions of the mining industry. It efficiently removes tramp metal from conveyor belts, safeguarding crushers, screens, and other downstream equipment.

Key Benefits for Mining Operations:

• Protects critical mining equipment by removing harmful debris from the conveyor belt before it causes damage.
• Designed to withstand heavy-duty use and tailored to the specific types of tramp metal found in your operation.
• Easily integrates into current conveyor setups, making it ideal for both new and existing mines.
• Removes tramp metal without halting production, increasing throughput, and reducing delays.
• Prevents costly downtime and repairs due to metal contamination in crushers, mills, and processing equipment.
• Reduces wear and tear on equipment, extending service life and cutting down on unplanned maintenance.

Designed for durability and efficiency, the CBSw Cross-Belt Sweeper keeps your mining operation running safely, smoothly, and cost-effectively.

The Cross-Belt Sweeper operates through a rotating, counter-weighted sweeper arm that performs a 360-degree motion perpendicular to the conveyor belt’s material flow. Powered by a gear brake motor, the sweeper arm delivers precise and controlled movement through the material stream, ensuring effective and targeted tramp metal extraction with each triggered cycle.

The conveyor belt is stabilised and guided during operation by a pair of inclined rollers or guiding plates, maintaining consistent belt alignment and ensuring that the sweeper arm follows the contoured profile of the supported belt closely throughout its sweep. This close conformance to the belt surface is important for effective metal extraction, as it minimises the gap between the sweeper arm and the material stream and reduces the likelihood of tramp metal passing beneath the sweeper without being captured.

When triggered automatically by the metal detection system, the sweeper arm is rapidly accelerated by the electric motor and sweeps through the material stream in a circular motion, removing the detected metal contaminant from the conveyor flow and diverting it away from the usable material. The speed and motion of the sweep are designed to extract the target material efficiently while keeping the loss of surrounding bulk material to a minimum.

The entire unit is enclosed in a durable cover housing that protects the mechanical and electrical components from the dust, moisture, and impact common in bulk material handling environments. Easy-access hatches on the housing allow operators to carry out inspection, cleaning, and routine maintenance quickly without requiring significant disassembly, minimising maintenance downtime and making the system straightforward to service over its operational lifespan.

The Cross-Belt Sweeper is controlled through an integrated control system that manages metal detection triggering, sweeper arm activation, and operational monitoring from a single point. When the metal detection system identifies a contaminant in the material stream, the control system automatically calculates the timing required to activate the sweeper arm at the precise moment the detected metal reaches the sweep zone, accounting for belt speed and the distance between the detection point and the sweeper position. This automated trigger and timing logic ensures that the sweeper arm is activated accurately and consistently without requiring operator intervention during normal operation.

Operational parameters including belt speed, detection sensitivity, sweep timing, and activation delays can be configured through the control interface to suit the specific characteristics of each conveyor installation and material type. These settings can be stored and recalled for different operational modes or material profiles, supporting consistent performance across varying production conditions without requiring manual recalibration between runs.

Real-time system monitoring provides operators with continuous visibility over detection events, sweeper activations, and system status, allowing operational performance to be reviewed and any anomalies to be identified and addressed promptly. Event logging captures a timestamped record of every detection and sweep activation, providing a traceable history of tramp metal removal activity that supports maintenance planning, operational reporting, and quality assurance documentation requirements.

Integration with plant-wide SCADA and process control systems is supported through standard industrial communication interfaces, allowing the Cross-Belt Sweeper to operate as a connected component within the broader conveyor and material handling control environment. Alarm and notification functions alert operators to system faults, maintenance requirements, or detection anomalies, supporting a proactive approach to system management and minimising the risk of unplanned downtime in continuous bulk material handling operations across Australia.