Great Changes in Technology of Conveyor Belt

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.

The Risks of Conveyor Belt Running Deviation

The belt running deviation is rather harmful during the operation. According to the actual operation of belt conveyor, the deviation effects on the operation and production of belt conveyors are mainly in the following aspects:
1. Failure breakdown emergency stop device
The failure breakdown emergency stop device with protective purposes is installed on the belt conveyor. When the belt deviation occur and near the failure breakdown emergency stop device, it will causes the device to stop the machine immediately, and hence causes the conveying process to stop. This will affect the efficiency of production line, and hence increase the cost of production. Some serious cases might lead the project unable to finish on time, or even causes the undesirable contract disputes.

2. Reduce the life-span of main components
Firstly, the breakdown of roller, bearings and other mechanical components, such as belt running deviates frompulley will cause the increasing of the force of roller, and hence it will increase the probability of failure. Secondly, it leads the belt to be worn out in a shorter period. The belt running deviation cause the materials spread onto the return belt. It will cause the belt and roller encapsulate to wear and tear abnormally as the materials can’t be fully removed from the return belt. Thus, the life-span of belt and roller will be shorten. Thirdly, it leads the tear and wear from the edge of belt, if the edge of belt collides with frame for a long time during the operation, it will cause the severe wear of belt edge and thus affects the life-span of belt which will leads to the increase of maintenance cost and also the operation cost. When the serious belt deviation occurs, it causes belt tearing directly. Belt deviation might lead to serious overturning of belt, causing the increasing of unilateral force ,hence it will lead to belt transverse fracture. 

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.

 

Troubleshooting of Mining Belt Conveyor

 As the development of the conveying technology, belt conveyor used for mining industry also changed rapidly, adding many new functions. These new functions provided convenience for the user's operation and maintenance. Mining industry are mostly make multiple machineries work together to complete the handing task. If improper operation or material blocking caused the conveyor stop working, the motor will prone to be overloading and making abnormal sound. At this time we should shut down the conveyor immediately and examine the conveyor to find out the failure reason.

   Because mining industry has more complex situation the machinery will be prone to cause problem, if we can’t find out the problem promptly then will bring a greater loss, so Mining Belt Conveyor should be installed a sensor in the right place. When a trouble happens on Mining Belt Conveyor, such as motor burning, transmission part damaged, belt or chain fracture, belt slipping,

 

  we should design and installed some sensor or control switch with the shut down and control function, so that when trouble happens the sensor switch will give out the signal of shut down the conveyor automatically and also give out alarm. It not only reduces the damage caused by the trouble but also find out the trouble part promptly save the maintenance man lots of time.

    Here we want to emphasis the take-up device of the belt conveyor. It is well known to us that the operation of thebelt conveyor should maintain proper tension, if the belt become sag and can’t meet the required tension, the belt will be prone to slipping on the transmission pulley. Providing that we can’t adjust the belt promptly, it not only affects the conveying efficiency but shorten the useful life of the belt. The take-up device of the belt is designed to make the belt up to the required tension to avoid belt slipping on the drive pulley and guarantee the deflection between idlers in the specified range. The new belt and the belt using after a certain time is different in the length and tension, so we should adjust the take-up device promptly.

       Mining Belt Conveyor is mostly work with multiple machineries, so the control and operation of the machinery are usually adopt intelligent controlling and remote monitoring technologies. Thus, when the trouble happens on the machinery, the automatic alarm device on the conveyor will give out signal to the operator promptly, then the operator can use the feedback information to find the trouble part directly and begin repair the trouble part. It not only saving the operator’s time of finding the trouble but also minimize the damage of the users caused by theconveyor shut down. 

Belt Conveyor Maintenance

The maintenance schedule for any conveyor can be divided into three stages:1.    Belt shut down and empty2.    Belt running empty

3.    Belt running loaded

(i)           Belt Shut Down and Empty

This is the 1^st step in inspect the conveyor belt because this allows the opportunity to check any damage to the belt or splice. The conveyor should be locked out while making this inspection.

Rubber belt damage should be repaired using the hot vulcanized repair method or the cold repair method. Belt fabrics that are exposed to the weather or to product contamination should be properly cleaned, dried then covered with new rubber. These repairs are critical to prevent moisture from penetrating the belt and breaking down the cover adhesions and to prevent product contamination from abrading the carcass and also breaking down the adhesions.

The splice can also be inspected and if damage in the splice is visible, it is suggested that the splice be repaired or replaced. This is also a good time to walk the conveyor and check the following components.

A)   Tail Pulley free from build-up and trapped material
B)   Tail Pulley damage
C)   Skirting in the loading area
D)   Impact Bed or Impact Idler damage
E)    Slider Bed clean and smooth
F)    Carrying Side Idler damage
G)   Carrying Side Self Trainers (operational and not tied off)
H)   Secondary Loading Stations (skirting, impact bed or impact idler damage)
I)    Tripper Frame damage
J)    Tripper Discharge Pulley – clean
K)   Tripper Bend Pulleys – clean
L)    Head Pulley and/or Drive Pulley (clean, check for worn lagging, re-lag Drive Pulley if rubber is old, worn, smooth and hard)
M)  Head Pulley cleaner or scraper – operational
N)   Head Pulley Snub – clean
O)   Return Idlers – clean and turning freely
P)    Bend Pulley – celan
Q)   Take-up – clean
R)   Return Side Self Trainers – operational and not tied off
S)    Damage to return side frame due to mistraining
T)   Plow or Scraper in front of Tail Pulley – operational.

The preceding list should be used as a guide when inspecting the conveyor while it is empty and shut down. Numerous items in the preceding list contained the words “clean or operational”. Pulleys or idlers that have build up on them will cause tracking problems. The same can be said for pulleys that have some of the rubber lagging worn off.

      Scrapers, plows and self-trainers must be operational to perform their tasks. Belt damage, pulley damage and tracking problems will result if these accessory pieces of hardware are not well maintained.

(ii) Belt Running Empty

The conveyor should be turned on and run empty. The purpose of this is to run the conveyor while running empty to check for any tracking problems, the system will need to be inspected under running conditions when loaded, because empty belts and loaded belts do not necessarily track the same way.

(iii) Belt Running Loaded
The next step in inspection process is to run the belt in a loaded condition. We will add a few new steps in the inspection process and repeat a few on the previous steps. The following is our check list for operating the conveyor while loaded:
A)   Tail Pulley – turning freely without bearing noise, product build up or carryback; belt tracking satisfactorily.
B)   Load area spillage
C)   Carry Side Idlers – turning freely
D)   Carry Side Self-Trainers – functioning
E)    Secondary Loading Station spillage
F)    Tripper Area (tracking and spillage)
G)   Head Pulley and or Drive Pulley (smoothly running, slippage when starting or running, belt cleaners – functioning, and belt tracking)
H)   Head Pulley Snub – turning freely without bearing noise and clean
I)    Return Idler – clean and turning freely
J)    Bend Pulleys – turning freely without bearing noise and clean
K)   Take-up Pulley – turning freely without bearing noise, clean, moving freely in the frame
L)    Return Side Self-Trainers – functioning
M)  General Belt Tracking
N)   Plow or Scraper in front of Tail Pulley – functioning

(iv) Corrective Action
The last step is to take the corrected action required on the conveyor in addition to: A) Clean Up
B) Lubrication
C) Safety concerns – such as installing or repairing conveyor crossovers, safety stop cables, holdbacks on incline conveyors, edge limit switches, motor guards, hand rails and etc.


A conveyor system with carryback on the return side is the single biggest reason that conveyor belts are replaced, return idlers and pulleys are replaced and structure is worn through. Material build up on the belt and hardware causes tracking problems that will lead to edge damage that leads to new belt and new idlers.

    We urge you to use scrapers on the head pulley and plows in front of the tail pulley as prevention for damage in your maintenance planning. Some sticky materials present a real challenge when it comes to preventing carryback. Cleated belts may be reversed to allow better release at the discharge point. A dual scraper system on the head pulley is the most common way to eliminate product carryback.

    A water spray on the belt cover along with wiper blades will effectively remove most products from sticking to the cover. A series of out of round (cam shaped) return idlers will also assist in cleaning. These idlers are spiral wound from the edges towards the center of the idler and work on the premise of a turning beater bar arrangement. A brush may be the only solution for cleated belts. If your belt is not effectively clean on the return run, then any bend pulley or head snub pulley that come in contact with the carry side of the belt will accumulate product.

    Henan Pingyuan would like to offer few hints on pulley and idler cleaning. All return side pulleys that come in contact with the carry cover can be lagged with a soft rubber vulcanized to the pulley. The constant flexing action of the soft lagging will cause material to fall off and reduce material accumulation.

    A lever weighted urethane scraper pressed against the pulley face, is an excellent way to remove build up. This system causes additional wear on the pulley face so it is suggested to use heavier walled return bend pulleys when using a scraper. If a scraper is applied to a head snub or bend pulleys at the take-up area, then deflector plates will have to be installed to deflect the build up away from the belt.

    Return idlers can be rubber covered and will help prevent product from sticking to the return idler. Return idlers can be purchased that are nothing more than disc mounted on a shaft. These discs can be made of soft rubber, urethane or ceramics. This type of return idler can be very effective to prevent build up.

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Henan Pingyuan Mining Machinery Co., Ltd is the most professional manufacturer of Belt conveyor, andVibrating screen, Bucket elevator, Screw conveyor, Scraper conveyor using the world's most advanced technology, we are willing to serve every company to meet your custom needs. our goal is "be the future global leader of mining machinery industry". have any questions, please contact us without any hesitation.

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.