The belt conveyor system is protected from overload via the overload of the electric drive motors. The motor overload indicator can be a simple bi-metallic or melting eutectic alloy or a complex computer-based motor thermal model.

Alternatively, the motor current can be monitored and any significant deviation from the standard operating signature for a pre-determined time will cause a power interruption.

A belt loading sail or paddle switch senses a belt overload at a specific point. However, such units must be designed to cater for the largest lump likely to be encountered in order to minimise spurious stops.

On the other hand, if a lump is large enough to activate the paddle switch, it makes operating sense to investigate the lump before it causes consequential damage downstream.

Complex belts are sometimes protected from overload by belt weigh scales that measure the belt loading at a given point.

Alternatively, a non-contact belt profile sensor, such as an ultrasonic, radar, laser or video device is used to measure the belt loading depth. Based on an assumed material density, the loading tonnes per hour can be projected. The actions regarding a single large lump apply in these cases as well.

Weigh meter controls are usually coupled to the belt feeding device, such as a belt, apron or vibrating feeder. The overload sensing signal is then relayed to the feeder controller and the feeder rate is reduced to comply with the requirements of the system.

Of course, unscrupulous operators may bridge any control and continuous spillage occurrences, despite any other protective measures that are in place. There is often evidence of such bridging or over-riding control of controls found during routine inspections.

Other methods of overload control are fusible plugs on fluid couplings and shear pins on flexible couplings. Electronic sensing has largely overtaken the use of mechanical devices and is less easily tampered with.