Skip to main content

Voith’s BeltGenius ALEX to help optimise belt alignment in conveyor systems

Published by , Assistant Editor
Global Mining Review,

Voith’s new BeltGenius ALEX (Alignment Expert) is designed to reduce the energy consumption and idler wear of conveyor systems. This piece of equipment analyses the alignment of carrying idlers in conveyor systems as part of its service portfolio. As soon as the system sensors detect a deviation from the set values during their temporary measurement, BeltGenius ALEX reports the problem and provides specific solution suggestions. In first installations, the system greatly reduced idler wear, energy costs, and associated CO2 emissions. 

Reliable belt conveyor operation is key to productivity in mines. Even small deviations from the optimum alignment increase energy consumption and lead to belt mistracking, with considerable material spillage and downtime. In addition, inaccurate alignment increases idler wear. This, in turn, leads again to unscheduled downtimes and high costs for spare parts. 

By using the BeltGenius ALEX developed by Voith, mine operators can avoid such expense and production losses. Voith service employees attach the measuring sensors to the edges of the belt on both sides. These sensors measure the alignment of each individual carrying idler. BeltGenius ALEX digitally measures all data and stores them on an integrated SD card. The sensor system detects exactly which carrying idlers and idler frames are affected and automatically analyses the origin of the problem.

During the process, each individual idler seat is measured. The analysis data are listed in a well-organised log that contains specific work instructions. These data include, among other things, information about which idlers are critical, as well as how big an adjustment must be made, in which direction,  and how far.

The result of the alignment work will be verified by conducting a second measurement run. The operator then receives the current values of the system along with a direct comparison, including an evaluation of the potentially achievable improvements. BeltGenius ALEX has been developed for all conveyor systems with belts thicker than 30 mm. 

According to Voith, its high savings potential has been confirmed in an initial pilot run. There were significantly fewer unscheduled downtimes thanks to the sensor-based, high-precision measuring on the conveyor belt. At the same time, the energy demand for horizontal material transport fell by more than 10%. Following alignment optimisation, wear on the carrying idlers also decreased considerably, extending their lifetime by one-fifth in this case. 

ALEX is part of the BeltGenius product family from Voith, which also includes BeltGenius ERIC, a digital twin that can be used by mine operators to view the performance of their belt conveyor systems at any time, allowing them to significantly increase productivity. Additional modules are currently being developed. 

Read the article online at:

You might also like


Ready to revolutionise the cement industry?

Join our sister publication, World Cement, in Lisbon, 10 – 13 March 2024, for their first in-person conference and exhibition: EnviroTech.

This exclusive knowledge and networking event will bring together cement producers, industry leaders, technical experts, analysts, and other stakeholders to discuss the latest technologies, processes, and policies being deployed at the forefront of the cement industry’s efforts to reduce its environmental footprint.

Get your early bird tickets NOW »


A Guide to Backstopping, Overrunning, and Indexing Clutches

Mechanical clutches are a vital component of many power transmission systems where you need to apply torque in one direction of rotation. U.S. Tsubaki Power outlines how recent innovations in clutch design and technology are making these products even more reliable and efficient.


Embed article link: (copy the HTML code below):