ELECON CONVEYOR PULLEYS

Alwasy step ahead in technology

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 Introduction
In the past three decades, few industries have changed
more rapidly than the material handling industry in India.
Technological advances and growing complexity of client
needs, coupled with customer awareness have created
a requirement for a new kind of organization, with a much
broader range of largely sophisticated and specialized
skills and capabilities than was normally found inthe
traditional companies.
Cotton duck belts were replaced by synthetics, and then
by steel cords. Capacities have catapulted from 200 tph
plant to 20,000 tph or more. New theoretical concepts
have replaced old ones, and a new era of computer
programmes has been initiated.
To comply with this trend, Elecon has moved into vertical
integration of all types to come up with the latest and
most dependable designs and technical know-how.
Conveyor pulleys been recognized as a critical component
of conveyor, failure of which could lead to extensive
damage and down time. Hence special attention has been
given to design an develop the most dependable pulleys.
The range of belt conveyor pulleys manufactured today
in Elecon comes in three basic categories, i.e.,
- Standard construction pulleys
- Heavy-duty construction pulleys
- Extra heavy-duty construction pulleys.

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Special custom pulleys are also manufactured
to comply with customer requirements.

Figure 1

Selection of pulley diameters D of belt conveyors are based on ISO:3684

A B C

Driving pulleys and pulleys Snub pulleys in the return run Bend pulleys , for a change of
exposed to high belt tension, under lower belt tension, i.e., direction of the belt of
i.e., main driving pulley on terminal tail pulleys in the case less than 30 0.
the head or on the tail; delivery of head driving; terminal head
pulleys under full tension; loop pulleys for down hill conveying
pulleys in the tripper; terminal if the terminal tail pulley is
head pulleys in the case of tail braked; snub and bend pulleys
driving, etc. in take-up devices.

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Design Special CNC machines ensure accuracy and
consistency for machine shafts. In case locking
A special computer programme has been evolved to elements are used, sophisticated machines are
optimize on design and obviate any calculation errors. available in shop, to achieve a high degree of surface
Pulleys are designed to cater to overload forces of finish and minimize ovality to ensure positive stress
short duration. distribution. All shafts are ground to close tolerance
where the bearing sits.

Quality
To ensure the best quality and dependability, a rigind Bearing blocks
form of stage inspection is enforced, starting with raw
Bearing with bearing blocks can be supplied along
materials to component checking and final assembly.
with pulleys, with 2 or 4 mounting holes. Variety of
seals can be provided depending on degree of
protection required and duty involved.
Pulley diameters and
face widths
Pulley diameters and face width dimensions are Non-magnetic pulleys
adopted as per IS:8531. However, the same can be
Special non-magnetic pulleys with stainless steel shell
supplied to comply with customer requirements.
and diaphragm plates are also manufactured for special
requirements.

Crowning on pulley face

For long conveyors, where the belt tensions are high, Balancing
the crowning pulley is injurious to the belt and
All Elecon pulleys are statically balanced.
subsequently reduces belt life. In view of synthethic
Dynamically balanced pulleys are supplied upon
belts used now, and with deep trough conveyor idlers,
request at extra cost.
crowning on pulley is a redundant feature and hence
it is not recommended. However, if required by
customer, crowning can be provided on pulleys as
per IS:8531. Stress relieve
All Elecon pulleys are stress relieved.

Lagged pulleys
Elecon can supply pulleys with hot vulcanized rubber Enquiry
lagging, plain or grooved, as required by client. Different We would be pleased to evaluate your requirements
patterns of grooving such as herring-bone or diamond and offer you precision engineered pulley on receiving
can be provided to increase tractive friction under dirty the following information :
or wet conditions. Diamond grooves have the
1 Pulley diameter
advantage of being installed in any direction,
2 Belt width
regardless of belt direction.
3 Bearing centres
4 Incoming belt tension
5 Outgoing belt tension
Pulley shells 6 Angle of belt wrap in degree
Pulley shells are accurately rolled from weldable quality 7 Number of drives on pulley
steel. Tolerances are maintained strictly within limits 8 Motor kW (each if 2 drives)
specified in IS:8531. 9 Belt speed
10 Type of high speed coupling
11 Type of drive employed between reducer and pulley
12 Rubber lagging : thickness, groove, pattern and
Pulley shafts
type
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Standard construction pulleys pulleys. However, the non-drive pulleys can be supplied
with keyed construction on requirement.
Elecon standard construction pulleys incorporate hubs
machined from weldable quality steel. The hubs
connect the shaft with the shell by end diaphragm
steel plates, which are welded with the hubs and shell.
Shaft to hub connection for drive pulleys would be
keyed, while it would be shrink fitted for non-drive

DRIVING PULLEYS
(Standard Construction)

NON-DRIVING PULLEYS
(Standard Construction)

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Heavy-duty zone. These locking elements are
construction pulleys self-centring, and self-locking, as well as
simultaneously, transmitting more torque than
Elecon heavy-duty construction pulley are provided the equivalent solid shaft with keyway and also
with steel diaphragms (end discs), welded with the
transmit axial thrusts without keys.
shell and incorporate friction based releasable locking
elements, which connect the shaft to the shell without This type of locking assembly also proves invaluable,
the use of separate hubs. This type of end discs make when shaft or shell require maintenance, as they
it possible to eliminate the weld in the high stress facilitate easy removal and installation of shaft.

DRIVING PULLEYS
(Heavy-duty Construction)

NON-DRIVING PULLEYS
(Havy-duty Construction)

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Extra heavy-duty
construction pulleys
Elecon also manufactures a range of custom-built For non-driving pulleys, the pulley body consisting of
extra heavy-duty pulleys suitable for any known shell and turbo-diaphragms rotate on the fixed axle,
application and to perform in arduous duties with with bearings mounted inside the pulley body.
extended fatigue life. This range of pulleys is designed
Elecon has successfully supplied a number of such
with turbo-diaphragms of weldable quality cast steel,
extra heavy-duty construction pulleys, both driving and
which are profiled to obtain even stress distribution. A
non-driving, for Neyveli Lignite Open Cast Mines,
characteristic of this type of diaphragm is in the
handling 20,000 tph of overburden by belt coneyors
welding of the diaphragm to the shell, where the
having 2400 mm wide steel card conveyor belting at
altermating fatigue stresses are far lower.
belt speed of 5.2 m/sec. The pulleys are designed
For driving pulleys, the shaft to hub connection is by and supplied to withstand belt pull of 320 tonnes and
means of heavy-duty locking elements, which have capable of transmitting 2 x 1250 kW of power. Elecon
the other characteristics and advantages similar to can also supply pulleys to meet even higher belt
the locking elements used for heavy-duty construction tensions and power transmission rating.
pulleys.