Selecting Methods of Belt Conveyor Roller

How to choose the right roller for the belt conveyor, the method are as the follows!
1.The abrasive and corrosive materials
2.The installation of the supporting roller of the equipment working conditions
Abrasive materials, such as clay, granite and black minerals may be on supporting and selection of important influencing factors, selection of wear resistant materials. To transport corrosive materials, such as salt and chemicals and need to choose resistance to corrosive materials of roller. In steel supporting roller coating or is selection of resistance to corrosion of high roller. Harsh environmental conditions especially in dusty conditions (cement, limestone, the ash) roller to have the best sealing system, provide the highest possible protection is necessary.

belt conveyor roller

What is the required parameter for belt conveyor model selection?

Last week, PK Machinery introduced the required parameter for screw conveyor model selection, today we would like to introduce the required parameter you need to offer if you want to purchase a suitable belt conveyor.

1. About material

1）Material name _______？

2）Material size _______mm

3）Size distribution_______%

4）Material water content _______%?

5）Handling capacity________ t/h?

6）Material density ________t/m³?

7）Material temperature _______ ℃?

8）Material is corrosive or not_______?

2. About belt conveyor

1）The length of the belt_____ m?

2）Belt width______ mm?

3) Belt thickness______ mm?

4) Form of belt conveyor（Mobile ,fixed or sidewall belt conveyor)_____?

5) If is inclined, what is the inclined degree_____?

6) Configuration requirement of driving device (domestic or imported brand) ______?

7) Upstream and downstream equipment _______?

  8) Working environment _______?

How much knowledge do you know about belt conveyor magnetic separator ?

When customers purchase belt conveyor, they only provide conveying material name, but seldom mention whether the material contains other impurities or not.For example, if long and big iron contained in the material, it will be easy to scratch the conveyor belt, so magnetic separator plays an important role.In this article,we will introduce the magnetic separator as follows:
Magnetic separator is applicable to various fields deironing, which can realize continuous iron absorption and removal.
Please pay attention to the conveyor belt, bandwidth, dip angle, material properties, moisture, material thickness an iron content percentage, the nature of the magnetic material, as well as the deironing requirements and the environment condition to select a suitable magnetic separator.
Magnetic separator can remove the ferromagnetic impurities which are mixed in material, to ensure the safe and normal transmission system work of the crusher, grinding machine and other mechanical equipment,at the same time it can effectively prevent belt scratch caused by the large, long iron besides,the grade of raw materials can be significantly improved.

Application of Sidewall Belt Conveyor in Thermal Power Plant

1.Requirements
Sidewall belt conveyor is the major equipment to convey coal and lime-ash in thermal power plant. Therefore it has high requirements for the security of equipment. Generally speaking, the whole transit line is equipped with twin channel sidewall belt conveyor, one is put into use, another is as standby application device. Thus, this coal handling system must be equipped with sidewall belt conveyor with 2500m-3000m length. Applying sidewall belt conveyor to thermal powder plant, it can not only simplify procedure, but also save cost.
2.Features
Due to power plant has high requirements for the security of equipment, technical requirements of sidewall belt conveyor are as follows:
1) It has different requirements for belt conveyor when it used to receive, convey or discharge materials. For instance, if the belt conveyor is used to receive materials, the belt speed of it shouldn’t be too high. If it is used to convey materials, it requires that trough angle of idler decrease properly. If plow discharger is put into use, the cover rubber of belt surface should be thicken properly. 
2)The belt speed should be low. Belt conveyor is mostly arranged in workshop, so it has high requirements for coal dust control. According to domestic and foreign practical experience, it’s better to adopt lower speed.

3)After installation of this machine, it seldom changes its layout.
4)Different coal type has different requirements for belt conveyor. For example, large coal particle size needs impact idler with high quality. Coal with less water and more dust needs guide chute with good sealing. 

Daily, Weekly, Monthly Belt Conveyor Check&Maintenance Work

When using the belt conveyor, less daily check and maintenance or do not pay attention to maintenance will greatly reduce the service life of the belt conveyor, when the belt conveyor problems occur, it will affect the work efficiency, so regular inspection for belt conveyor parts is needed.
Daily check
Mechanical items: inspect the guardrail, bridge, roller, pulley, turnabout pulley and belt.
Electrical items: inspect the anti-skid device, deviation switch, emergency stop switch, tear detection device, anti-reverse device.

Weekly check
Mechanical items: inspect the driving wheel, guide wheel section, reducer, inspect the machine's tail, check tensioning device and pull rope device.
Electrical items: inspect the main motor, inverter, filter, repair and inspect the main transformer wiring, electrical control, power system.
Monthly check
Mechanical items: inspect the rope wheel, transition wheel, guide wheel, driving wheel, belt wheel, tensioning car and check the oiling.
Electrical items: inspect the fastening bolts, fast switch; the maintenance and repair of commutator, limit protection, emergency stop protection and the alarm system. 

 

To avoid the accident please take notice like this

1. Fixed belt conveyor should be fixed on the foundation in accordance with the instruction, before running, the wheels should be skidded by brake.
2. Please check the revolving parts, such as whether belt buckles and bearing device is normal, whether the protective device is complete and whether the belt tensioning condition is adjusted properly before start-up;
3. It must be no-load for start up, when running is normal, you can fill into the material, material filling before starting up is not allowed;
4. If belt conveyors need to work in series, we should start it from the discharging section to the feeding section orderly, only when the operation is normal ,can you feed the material;

5. When belt deviation appeared while the belt conveyor working, please stop the operation to adjust it in time, in case of edges wearing and load bearing;

6. The work environment and material temperature should be kept in -10℃-50℃；
7. The conveyor must not convey people or people walking along it.
8. Stop feed material before stop the conveyor, after materials are discharged completely you can stop the conveyor;
9. Belt conveyor motor must be in good insulation;

     

10.Do not use your hand to pull the belt when belt slips in casa of accidents happening.

Installation safety technical measures and matters of coal mine belt conveyor

1. Please pave the conveyor belt in strict accordance with the belt central line that production department gives. Belt should be paved to make sure flat, straight, and below rollers complete and effective, sweeper should be conformed to the requirements, lining plate of head and tail frame, as well as the guardrail should be complete and reliable.
2. Belt conveyor parts should be transported according to the order of tail frame, middle frame and the head frame, after transporting to the designated location, please put them away as per the transportation order along the roadway.
3. Belt conveyor should be installed according to the order of head frame, middle frame, the tail frame, central line of each pulley belt conveyor should be in a straight line.
4. Belt conveyor parts should meet the requirements, the anchor bolt should be fixed and tighten reliably.
5.All sorts of protection device of belt (Anti-frog protection, speed protection, temperature protection, automatic water spray protection if overheat, deflection protection) after the installation is complete, please test each protection device to make sure they are and sensitive working in good condition.
6. Please set up a bridge for walking where people go cross the belt conveyor frequently.
7.The electric switch protection device must be completed which should be sensitive and reliable ,the protection setting values must conform to the requirements, and keep them from water and rain, there should be enough space for walking and repairing, cable should be placed neatly and in order, communication signal should be in good condition, light and sound should be clear and reliable, control signal device should be complete, sensitive and reliable, explosion-proof lighting lamps and lanterns should be installed.
8. Both the head and tail section of belt conveyor must be equipped with two fire extinguishers and fire sand box which is not less than 0.2 m3.
9. Sweeper installation must meet the production needs. Sweeper and conveyor belt surface must contact well to ensure appropriate tightness and uniform contact, please also make sure both the head and tail section must be equipped with a sweeper.
10. In the section that the roadway changes to slope where belt waves easily, to ensure the belt frame transition smoothly, you can by adjust the supporting leg of conveyor.
11.After completing all the installation ,ensure all rollers and the belt are connected in good condition, then you can commissioning the conveyor.

Steel wirerope installation direction reference by us

Because of having wheels Mobile belt conveyor usually can be moved anywhere as you like, that’s a kind of convenient loading equipment with high efficiency. While, with the lifting device height can be adjusted. Most Mobile belt conveyor is widely used in warehouse, ports, mining site, coal yard, construction sites, and so on.

 The belt width and length can be custom-made according to the customer’s requirements. However, we usually need disassemble the whole set during transportation because the packaging volume is large. Clients will assemble the mobile belt conveyor when they get it locally. What should be bold is that the steel wire rope and conveyor belt installation direction is very important in the whole assembly process. Proper installation direction of the steel wire rope and conveyor belt will do impact on the lifting and running ability, in order to make sure the installation direction clearly, you can take the drawing which is drawn by our engineer as reference:

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.

Maintenance Tips of Conveyor Belt

In the use and storage of conveyor belt, it should kept clean, avoid direct sunlight or exposed to rain and snow, prevent contact with acid, alkaline, oil, organic solvent and other substances, and also located at least one meter away from heating device. The temperature of the storage should maintained at between 18-40 ℃ , the relative humidity should maintained between 50-80℃.In the storage period, conveyor belt should be placed in rolls, but not folding; in the placement, it should turn-over once in every seasons. Different types and standards layers number of conveyor belt should not be connected together while used, the best connection is used the bonded process. Type, structure, standard, number of layers for conveyor belt should be used according to the reasonable choice.

 

Conveyor belt operating speed generally not more than 2.5 m/s. For large lump size, material with large abrasiveness and fixed unloading device should use low velocity. The relationship between driving pulleydiameter and coating layer of conveyor belt, supporting of driving and bend pulley and also requirement for trough angle of idler roller should according to the design specification of conveyor belt, reasonable selection. Direction of feeding should along the operating direction of the conveyor belt, use chute in order to minimize the impact of material fall on receiving belt, reduce material’s free fall distance. The feeding section of conveyor belt should shortened the spacing of idler and use absorber idler as discharge section. The belt should use striker plate with moderately soft, to avoid the rigid striker plate will scrape the belt surface of conveyor belt.

Useful tips of selective purchasing and storing conveyor belt

Selective purchasing
1.Describe the name and characteristics of specific materials accurately, specially the particle size, temperature and if acid ,alkali resistance or special requirement. For instance, illustrate the temperature used for the heat resistance conveyor belt.
2.Describe the specific application areas, requirement specification (width, length, number of piles, thickness, etc.), especially the temperature used and convey capacity of heat resistance conveyor belt.
Storing
1.In the process of conveyor belt transport and storage , it should keep clean and keep it from direct sunlight ,rain and snow, prevent it from contacting with acid, alkaline, oil, organic solvent and other substances, and also locate it at least one meter away from heating device.
2.The temperature of the storage should be maintained between 18-40 ℃ , the relative humidity should be maintained between 50-80℃.
3. In the period of storage, conveyor belt should be placed in rolls instead of folding and it should be turned over once every season.

 

Installation,Debugging and Operation for Tripper Conveyors

Tripper conveyor is a mobile device which can unload materials at the arbitrary point of horizontal section of the belt conveyor, it’s a single part of the belt conveyor. The installation, debugging and operation notes are as follows:
Installation
The installation and primary debugging of tripper conveyor are finished before leaving factory, the only thing needs to place the tripper conveyor on the guide rail, and the conveyor belt should be through the pulley, roller group of tripper conveyor and make sure the conveyor belt goes by the driving pulley of head section, the turnabout pulley of tail section of belt conveyor.

Debugging and operation
Upon the completion of the conveyor belt connection, tripper conveyor cable arrangement, you can debug according to the following steps:
Please check whether the reducer is lubricant, whether there are obstacles that the tripper conveyor may collide when it walks around before start-up .
Inching run the tripper conveyor the first time in order to see if the brake of tripper conveyor is adjusted well, it can not only avoid it collides with the potential barriers, but also can check the facilitating conditions of the guide rail and the walking wheel of tripper conveyor, as well as the operation situation of every part of tripper conveyor.
After confirming all above mentioned operations are normal, the tripper conveyor can be operated on the guide rail at any point, the purpose of the test is mainly observing the walking flexibility, reliability, walking wheel and the guide rail, please adjust it if necessary.
After the above mentioned is qualified, the tripper conveyor can be put into use.

The Role of Conveyor Belt Cleaning Device

The belt conveyor is often used to transport viscous materials, such as coal dust, mud, powder materials and etc.. Some of them will stick on the working surface of belt conveyor, which cannot be removed when discharged the materials. At this time, the adhesive material will then enter the return idler, the roller become dirty as attachment stick on it. Materials enter the roller casing, thereby increasing the radial and thrust load of bearing block, causing rapid wear of bearing. The materials deposit on the roller casing will tear the rubber surface of the belt conveyor, accelerate the wear out failure of belt conveyor. If sticky materials enter the tail bend pulley, it will stick on the surface of roller. The more the viscous materials stick on it, the greater the force of the sticky materials, which will result belt deviation and increase belt wear, leading to serious consequences.

The remaining material on the belt conveyor will increase the friction force on roller, sometimes it may cause the tear on the rubber surface of belt conveyor and also the layer of roller encapsulate. If the cleaning device can function well, it can prolong the service life of the roller, belt conveyor and etc.. This shows that the cleaning device has a significant effect on belt conveyor. In the process of operation, if you want to clean the sticky material on the tail bend pulley through anthropogenic removal, it often prone to serious bodily injury or death. Hence, in order to ensure the normal operation of the belt conveyor, the sticky material must be cleaned up by cleaning device before materials enter into the snub pulley.

 

What are the Components of Belt Conveyor

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!

 

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

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.

Three Horizontal Sections of Large Angle Belt Conveyor

Large angle belt conveyor is suitable for the unit mass of 500 ~ 2500 kg/m3 and the material large size of about 100 ~ 250 mm, the features of large angle belt conveyor are: simple structure, convenient maintenance, space saving and investment saving. Here PK Machinery will explain and introduce three kinds of horizontal section:
1. Upper horizontal section
In order to adapt to the requirement of different discharge height, the head frame is divided into low type frame (head frame height = 1000 mm), middle type head frame (head frame height = 1100 ~ 1100 mm) and high type head frame (head frame height = 1600 ~ 1600 mm).
Correspondingly, low type convex segmental arc frame and low type middle frame support (matched head height = 1000 mm), middle type convex segment frame and middle type frame support (matched head frame height = 1100 ~ 1500 mm), high type convex segment frame and high type middle frame support (matched head frame height = 1600 ~ 1600 mm) will match with upper horizontal section respectively
2. Lower horizontal section
The lower horizontal section adopts low type middle frame support.
3. Inclined section
The inclined section of large angle belt conveyor adopts low type middle frame support. When the conveyor inclined angle β ≧ 45 °, we suggest adopting Ⅱseries low type middle support.

The connection of upper horizontal section and inclined adopts the convex arc segments frame , and the lower horizontal section and inclined section adopt concave segmental arc frame to connect so as to realize the smoothconveyor belt transition.

Please Focus on Belt Speed Selection and Principle of Belt Conveyor

As we all know, the most decisive factor of belt conveyor throughput is the belt speed, here we would like to introduce the selection method of belt conveyor belt speed:

(1) If the conveying capacity of belt conveyor is large, belt width is wide, please select a high belt speed.
(2) If the material is easy to move with big granularity and strong grinding property, please select a low belt speed.
(3) If material conveying interval is long, please choose a high belt speed; If material conveying interval is short and the conveyor angle is big, please select a low belt speed.
(4) If there is large amount of dust during conveying, the belt speed would be 0.8 m/s ~ 1 m/s.
(5) If belt conveyor works with a discharging tripper, the belt speed should not be higher than 2.5 m/s.
(6) If belt conveyor conveys finished product items, the belt speed should be less than 1.25 m/s.

Belt speed selection principle of belt conveyor : the belt speed of belt conveyor is related to belt width, throughput, material size, material properties and conveyor angle. When belt conveyor transports upward and dip angle is large, the tape speed should be low; When belt conveyor transports downward, the belt speed should be much lower. Belt speed selection also should match the cooperated material discharging equipment type, when adopts plough type discharging machine, the belt speed should not exceed 3.15 m/s.

How to Solve Portable Belt Conveyor Belt Skid Problem

Portable belt conveyor is a lightweight continuous conveying equipment with the features of high efficiency, good mobility, and convenient usage. It not only conveys bulking material but also realize conveying bagged material, the angle and lifting height is adjustable. In our daily life of operation, we may have trouble of belt skid problem, today PK Machinery will introduce the method to solve the problem:

1.You can adjust the stroke of tension to increase the tension to solve belt skid problem for the portable conveyor which adopts screw or hydraulic tensioning . However ,if the stroke of tension is not enough, it may lead to permanent belt deformation ,and you need to cut a piece of belt off and vulcanize again.

2.If you require long stroke of tension when using nylon or EP belt, you can also vulcanize the belt or increase the stroke of tension to solve belt skip problem.