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1. BELTING SYSTEM
1.1
Belting
Conveyor Transmission
Flat Troughed
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.
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
λ HIGH STRENGTH
λ LOW GROWTH
λ GOOD TROUGHABILITY
λ NO BUCKLING
λ FIRE RESISTANCE
λ ELECTRICAL CONDUCTIVITY
4.3 COVERS
Grade
No of Ply, 4
λ S I 1891
λ B S 490
λ DIN 22102
λ AS 1332
1. Conveyor data
λ Width
λ Maximum tension
λ Pulleys diameter head, tail, snub
λ Idlers
λ Material to be carried
λ Method of jointing
2. Carcass Selection
λ Maximum tension
λ Pulley sizes
λ Impact load
3. Cover Selection
λ Top Cover
λ Pulley cover
λ Breaker
5. 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.
Manual take up
6.1 Generally the feed to the belt comes from fairly large reserve of
material, a continuous uniform amount must be taken from the reserve to
load the belt as along as it is running. Some machine feeding device is
required for this purpose.
1. Pan feeders
2. Vibratory feeder
3. Reciprocating feeder
4. Belt feeder
6.2 CHUTES
Once the rate of feed is determined & set, speed and placement of
material on the belt are controlled by the loading chute & skirt boards.
During starting & stopping when the load has a trajectory too low to reach
the chute, provision of convergence & dribble chute are also available.
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.
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 order by returned idlers.
100 to 125 mm dia : 1.5 to 3 m/s belt speed (ball bearing of 16mm ID)
1600 kg/m3 material flow 150 to 175 mm dia : 4 to 5 m/s belt speed (Ball
by 32 mm ID) more than 1600 kg/m3)
The most commonly used toughing idler has three rolls of equal length
with inclined rolls usually of angles of 20 deg. 35 deg & 45 deg. 20 deg
are standard in most application.
Return idlers carry bearing loads and operates against dirty side of the
belt.
7. INSTALLATION
λ Each rolls of belt is marked with an arrow that shown the direction
of rotation on the package.
λ For hosting use a bar passing through the hole in the Centre of the
roll
In mounting the rolls the belt must load off the top of the roll if it is being
pulled onto the troughing idler but off the bottom of roll if it is being pulled
onto the return idlers.
In some mines, installation of the belt my be by pulling off the roll and
reefed so have large bends to avoid strain on belt.
In some underground application belt must make 90 deg trust with turn
table mounted spindle are often used.
The old belt clamped off and cut, and new belt is spliced to the leading
end of the old belt by using plate fasteners. the trailing end of the old belt
is hooked to a tractor or other means of providing traction.
The conveyor drive motor is used to pull on the used belt while the towing
device drags the old belt away.
The amount tension required in a belt at splicing depend upon the take-up
then the average funning tension in the belt, the point along the conveyor
where the splice is being made, and whether the belt is tensioned by
pulling in one direction only or in both direction. If a belt is spliced at the
top of a slope, more splicing, tension is required than if spliced at the
bottom.
λ CARRYING IDLERS
a) Shifting the idlers axis with respect to the path of the belt, known as
KNOCKING IDELER
λ RUTURN IDLERS
These idlers are pivoted about a central pin, results self aligning effect.
Centre pivoted return idlers are some times connected in group of two or
three to operate together and are actuated by a external mechanism that
takes its action from the belt position. They have a very strong influence
in centering the return, as it approaches the tail pulley.
They can be used to assist in training the belt initially to prevent it from
running off the pulley and damaging itself against the structure of the
conveyor system.
No WEIGHT TO BE
PLACED ON TOP
8.1.1 Small conveyor drives using a line start with low starting current.
8.12 Conveyor having high belt tension a high starting torque and low
starting current are considered.
8.2 Couplings
Various coupling between motor & gear box can be used to control the
acceleration of the belt independent of motor acceleration and to relieve
current in rush by getting the motor under way before loading it. Fluid
coupling are used to facilitate the start by allowing the motor to a acquire
some speed and starting current inrush to fall, before the load is picked
up. Two types of fluid coupling are used.
In belt conveyor system safety devices are IN BUILT. There are two types
of safety devices provided.
15. List and check important block bolts connection. Coupling bolts,
bearing block. And other drive bolts.
16. Check back stock (Hold back)
17. Check brakes if provided.
18. Check abnormal belt war & tear and belt wander and note for
analysis.
19. Check condition of splices for belt jointing.
20. Check wear pattern of Idler rolls.
21. Check misalignment of drivers of low speed coupling and high
speed coupling periodically.
22. Check and note particular area for belt running off Centre and
correct if required.
23. Check for damaged Idler supporting structure.
24. Check for V-plugh or return belt cleaning devices.
25. Check function of pull cord switches.
26. Check function of belt sway switches
27. Check function of centrifugal switch.
28. Check for any material stickiness in chute and hopper
29. Check function of Magnetic head pulley/over head magnetic
separator/suspended magnet etc.
30. Check function of Metal detector, if provided.
31. Check all seal leakage in gear drives.
32. Check for conveyor skirting rubber, its clamps and gap etc.
33. Check for central loading of material onto belt.
34. Check motor current on load and without load for comparing with
Tonnes per hour loading.
35. Check for slippage of belt over pulleys and belt tension.
36. Check for movement of take up trolley.
37. Check for wear/tear of chute/hopper liners.
38. Check for vibration level for drives and other connecting structure
39. Check for belt swaying due to wind thrust.
CAUSES CORRECTION
λ Load being placed on belt off Adjust chute and loading conditions
center so as to place loss center of belt.
Causes Correction
λ Sticking idlers.
λ Skirt board seals too stiff and Use more pliable seals (do not use
pressed against belt old belting.
CAUSES CORRECTION
See XIV
Causes Correction
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.
See VIII
CAUSES CORRECTIONS
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 A light joint
λ A strength joint
= 6 + (N-1) S
Where b = bias length
N = number of plies
U = Step length
400 200
600 300
750 375
900 450
1050 525
1200 525
1350 600
1500 600
1800
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