10–15 Ton Compact Dual-Rope Winch Tensioning System Engineering Solution

Project Background

The client's site features a heavy-duty belt conveying system operating long-term under:

High-dust environments

High-humidity conditions

Heavy-load material transport

The original system employed a vertical counterweight tensioning structure, a traditional mechanical tensioning method.

Following production line upgrades and structural adjustments, internal space has been significantly reduced, rendering the existing tensioning system inadequate for new operational requirements.

Issues with Existing System

Based on site photos and discussions, the original system exhibits the following core problems:

1️⃣ Excessive Space Occupancy

The tall vertical structure consumes substantial vertical space, which cannot be retained for the new project.

2️⃣ Severe Structural Aging

Noticeable corrosion

Difficult maintenance

Declining reliability

3️⃣ Incompatibility with new conditions

The new project's installation area has limited internal space, precluding the placement of large-volume vertical tensioning devices.

Customer's Core Technical Requirements

Based on preliminary discussions, the customer explicitly requested the following:

✔ Tensioning capacity

10–15 tons

✔ Maximum displacement range

1.3 meters effective stroke

✔ Dual-rope design

Symmetrical force distribution

Enhanced tensioning stability

Reduce risk of uneven loading

✔ Two control system options

Client requires separate proposals for:

Option A: Manual Control System

Cost-priority

Button operation

Retains basic protective functions

Option B: PLC Automatic Control System

Optional load cells

Automatic tension adjustment

Variable frequency control

Closed-loop tension management

✔ Key Constraints

Installation space significantly smaller than original model

Equipment dimensions must be optimized

Must be embeddable within existing steel structure framework

Implementation Technical Solution

To meet dual requirements for space and load capacity, we designed:

Compact Horizontal Dual-Rope Winch Tensioning System

1️⃣ Optimized Mechanical Structure Design

Low-profile horizontal layout

Replaces original vertical structure

Significantly reduces vertical footprint

Suitable for confined space installation

Dual-rope drum configuration

Single drum with symmetrical dual-side rope payout

Or dual-drum balanced structure

Ensures balanced force distribution

Enhances tensioning stability

Stroke-Matching Design

Through optimized pulley ratio and rope path design:

Achieves 1.3-meter effective displacement

Ensures 10–15-ton tensioning capacity

2️⃣ Manual Control Solution (Economy Type)

Suitable for budget-sensitive projects.

Configuration includes:

Heavy-duty electric winch

Dual-rope-exit structure

Mechanical limit protection

Slack rope detection

Local button control

Emergency stop system

Features:

Lower cost

Simple structure

Easy maintenance

Suitable for infrequent tension changes

3️⃣ PLC Automatic Control Solution (Smart)

Suitable for scenarios with significant load fluctuations and high stability requirements.

System configuration:

Variable frequency drive motor

PLC control system

HMI operating interface

Optional load cell

Closed-loop automatic tension adjustment

Automatic Operation Logic:

Set target tension

Automatically start when reaching lower limit

Automatically stop when reaching upper limit

Real-time tension data display

Automatic belt elongation compensation

Advantages:

Extends conveyor belt lifespan

Reduces slippage and impact

Enhances system safety

Minimizes manual intervention

4️⃣ Compact Dimensions Design Principle

To address the core constraint of “limited installation space,” we:

Optimize frame structure

Minimized unnecessary external dimensions

Compact arrangement of drive and drum

Remote control cabinet placement

Goal:

Significantly smaller equipment size than original vertical tensioning systems

Adaptable to retrofit project space constraints

Technical Specifications

Project Implementation Value

This solution not only resolves space constraints but also delivers the following engineering benefits:

✔ Successfully replaces traditional vertical tensioning structures

Enables structural upgrades and retrofits.

✔ Enhanced system stability

Dual-rope design ensures balanced force distribution.

✔ Tiered cost options

Accommodates varying budget requirements.

✔ Supports automation upgrades

Reserves interfaces for future intelligent system retrofits.

✔ Reduced maintenance risks

Minimizes structural aging and manual adjustment hazards.

Project Positioning Summary

This project delivers:

10–15 ton tensioning capacity

Dual-rope symmetrical structure

Manual/PLC automatic control options

Upgradeable closed-loop tension control

for industrial conveyor system retrofit winch tensioning solutions.

FAQ

Q1: Does Kailude support non-standard stroke designs?

A: Custom stroke ranges available per site requirements.

Q2: Can the winch structure undergo anti-corrosion treatment?

A: Supports sandblasting, anti-corrosion spraying, and heavy-duty anti-corrosion solutions.

Q3: Is the dual-rope structure more stable than single-rope?

A: Symmetrical force distribution in dual-rope design significantly reduces load imbalance risks.

Q4: Does Kailude provide PLC control program support?

A: Complete control logic and parameter configuration support available.

Q5: Does Kailude have industrial heavy-duty application cases?

A: Proven experience in mining, power plants, ports, and other industries.