Belts

Conveyor systems
Conveyors
• To carry out the
transportation of
material(often heavy)
in an efficient and
effective manner
• Used in variety of
industries i.e.
chemical, automotive,
bottling,
pharmaceutical,
aerospace, etc.
Types Used in Cement Industry
1. Roller conveyors
– Used for conveying rigid material along the flow line
– For example, tyres and alloy rims are conveyed along the flow
line in automotive industry
2. Air conveyors
– Used to move light weight
material i.e. empty bottles,
clinker etc.
– Cement industry, mineral water
plants etc.
3. Pneumatic and vacum
a) For the bulk transport of light weight material that is
smaller than 20mm in size
b) Massive use in plastic industry
4. Bucket
a) Designed for
vertical elevation
b) Usually dry and
free flowing
material
5. Apron
a) Made up of apron plates hinged togather
b) Huge, abrasive, and heavy material
c) High temperature
6. Belt conveyors
– Used for bulk processing of material
such as raw material(nylon, polyester)
– Used in amazon warehouses
– Used in Grocery stores(PVC belts)
– Used in airports(neoprene)
– Mining & milling industry, cement
industry, etc.
Nomenclature
Rubber belt Material
1. Carcass
To provide tensile and shear strength to the belt
Types
a) Multiple ply belt- layers of woven belt fabric
b) Reduced ply belt-high tensile textile fabric
c) Steel cable belting-parallel steel cables imbedded
d) Solid woven belts-impregnated with PVC
2. Top/bottom cover
a) Protect the carcass from impact damage and load
abrasion
b) PVC, Elastomers, Synthetic rubber
2. Top/bottom cover
a) Protect the carcass from impact damage and load
abrasion
i. Elastomers, Synthetic rubber
b) PVC,
3. Edges of belts
a) Moulded
b) Cut and sealed
c) Cut
Idlers
1.Components
a) Roller bearing
b) Labyrinth seal
c) Pipe
d) Shaft
e) Housing
2.Types
a) Carrying
i. Offset
ii. Trough idler
iii. Flat belt idler
b) Return
Idler cont’d
c) Impact
cushion Idler
d) Self-cleaning
e) Self-aligning
Pulley
1. To
i. Drive the belt
ii. Tension the belt
iii. Change direction of belt
2. Drive Pulley are lagged to increase traction
between pulley and belt
Types of lagging
1. Rubber lagging
2. Lagging grooving
Pulley cont’d
3. Types
a) Drive
b) Snub
c) Bend
Drive system
1. Power rating
a) Depends on
i. Frictional force
a) Number of idlers
b) Number of scrapper
c) Number of lagged pulleuys
ii. Weight of the load
iii. Speed differential at loading/discharge points of belts
iv. Elevation
v. Weight of the belt
vi. Speed of belt
Drive system
2. Types
a) Single drive
b) Two drive
Drive configuration of belts
1. Single drive with
head discharge
2. Single drive with
advanced discharge
3. Two drives with head
discharge
4. Two drives with
advanced discharge
Drive system
3. Arrangement
a) Pulley attached with gear box without coupling
b) Driven by geared motor
c) Pulley driven by motor with chain drive/belt drive
d) Pulley coupled with gear box
a) Fluid coupling
b) Flexible coupling
Cleaning system
Scrapper
1. To remove the sticky material from the belt
2. Types
a) Pre-cleaners
b) Secondary
c) Rotary brush cleaners
Plough deflector
a) To wipe the material

off the inner side of
the belt
Dedusting filter
Loading chutes
1. Important considerations
a) Speed of the belts must be nearly same
b) Material is delivered centrally onto the belt
c) Material to be loaded while the belt is in transition
Loading chutes
2. Components
a) Baffle bar
b) Skirt board
c) Stone box
d) Impact plate
e) Wear Liner
f) Tailgate sealing box
g) Sealing strips
h) Dedusting filters
Discharge chutes
1. Components
2. Special Types
a) Spiral lowering
chutes
b) Bin lowering
chute
c) Rock ladder
lowering chute
d) Telescopic
chute
`
Tension system
1. Function
a) Correct tension for the drive pulley
b) Control sagging
c) Absorb shocks when starting and stopping the conveyor
d) Compensate for belt elongation and shrinkage
2. Types
a) Screw
b) Take up type
c) counterweight with tension drum on carriage
Screw take-up
 Components
– Chassis
– Counterweight
– Threaded rod
– Tail pulley
Gravity Take Up
 Components – Guide posts
– Diversion pulley – Take-up pulley
– Belt – slide
– Counterweight
– Frame
Behaviour of belt
• Sway
• Sway causes
Safety devices
1. Trip wire
2. Sway switch
3. Speed monitor
Maintenance
Weekly
1. Pulley cleaning
2. Lubrication of the levers(pressure adjustment) of the scrapper
3. Wear resistant rubber condition (on the scrapper) monitored
4. Movability of plough deflector on the bolts is observed
Lubrication of bolts
5. Walking along the entire conveyor to analyse the movement of
the idlers. Replace the malfunctioning idlers
Maintenance
Monthly:
1. Clean drive station
2. Check pulley for mechanical fault
3. Fastening of pulley bearing housing & Temperature(allowable 60⁰)
4. Check rubber lining(lagging) of the pulley
5. Cleaning take-up station
6. Check that the belt tension is correct
7. Rubber seal strips are analysed for any wear
8. Check the emergency trip wire is intact
Maintenance
Yearly:
1. Change pulley bearing with lubricating grease BG- U
(twice a year)
Design consideration for belts
Material characteristics
1. Lump size consideration
a) Influences belt specifications i.e. belt speed, width, carcass type etc.
b) Influences idler specification
2. Temperature of the material

3. Flowability
a) Influences the slope angles of the belt
b) Determined by angle of surcharge and angle of repose
c) Size
d) Roughness/smoothness of surface
e) Moisture content
4. Behaviour of material on moving belt
Relation b/t flowability and angle of
surcharge and repose
Material class description
Belt specifications
1. Belt tension rating
2. Top and bottom cover
a) Grades of belting under ISO 10247
3. Carcass type
a) Multiple ply belt
b) Reduced ply belt
c) Steel cable belting
d) Solid woven belts
Belt specifications cont’d
4. Belt width
a) Lump size
b) Availability of
belts
5. Trough angle
i. Increase carrying capacity
ii. Different belts have different max trough angle
6. Minimum bending radius
7. Transition distance
8. Belt speed
9. Centralization of the material on the belt
Idler Requirements
To support the belt and protect the carcass
Idler Selection
Selection depends on
1. Type of service
2. Operating condition
3. Load carried
4. Belt speed
Types of idlers
1. Carrying idler
a) Flat bed
b) Troughing idlers
c) Offset troughing idler
d) <800 two carrying idlers
e) >800 three carrying idlers
2. Return idler
3. Rubber cushion impact idler
4. Self cleaning idler
Pulleys
Types of pulleys
• Plain pulley
• Self-cleaning wing type pulley
• Crowned pulley
Lagging
Lagging is covering the drive pulley with rubber, fabric, ceramic etc. to
increase the traction between belt and pulley.
Predetermined parameters
1. Capacity desired
2. Space limitations
3. Capital constraints
Q&A
Ask away!
Thank you

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Conveyor systems

a) To wipe the material

2. Temperature of the material

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