Belt Conveyor System
1. BELTING SYSTEM
Rubber belting constitutes a major outlet for rubber in industrial
application. Rubber belts can be generally divided into flat belt and 'V'
belts. The flat belts further split into conveyor and transmission belts.
1.1
Belting
Flat belting 'V' belting
Conveyor Transmission
Flat Troughed
a) Conveyor belts : It carries material at low speeds and operate over
relatively large pulleys.
b) Transmission : It is used to transfer belts power and operate over
relatively large pulleys.
c) V belts : It transmits power between 'V' grooved pulley.
2. CONVEYOR BELTING, FUNCTIONS & ARRANGEMENTS
belt conveyors are used to carry economically a greater diversity of bulk
material at higher capacity and for greater distances than any other kind
of continuously operating such mechanical Conveyor. It can be used for
material varying in lump size, moisture contend, chemical characteristics
and temperature.
A belt conveyor carries material on the up run of the belt and is charges
the load over the head pulley, the empty belts running below. Belts
conveyor may be horizontal inclined or declined or follows a combination
of these paths.
Flat belts are generally used to carry bottle bags and packaged materials.
Troughed belt increase the loading without fear of spillage of the material
and is suitable handling bulk material in both dry and semi wet conditions.
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Belt Conveyor System
GENERAL ARRANGEMENTS
OF BELT CONVEYOR
1. TAIL PULLEY
2. HEAD PULLEY
3. TAKE UP
4. SNUB PULLEY
5. TROUGHING IDLER
6. TRAINING IDLER
7. IMPACT IDLER
8. RETURN IDLER
9. DISCHARGE CHUTE
10 FEED CHUTE
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Belt Conveyor System
4. CONVEYOR BELT CONSTRUCTION
4.1 In general a conveyor belts has to meet the following basic
requirements.
λ HIGH STRENGTH
λ LOW GROWTH
λ HIGH IMPACT RESISTANCE
λ GOOD TROUGHABILITY
λ NO BUCKLING
λ EFFECTIVE MECHANICAL SPLICING
λ GOOD ADHERING BETWEEN COMPONENTS
λ RESISTANCE TO ATMOSPHERIC CONDITIONS
4.2 Other requirements for special application
λ FIRE RESISTANCE
λ ELECTRICAL CONDUCTIVITY
λ NO TOXICITY IN THE COMBUSTION GASES.
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Belt Conveyor System
1. STRAIGHT PLY CONSTRUCTION
2. BREAKER PLY CONSTRUCTION
3. STEPPED PLY CONSTRUCTION
4. ARM LOCK EDGE CONSTRUCTION
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Belt Conveyor System
4.3 COVERS
Primary purposes of the cover to protect the belt conveyor against
damages. Therefore, the top cover normally will be greater in thickness
than the bottom cover to take care wear of conveying side of belt.
Cover
Insulation
Gum
Fabric Reinforced
Cable Steed-Cable
Conveyor Belt
Cables Cover Breaker
Insulation Gum Plies
The most common carcass construction is general use in the multiply
type, which is made up of two or more plies of waver belt fabric
previously impregnated with an elastomer.
Figure 3-10 Rubber Covered, Folded Edge.
Carcass Conveyor Belt
Figure 3-11 Rubber Covered, Raw Edge
Carcass Conveyor Belt
Raw or cut-Edge Conveyor Belt
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Belt Conveyor System
4.4 DIFFERENT GRADES OF BELTS
λ General purpose : Carrying ores : M-24
Carrying coals, Ash, Cement : N-17
λ Heat resistant : Y Tex
Y therms
λ Fire resistant : CAN, CSA, MSHA
4.5 BELT DESIGNATIONS
200/2, 315/3, 365/3, 500/3, 630/4
800/4, 1000/4, 1250/4, 1250/5, 1500/5
1500/6, 1800/6, 2000/4, 2000/5
2000 4 10+6 M-24 cut edge
Grade
Bottom cover, 6mm
Tob Cover, 10mm
No of Ply, 4
2000 KN Tensile Strength 1 m Width
4.6. NATIONAL AND INTERNATIONAL STANDARD
λ S I 1891
λ B S 490
λ DIN 22102
λ AS 1332
4.7 TYPICAL CONVEYOR BELT SELECTION
1. Conveyor data
λ Width
λ Maximum tension
λ Pulleys diameter head, tail, snub
λ Idlers
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Belt Conveyor System
λ Material to be carried
λ Method of jointing
2. Carcass Selection
λ Maximum tension
λ Minimum plies for load support
λ Maximum plies for empty troughing
λ Pulley sizes
λ Impact load
3. Cover Selection
λ Top Cover
λ Pulley cover
λ Breaker
5. TAKE UP
5.1 PURPOSE OF TAKE UP
Take up devices, the name from the fact that it takes up changes in belt
length. In taking up length they maintain tension.
Often the critical point lies immediately following the drive since it is
necessary to maintain tensions at the point to prevent slippage on the
drive pulley. As some cases, however the critical point may not be near
the drive but at some point of lower elevation such as foot of a slope on
the bottom of a dip in the conveyor line.
5.2 TYPES OF TAKE UP
1) Manual : Screw type
2) Automatic Gravity hydraulic Pneumatic, electric
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Belt Conveyor System
An automatic take-up (counter weight) must provide sufficient travel to
handle any elastic length changes due to load variation or temperature
changes plus inelastic changes likely to occur between refastening or
replacing.
Manual take up
The screw type (providing enough movement to establish initial tension in
the belt and to provide periodic readjustment as the belt stretches.
Automatic take-up, the counter weight type provides sufficient travel to
handle any elastic changes due to load variation.
Tail pulley take up in provided by mounting. The tail pulley on a carriage
the runs parallel to the Centre line of the belt.
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Belt Conveyor System
6.3 SKIRT BOARDS
The chute having delivered load the succeeding belt; has no further
control of the material. To control on loading turbulence, the skirt board
are necessary.
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Belt Conveyor System
6.4 IDLERS
Conveyor belt operate idlers. The volume of material carried over the
toughing idlers, trained through the guided path by training idler &
returned to the cyclic orderi
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Belt Conveyor System
VI. BELT SHRINKS
λ Absorbing moishere Put in extra piece and install with
take up hold away down.
VII. GROOVING, COUGING OR STRIPPING OF TOP COVER
λ Skirt board seals too stiff and Use more pliable seals (do not use
pressed against belt old belting.
λ Excessive space between belt Adjust seals to minimum clearance.
and skirt seals.
λ Metal sides of chute skirts too Adjust to at least 25mm between
close to belt metal and belt & have gap
increasing in direction of travel so
as to prevent material jamming at
this point.
λ And gap not increasing
λ In direction of belt travel,
chute.
λ Material handing under Install cushion idlers to hold up
impact at loading point against skirts.
allowing material to be
trapped against skirt.
λ Material hanging under back Improve loading to prevent spillage
panels of chute. or install baffles.
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Belt Conveyor System
λ Jamming of material in chute Widen chute.
CAUSES CORRECTION
VIII. SHORT BREAKER IN CARCASS PARALLEL TO BELT EDGE AND
STAR BREAKS IN CARCASS.
λ Impact of humps on belt Reduce impact use cushion idlers.
λ Materials trapped between Install plows or scrapers on return
belt and pulley ahead of tail pulley.
IX. TRANSVERSE BREAKS AT BELT EDGE
See I, II, III
λ Belt edges folding on IV, install limit switches to stop belt
structure in case of extreme shifting, provide,
more lateral clearance.
λ Mildew Replace with mildew resistance
carcass.
λ Fine idler before head pulley Adjust older position in accordance
located too close or too high with recommendations.
with respect to head pulley.
λ Inadequate convex curve.
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Belt Conveyor System
VIII. COVER BLISTERS OR SAND BLISTERS
λ Cover cuts or very small Make spot repair with vulcuniser or
cover puncture allow fine self curing repair materials, in
particles to work under cover severe & repeating cases refer all
away from. details to Goodyear for analysis.
See XIV
XI. EXCESSIVE TOP COVER WEAR UNIFORM AROUND BELT
λ Dirty stuck or misaligned Install cleaning devices, wash belt,
return rolls used rubber disc return idlers
repair, replace, & realign return
rolls.
λ Cover quality too low Replace with belt of heavier cover
gauge or higher quality rubber
λ Pile up spilled material at tail Improve house keeping and
pulley loading.
λ Side loading or poor loading. Redesign chute to make load feed
onto belt in same direction as belt
runs and at approx, same speed as
belt.
λ Excessive sag between idlers Increase tension if it is unnecearily
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Belt Conveyor System
cause load work and shuffle low, reduce idler spacing.
on belt as it passes over
idlers XI.
II. BELT CENTER RAISES OFF TROUGHING IDLERS BOWING
TOWARDS LOADS.
λ Oil in material Remove source of oil if possible to
complete life present belt cut
longitudinal grooves in cover with
tire grooving tools to relieve
transverse pressure exerted by
swelling rubber, replace with proper
ORS belt.
Causes Correction
XIV COVER SWITCH IN SPONSOR LINES ON PULLEY SIDE
COINCIDENT JUNCTION OF TROUGHING ROLLS
λ Spill oil or grease Better house keeping
λ Over lubrication or of top run Reduce quantity of grease used and
idlers check greases.
XI FASTENERS PULLING OUT
λ Mildew Replace with mildew resistant
causes
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Belt Conveyor System
λ Wrong type of fasteners are Replace belt with proper type and
not tight. size of fastener and set put
schedule for regular fastener
inspection, retighten new fastemers
after a few hours run.
λ Tension too high Check tension in belt and if too high
see VI. For corrections; use
vulcanized splice.
λ Heat Use vulcanized splice recess
fastenders and cover with self
curing repair material.
XVI TRANSVERSE BREAKS IN BELT IMMEDIATELY BEHIND
FASTENERS
λ Fastener plates too long Change to smaller, shorter fsteners:
increase pulley size.
XVII LENGTHWISE RIPS PARTIALLY OR ENTIRELY THROUGH BELT.
See VIII
λ Belt running of and snagging See I,II,III and IV
on structure
λ Puncture by tramp iron at Use metal detector or magnetic
chute remover, use wire insert belt
construction.
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Belt Conveyor System
λ Fastener failure See XV.
XVIII CREACENT BREAKS IN CARCASS, OR MUSHY SPOTS WHERE
CARCASS ROTTED UNDER COVER.
λ Mildew Replace with mildew resistant
carcass
XIX LENGTHIWISE RUPTURE OF CARCASS WILL TOP COVER AND
POSSIBLE PARTS OF PULLEY COVER UNBROKEN.
λ Belt running off against See I, II, III, & IV
structure and folding back on
use. If as it passes around Install limit switches.
terminal pulley.
λ Jointing of many breaks due Reduce impact, use cushion idlers.
to impact of material on belt.
CAUSES CORRECTIONS
XX CARCASS FATIGUE AT IDLER JUNCTION
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Belt Conveyor System
λ Improper transition between Increase transition length, use
trumped belt and terminal transition idlers, elevate terminals
pulley. pulley.
λ Severe convex vertical curve Decrease idler spacing in curve
area, use transition idlers, increase
curve radius, remove or lower ands
elevated idlers in curve area.
λ Excessive forward tilt of Reduce forward tilt.
trough rolls.
λ Excess gap between idler Replace with heavier belt, replace,
rolls. with idlers having max gap of 10
mm.
λ Insufficient transverse Replace with the proper belt.
stiffness
XXI. HARDENING AND CRACKING COVERS WILL EVENTUAL
HARDENING OF CARCASS AND LOSS OF DUCK STRENGTH.
λ Heat Consult belt
Manufacturer
For correct heat
Resisting belt.
12. BELT JOINING
The fastened joint does not provide the strength obtainable with a
revealed space. Whenever practical, the vulcanized space should be used
as means of jointing conveyor belting where vulcanizing splices can be
used. They have the following advantages.
λ Freedoms from tear
λ A light joint
λ A strength joint
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Belt Conveyor System
λ More strength in splice.
12.1 Length of splices.
= 6 + (N-1) S
Where b = bias length
N = number of plies
U = Step length
For belt width (mm) Brass length (mm)
400 200
600 300
750 375
900 450
1050 525
1200 525
1350 600
1500 600
1800
12.2 Spice Tools
50 mm roller, sticker, 100 mm Knife vent, combination of ply knife and
prodder, ply knife, Mill knife Awt, Mill knife blades, ply lifter (Screw driver,
carpenters pincers, scissors Rule, Skiving knife, sharpening stone
MARKING PANEL, VICE GRIP, CABLE COME ALONG.
ΕΕΕΕΕΕΕΕΕΕ
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Belt Conveyor System
Reference : Hand book of conveyor & Elevator belting Good year.
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