Maintenance Work for Belt Conveyors

Maintenance Work for Belt Conveyors

When it comes to actual operation of belt conveyor, if there is less maintenance, it will greatly reduce its lifespan. There is no doubt that belt conveyor occurs problems will seriously affect work efficiency. So it’s necessary to maintain components of conveyor belt timely.

Daily Care

Mechanical items: check guardrail, rollers, pulley, bend pulley, belt

Electrical items: check anti-skid device, belt sway switch, tear detection device, anti-reverse device

Weekly Care

Mechanical items: check driving wheel, guide wheel, tension device, belt pull rope device

Electrical items: check main motor, filter, power control, power system; repair main transformer wiring

Monthly Care

Mechanical items: check all parts of rope wheel, transition wheel, guide wheel and belt pulley

Electrical items: check fastening bolts, fast switch, emergency stop protection and alarm system

Matters should be noted during belt sway switch installation and adjustment

Matters should be noted during belt sway switch installation and adjustment

Belt sway switch is used to check the belt running deviation of the belt conveyor, it is a safe protection device of automatic alarm and stop when the belt running deviation appears.Belt sway switch is fixed on the conveyor belt bracket, action bar is at the side of the belt, when the belt running deviation appears, force the action bar deviation, and touch the alarm micro switch. If the belt running deviation continues,will touch another group of contact, and the conveyor will be protective to stop.

In the installation and adjustment of belt sway switch, what matters should we pay attention to? PK Machinery will answer for you!

1. Belt sway switch should be located on both sides of the conveyor belt, the vertical roll should be vertical with conveyor belt edge flat, and both sides of the conveyor belt are located at 1/3 height of vertical roll.

2.The distance between the vertical roll of belt sway switch and the normal position of conveyor belt should be 50 ~ 100 mm.

3.The quantity of belt sway switch ought to be determined according to the length of the conveyor, types and arrangement. Commonly it is located on the conveyor head, tail, convex segment, concave segment and the middle position.(Note: when the conveyor is longer, a pair of belt sway switch can be located every 30 ~ 35 m.)

4.Belt sway switch connects the conveyor middle frame through the mounting bracket, switch bracket will be welded with conveyor frame after the installing completion of the conveyor, and belt sway switch shall be bolted in the bracket.

Ways to Maximize the Performance of Belt Conveyor

Ways to Maximize the Performance of Belt Conveyor

During application of belt conveyor, it is beneficial to reduce operating resistance by using high precision conveyor rollers and high performance belt. Revolving resistance of rollers and forward resistance of belt conveyor account for 50% main resistance in belt conveyor. If the belt conveyor length is more than 80m, main resistance will be influenced by device condition, friction coefficient related to real working condition, conveyor length, rotating quality in unit length of roller, belt quality, material property, etc.

Apart from above mentioned influential factor, we can refer to the following ways to maximize the performance of belt conveyor:

1.Reduce or adjust belt deviation;

2.Add lubricating oil to components of belt conveyor;

3.Clean up the sundries produced in transportation promptly;

4.Tension force of belt conveyor should be adjusted the best status;

5.Please add oil to conveyor pulley at fixed period to ensure smooth rotation;

6.It’s better to adopt vulcanized joint, though it costs too much money, it can keep a longer service life(especially suitable for fixed belt conveyor).

How to prolong lifespan of belt conveyor

How to prolong lifespan of belt conveyor

Quality of belt is the main reason to impact on belt conveyor lifespan, so it must purchase the belt with high quality. Meanwhile, it should make sure that sweeper is reliable to use so that there is no material on the return belt. Otherwise, materials adhered to return belt will be taken to the surface of drive pulley and bend pulley, then it will damage belt and reduce its lifespan.

There are some problems in the use of belt conveyors sometimes, to which require you to pay attention that you can greatly extend the service life of belt conveyor.

1. If there is the phenomenon of belt slipping on drive pulley, users should find the reasons and adjust it promptly.

2. Please always check the belt connectors, if there is local damage, please repair it or replace conveyors joints.

3. Please check rollers using conditions regularly. Adding proper lubricating grease into sealing ring when making maintenance. And replace inflexible rotating rollers immediately.

4. It must add good quality lubrication into all rotating parts of belt conveyor. Please add lubrication at fixed period in accordance with the requirements.

5. Please ensure that the cleaning device has good working conditions, and the damaged components should be replaced.

6. Please check tension level of belt conveyor regularly. If the belt is loose, please tension it promptly and observe whether the belt is off tracking, otherwise it should be adjusted timely.

Great Way to Select Great Tripper Car

Great Way to Select Great Tripper Car

Tripper car can be designed to discharge materials continuously along the belt conveyor longitudinal direction. Tripper car is one kind of dumping device, it can achieve discharge materials at any points or both sides or only one side.

Tripper car orbit is welded on the top of belt conveyor middle frame, the track length is designed according to customers’ requirements. Achieve discharge materials along the longitudinal direction of belt conveyor.

In order to provide the best design, please offer the following technical parameters:

1. Required discharging length ____m;

2. Installation location and space limitations of belt conveyor system;

3. Required capacity ____ t / h;

4. The belt conveyor length _______m;

5. Material name _______;

6. Material particle size ____mm;

7. Material temperature _____ ℃;

8. Material proportion ____ t / m3;

9. Required belt width _____mm, or we will design it based on the capacity and other parameters.

Do you know difference of TD75, DTII and DTIIA series belt conveyor

Do you know difference of TD75, DTII and DTIIA series belt conveyor

Specifications of TD75, DTIIA, DTII series belt conveyors are the national standard of China belt machine, which represent three types of conveyors.During the model selection,the standard should be noticed. How to choose a proper type to save client’s cost? The following is the characteristics of the three types of conveyors:

TD75 series conveyor is the first standard belt conveyor, it can be used to convey small lump, granular, powder material, due to simple structure, low cost, easy maintenance, convenient maintenance, and large transport capacity,TD75 series belt conveyor becomes a common machine,it can be single or multi sets running to form a horizontal or inclined conveyor system.

DTII series belt conveyor is designed according to the components. The designers can design and assemble the conveyor according to the requirements of transportation, different terrain and working conditions,it has a wider use compared with TD75 type.

DTIIA series belt conveyor a heavy duty machine is mainly used to transport large density, large transport capacity and long transmission distance, conveyor selection is determined according to many parameters.

Portable Belt Conveyor in PK Machinery

Usage Occasions of Magnetic Separator in Belt Conveyor

Usage Occasions of Magnetic Separator in Belt Conveyor

In the belt conveyor procurement, clients always only provide information about material name, while do not specify whether the material contains other impurities. For example, material contains large and long iron which is easy to damage conveyor belt. This article makes a description about magnetic separator when it is used in the belt conveyor. 

Magnetic separators apply to all industries expected to remove iron, and it can achieve continuous iron absorption and removal. 

It should be noted that inclination of belt conveyor, material property, material humidity, and the thickness of material as well as iron content, nature of ferromagnetic material, iron removal requirements, etc. 

Magnetic separator is a kind of device which can generate powerful magnetic attraction. It can eliminate ferromagnetic impurities mixed in the material to ensure conveyor equipment can work normally. What’s more, it can effectively prevent accident of large and long iron to damage conveyor belt as well as significantly improve the quality of raw materials. According to their way of doing unloading iron, it can be divided into artificial unloading, automatic unloading and process control unloading and a variety of work unloading iron. Due to usage occasions and different magnetic structure, it has formed a variety of product lines.

Regular Maintenance of Belt Conveyor

Regular Maintenance of Belt Conveyor

After belt conveyor is put into use, it’s necessary for users to pay attention to the regular inspection. Otherwise, it will not only affect the working efficiency of belt conveyor, but also reduce its lifespan.

Daily Inspection

Mechanical Parts: rollers, pulley, belt, bend pulley, guardrail.

Electrical Parts: belt sway switch, anti-reverse-rotation device, antiskid device, tearing detection device.

Weekly Inspection

Mechanical Parts: inspect the driving wheel and every reducer, check tail of machine, tension device and pull switch.

Electrical Parts: the main motor, frequency converter, power system, etc.

Monthly Inspection

Mechanical Parts: all parts of rope sheave, transition pulley, driving wheel, tension car and pulley.

Electrical Parts: joint bolts, high-speed switch, commutator, position limitation protection and other warning systems.

  

 

How Much Do You Know About Installation Measures of Belt Conveyor

How Much Do You Know About Installation Measures of Belt Conveyor

1.When users pave belt, it’s better to pave according to the middle line of belt strictly.Cleaning device should meet the specification, and blanking plate of head as well as guardrail of tail should be reliable.

2.When users transport components of belt conveyor, it’s better to deliver them in order of tail, middle frame, head and belt. After arriving at the designated location, those components should be displayed as per the transportation order.

3.When users install the belt conveyor, it’s better to do it according to the order of head frame, middle frame, tail and belt.Center line of each pulley and belt conveyor should be in a same line.

4.After installing all protective devices of belt conveyor,such as velocity protection, temperature protection, deflection protection and so on, users had better do commissioning for those protective devices and hang protection signboard. 

5.There should be equipped 2 fire extinguishers and emergency sand box which is not less than 0.2 m³ on both head and tail of belt conveyor.

6.The installation of cleaning device should meet the production’s requirements. It should have a good connection to the conveyor belt surface. Also, there should be installed one cleaning device on both side of head and tail.

7.If all parts of belt conveyor have been installed totally, it’s better to do commissioning.

Better Understanding on Installation Direction of Steel Wirerope in Portable Belt Conveyor

Better Understanding on Installation Direction of Steel Wirerope in Portable Belt Conveyor

Due to the wheels and lifting device, portable belt conveyor can move freely and be adjusted lifting height. So it has high efficiency when conveying things and can be widely used in port, warehouse, station, coal field and other places.

According to different requirements, portable belt conveyor be customized in different belt width and length. But because of its large volume, it need to be disassembled during transportation and installed by customer when they receive the machine. Therefore, it is very important to know how to install steel wirerope and belt. Appropriate installation direction of steel wirerope and belt will directly affect the lifting and operation capacity of portable belt conveyor. With the purpose of showing the installation direction better, our engineers provide the following drawing for your reference，hope users can have a better understanding.

Introduction of Tripper

Introduction of Tripper

► Brief IntroductionBelt conveyor tripper is a mobile device which can unload materials at the arbitrary point of horizontal section of the conveyor; it’s a single part of the conveyor. Movable tripper can be divided into light-duty type and heavy-duty type.

 

► Features
    1.Durable
    2.High efficiency
    3.Simple structure
    4.Stable operation
    5.Easy to maintenance
    6.Multiple discharging points
    7.Moving freely with wheels

► Advantage

    1.Heavy duty structural frames and supports – to provide system rigidity

    2.Heavy duty inlet skirting – to eliminate spillage at discharge transition

    3.Abrasion resistant belting – to reduce wear and increase life span

    4.Heavy duty idlers with anti-friction bearings – to increase idler life and reduce horsepower requirements

    5.High torque drive units – to power through upset conditions 

    6.Modular design shipped with limited field assembly required for drop in, bolt in place field installation

    7.May be fitted to any new or existing conveyor

    8.Single and dual side discharge designs

    9.Evenly distribution of materials 

    10.Save storage space

    11.Powered tripper movement through cable/winch assembly or powered wheels, crowned bend pulleys for positive belt tracking 

    12.Shuttling cross conveyor belt design available with side to side movement

    13.Cross over platform/operator deck available on cross conveyor tripper

    14.Engineered to meet new project requirements and also to retrofit existing conveyors

 

►  Application
XLP Tripper is always used at a large belt conveyor, it applies in the occasion where the belt conveyor has a discharge requirement, such as mining, power plant, steel plant, port, etc.

Introduce Shuttle Conveyor

Introduce Shuttle Conveyor

► Brief Introduction
Shuttle conveyor is designed for conveying material moves along a transport direction on the steel track which is usually installed on the top of the storehouse.Reversible conveyor mainly used to discharge material constantly in multi-point when the discharging points could move.

 

► Advantages

    1.Multiple discharge point

    2.Discharge continuously in long distance

    3.Two way running and discharging

    4.Compact structure with low height

    5.Convenient installation and maintenance

                             

► Application
Large capacity shuttle conveyor is mainly used for disperse and store the material, especially the materials need to discharge averagely in order to take full advantage of the space and then store more material. So it could be used in agriculture, power plant, raw material stocking, metallurgy industry, etc.

 

Great Changes in Technology of Conveyor Belt

Great Changes in Technology of Conveyor Belt

With the development of scale of mine, belt conveyor has kept on towards large scale and presents features of large capacity and long distance. Belt conveyor with long distance and multi power has achieve successful research and development, it changes the single load-carrying way that is given by rollers and adopts multipoint electric drive. This method can address the traditional problems that are changing conveyor belts frequently and belt breakdown easily. Also, the successful development of this kind of belt conveyor can reduce the cost of equipment greatly. What’s more, its advantages are reducing thenumber of transshipment or fall of ore during operation and avoiding environmental pollution.

 

The successful development of belt conveyor with 1km-100km belt length, adopting multipoint electric drive which can reduce 10%-30% investment and operation cost. Especially, it can decrease belt strength and eliminate risk of tapebreak of upward transport belt conveyor with large angle and long distance. And then it can prolong the lifespan of belt more than 5 times. Multi-power belt conveyor not only can achieve the goal of lower investment, lower consumption and resistance, but also operate stably more than 10 years. In this way can it improve the running rate and economic benefit greatly.

Introduce Sidewall Belt Conveyor

Introduce Sidewall Belt Conveyor

►Brief IntroductionSidewall belt conveyor is continuous transporting equipment of loose bulk materials such as coke, coal, limestone, sand and gravel. It adopts high quality conveyor belt with corrugated sidewall and horizontal baffle. Sidewall belts are used to convey material up inclines. The sidewall increases the carrying capacity of the belt and prevents product from falling off the edges of the belt. Hot vulcanization provides a 5x greater adhesion between the belt and sidewall, eliminating the need for bolting the sidewall to the base belt. Greater adhesion also prevents the sidewall from lifting and separating from the base belt, extending the belt life.

                 

►Features
   1.Long service life
   2.Reduced maintenance
   3.Low power consumption
   4.Reduced number of transfer points
   5.Quick installation and quiet running

                   

►Advantages

   1.Flexible transportation – can convey all kinds of bulk materials such as coal, ore, sand, fertilizer and grain in horizontal, oblique, vertical or other angle directions. 

   2.High tensile strength

   3.Increases belt capacity

   4.No spillage with steep angle conveying

   5.Decrease necessary conveyor footprint

   6.No transfer points- the belt are capable of turning at any angle right from feed hopper to discharge point

   7.Maximum utilization of space – able to convey material at angles up to 90 degree

   8.Decrease maintenance costs with fewer drive units and components

   9.Long lifespan

   10.Low power requirement – requiring low power to move loaded belts

   11.Quiet smooth running – as belt runs on rotating idlers, low resistance is achieved that in turn ensures quieter operations

►Application

   1.Coal and wood-chip fired power stations

   2.underground mining (coal and ore)

   3.Shaft conveying for tunnelling and underground mining

   4.Steel industry

   5.Ship loading and unloading, ship to ship loading

   6.Sand preparation in foundry plants

   7.Silo feeding

   8.Slope conveying in openpit mining

   9.Waste recycling, soil purification and water treatment

   10.Handling of large material flows in the horizontal path

                   

►Working Principles

The horizontal loading section a deflection wheel bends the belt into the feeding of the bulk material takes place on a mostly horizontal feed path, where the side wall belt is supported by loading impact idlers. The feeding of the conveyed material can be achieved by direct feeding from a hopper, over a chute, a feeding belt or a feeding pulley. The selection of the optimum feeding station depends on the properties of the bulk material and the belt speed of the vertical conveyor. The upward and downward strands are encased from the bottom to the top. Substructures or support rollers are not necessary in this section.

The vertical section leads over a deflection curve into the horizontal discharge section. The deflection curve is made up of a number of high specification pulleys. These pulleys experience the vectored load of deflecting the belt tension from vertical to horizontal. 

At the drive pulley, the bulk material is discharged and the belt is returned to the back going strand. Depending on the bulk material properties, the drive pulley is followed by a beater wheel for belt cleaning in the return side. The beater is self-driven. Material that fails from the belt goes into the main delivery chute. Lateral deflection wheels turn the belt from the horizontal back to the vertical.

►Selection condition

1. What is the conveying material and its physical characteristics? such as bulk density, feeding size, temperature, mositure content etc.

2. What is the processing capacity of the conveyor?

3. What is the inclination angle of the conveyor?

4. What is the lifting height (distance between inlet and outlet)?

5. What is the length of horizontal section?  

               

►Maintenance

    1.Idlers: These must rotate freely, and be free from any material build-up. Lubrication of all moving parts on a planned basis is essential for dependable operation and minimum maintenance. Component life will be extended by following the manufacturer lubrication instructions.

    2.Pulleys: These should be free from any material build-up. The lagging on the drive pulley should be inspected on a regular basis. If the lagging is in poor condition it may be necessary to apply more tension than is normally necessary to drive the belt resulting in premature wear.

    3.Deflection Gear: Again, these must be free to rotate freely.

    4.Feed Hopper: It is important that this is just free from the top of Sidewalls, any rubber seals around the hopper need checking for wear to prevent excessive dust or spillage.

    5.Tracking: The belt should run without touching any side members or deflection gear, please refer to the section on belt tracking if the belt is running out of alignment.

    6.Good housekeeping: This is necessary for continuous operation and low maintenance. Spillage and build-up of material can eventually cause the idlers to stop rotating and an accumulation of lumpy material can cause belt damage.

                     

Check: The belt edges, Sidewalls, Cleats and the belt splice need to be checked on a periodic basis for wear or separation. Any minor areas of damage should be repaired as soon as is possible.

The Selection of Corrugated Sidewall Conveyor Belt

The Selection of Corrugated Sidewall Conveyor Belt

Sidewall belt conveyor is a kind of large capacity transport equipment that can convey bulk materials such as coke, coal, limestone, sand and gravel. So with regards to sidewall belt conveyor, it is a great significant for user to select conveyor belt with high quality. This article will introduce you how to select conveyor belt. Any interest, please follow it.

Corrugated sidewall belt is used for pulling and carrying purposes for corrugated sidewall conveyor. It consists of a baseband, corrugated sidewall and baffle. The corrugated sidewall connects with both sides of baseband while the baffle connects with both side of corrugated wall accordingly to a certain space. 

1. Baseband 

The baseband appearance of corrugated sidewall belt is the same with ordinary belt ,but its lateral stiffness is greater than ordinary belt. Usually corrugated sidewall belt adopts special belt as its baseband, the tensile materials (core layer) can be divided into four kinds: cotton canvas, nylon canvas, polyester canvas and steel wire. 

2. Corrugated sidewall
This series of products using S-type of corrugated sidewall.

3. Baffle

a) This series of product is recommended to use type T, type TS (B), type TC, type TCS (B) and type C baffles. 

b) Type T and type TS (B) baffles are only suitable for conveyor angle β≤40 ° while type TC and type TCS (B) and type C of baffles are suitable for conveyors with any transmission angle. 

c) Type C baffle is suitable for conveying viscous materials. On the other hand, if the conveying angle and material density are greater, then type TCS (b) baffle should be used. 

d) The spacing between baffles is integral multiple of waveform of the corrugated sidewall. The spacing between baffles (TS) and height (H) are related to conveying angle β.

Risks of Conveyor Belt Running Deviation

Risks of Conveyor Belt Running Deviation

The belt running deviation is rather harmful during the operation. Actually it will affect the efficiency of conveyor capacity and lifespan of belt. So it must  turn off the machine when the belt is off tracking.

The belt running deviation is rather harmful during the operation. According to the actual operation of belt conveyor, the deviation effects on the operation and production of belt conveyors are mainly in the following aspects: 

1. Failure breakdown emergency stop device

The failure breakdown emergency stop device with protective purposes is installed on the belt conveyor. When the belt deviation occur and near the failure breakdown emergency stop device, it will causes the device to stop the machine immediately, and hence causes the conveying process to stop. This will affect the efficiency of production line, and hence increase the cost of production. Some serious cases might lead the project unable to finish on time, or even causes the undesirable contract disputes. 

 

2. Reduce the life-span of main components

Firstly, the breakdown of roller, bearings and other mechanical components, such as belt running deviates from pulley will cause the increasing of the force of roller, and hence it will increase the probability of failure. Secondly, it leads the belt to be worn out in a shorter period. The belt running deviation cause the materials spread onto the return belt. It will cause the belt and roller encapsulate to wear and tear abnormally as the materials can’t be fully removed from the return belt. Thus, the life-span of belt and roller will be shorten. Thirdly, it leads the tear and wear from the edge of belt, if the edge of belt collides with frame for a long time during the operation, it will cause the severe wear of belt edge and thus affects the life-span of belt which will leads to the increase of maintenance cost and also the operation cost. When the serious belt deviation occurs, it causes belt tearing directly. Belt deviation might lead to serious overturning of belt, causing the increasing of unilateral force ,hence it will lead to belt transverse fracture. 

What are the Components of Belt Conveyor

What are the Components of Belt Conveyor

Belt conveyor includes conveyor frame parts, composition of other components(roller,drum pulley,conveyor belt,driving device ),cleaning device,protection device and electronic control device.This article introduces those kind of knowledge detailedly.

1. Conveyor frame parts

Including: head frame, tail frame, intermediate frame and supporting leg which are produced by cutting, welding, punching and polishing with standard channel, angle iron, steel and other. 

2. Composition of other components:

i. Roller

Roller has the highest quantity and is the most carrying parts of belt conveyor. Impact roller, friction centering carrier roller, belt conveyor roller, and so on are included. The lifespan of roller is depends on the usage, usually the roller needs to be replaced every one to two years.

ii. Drum pulley 

Power conversion device and redirection device of belt conveyor including the drive pulley and return pulley. It is durable but the bearings need to be lubricated.

 

iii. Conveyor belt

It is one of the most expensive parts of belt conveyor, and also an important part to carry the materials. Hence, it needs to be maintained properly.

iv. Driving device

It is the power source of belt conveyor. Commonly motor works together with reducer, however, motorized pulley can also be used. 

3. Cleaning device

Including : head cleanser, non-loaded cleanser, tail cleanser, spring cleanser and so on.

 

4. Protection device
Including : pull-cord switch, running deviation switch, skid detector and so on.

5. Electronic control device:
Including: electric cabinet, power protection device.
All the parts mentioned above are needed to ensure the normal operation ad production of belt conveyor, hope this article is helpful!

 

Our website:www.pkmachinery.com

What Should We Note During the Installation of Large Angle Belt Conveyor

What Should We Note During the Installation of Large Angle Belt Conveyor

when large angle belt conveyor is installed, there are something notes to which we should pay much attention. So this article can introduce you this kind of knowledge detailedly.

Large angle belt conveyor can be transported with large inclination , it even can be vertical. It adopts sidewall belt as the main part. The advantages are: large conveying amount, small space occupation ,small noise etc. which is widely used for conveying powder, blocked material. Here PK Machinery will introduce the installation notes during installation:

1.Check whether the components of large angle belt conveyor are complete or not 

Generally speaking, belt conveyor includes lots of components: head & tail frame, concave & convex segmental arc frame and middle frame, however, the quantity of trough roller frame, rollers and sealing cover is big, you need to check carefully and guarantee the components are transported to the right place.

2.Installation, positioning and welding of head and tail frame, concave and convex segmental arc frame

First of all, please find the center line of the belt conveyor by using a steel wire. When installation, please make the head & tail frame, concave & convex segmental arc frame subject to the center line.

3.Check belt running and adjust the belt if it runs off tracking

After installation of belt, trough roller, self-aligning roller and vertical roller, connect the power supply , run the belt and adjust the belt offset distance .

4.Installation of large dip Angle belt conveyor accessories and bolts

After adjusting the belt, you can start to install the sealing cover, head cover and fastening bolts.