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. 

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.

Why will Belt Conveyor Motorized Pulley Get Rusty

During the operation process of belt conveyor, it will occur some problems due to incorrect method of using or wear and tear, therefore, we need to know some knowledge in order to ensure the normal operation. Here PK Machinery will list some reasons why motorized pulley of belt conveyor will rust:
1. Electroplating time is not enough, it dues to the problem of process flow;
2. Air liquidity of the location where motorized pulley stores is not good, or the location is wet, it is may due to the large difference in temperature;
3. If the package sealing breaks, the motorized pulley may oxidate and get rusty;
4. The most important point is that before electroplating, the dirt on motorized pulley surface is not being cleaned well, it is also one of the reasons why the motorized pulley will get rusty.

 

How to Prolong Working Life of Belt Conveyor

    Belt conveyor widely used in mining, metallurgy, coal, fertilizer, chemical, cement and other industries. The usage of belt conveyor is to convey bulk materials or pieces materials to another location according to different transferring requirements. The conveying systems can comprised only one belt conveyor or several conveyors or combined with other conveying equipment. The belt conveyor can be installed horizontally or incline to satisfy the clients requirements.  

 The reliable operation of belt conveyor is vital in industries. The risk of failures in operations needed to be eliminated. The technical team or mechanical workers should do inspection regularly and pay attention to the case or parts. The conveyor belt life span can be extended up to 4 times if transfer points are controlled correctly. The conventional chute systems or transfer points generally drop the material from point A to point B.  The height of the drop normally is not taken into account however this is the most critical factors that affect belt conveyor lifespan. The dropping products with lump sizes up to 500 mm directly onto an outgoing conveyor belt will create a massive impacts and resulting in belt damage over a short period. 
    Besides, the foreign objects which move through the systems also affect the life span of belt conveyor. When a new underground mining operations are being established, there are some foreign objects such as concrete, iron, pillars and steel ropes may fallen on the belt conveyor. This normally will cause blockages or stoppages. Controlling the flow of materials onto conveyor belt is to reduce impact has become a topic for discussion and numerous solutions being proposed. There are a lot information are needed to design on a transfer point which satisfy the proposed concept. The information includes product type and consistency, conveyor trajectory angles, transfer height and distance.   
    Just obtaining this information is not sufficient, it is necessary to do an on-site assessment to verify the data. This enable engineers to tackler other issues which could be causing impact damage on the belt conveyor. In addition, uneven conveyor belt loading, flooding of the belt and blockages could cause damage too. A good design of belt conveyor can prolong the life span and increase the efficiency of the operation. 

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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.

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.

Hazards and Safeguarding Methods of belt conveyor

Typical Conveyor Hazards and Safeguarding Methods

Belt Conveyors

Hazards:

•Belt conveyor drive mechanisms and conveying mediums

•Conveyor take-up and discharge ends

•Where the belt or chain enters or exists the in-going nip point

•Where the belt wraps around pulleys

•Snub rollers where the belt changes direction such as take ups

•Where multiple conveyors are adjoined

•On transfers or deflectors used with belt conveyor

Hazard Controls:

-Nip and shear points must be safeguarded

-Side guards (spill guards) can prevent contact with power- transmission components, in-going nip points and the conveying medium

-Secondary safeguards include railings or fencing or safeguarding by distance (location) and hazard awareness devices such as pre start-up signals and warning signs. 

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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.

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.

   -------------------------------------------------------------------------Henan Pingyuan Mining Machinery Co., Ltd is the most professional manufacturer of Belt conveyor, and Vibrating 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. 

Protective Device’s Type and Function of Belt Conveyor

 There are some protective device inside the belt conveyor to prevent accidents and ensure the safety when conveying materials. Protections of belt conveyor consist of belt sway protection, belt-broken protection, sliding protection and emergency stop pull switch. Belt sway, belt-broken and sliding protections are course switch with simple structure and low cost, the working principle is that the machine would stop when belt touched switch. Emergency stop pull switch rely on an electric switch and pulls the steel cord wire installed on both sides of the belt.

Speed sensors: using hall elements to detect the speed of belt conveyor. If the speed of driven wheel is in 50%-70% Va, or the speed of belt conveyor is less than or equal 50% Va or greater than or equal 110% Va, and after 5-10 seconds delay, the controller would cut off the power source automatically to protect the speed.

Disalignment transducer: be off-state in normal, and close when operation. It will cut off the power source automatically to stop belt conveyor.

Coal blocking transducer: breakover by two electrodes, through leads give the reaction of coal volume to protective device. It monitors the coal volume in bucket and bunker, and will cut off the power source when bunker is full or coal piling in machine head to achieve protection. 

Scram protection: there is pull urgent stop switch installed on the control panel of each controller and the belt side, used in emergency stop when trouble.   

Overtemperature protection: uses a temperature senor to monitor the temperatures of bearing and other parts of belt conveyor and environment temperature. When the temperature of the monitoring points is more than the set value, the controller will cut off the power source automatically to protect the machine and start sprinklers to cool.

Smoke transducer: when detects the smoke produced, the controller will cut off the power source and start the dust extinguishing sprinkler device. 

Rip transducer: when the belt has longitudinal tear problem, the coal falls on the sensor, and the controller will cut off power source to stop the belt conveyor. 

Safety protection device of belt conveyor is used to monitor and give alarms when happens troubles in operation. It can make the conveyor system safety production, proper operation and protect the safety of operating personnel. Besides, it can also facilitate centralized control and improve the level of automation.

Common protection and monitoring devices are as follows:

Longitudinal tear protection device: used to detect the belt conveyor. When there are material sharps in conveyor and the belt torn from middle, the controller will cut off power source.

Belt sway switches: used to detect the conveyor belt running deviation and distortion degree, can prevent edge damage and materials diffused to realize automatic alarm and stop the machine. A  warning signal when the mild deviation, delay action, alarm and automatic shutdown when severe deviation. Generally installed in the head, middle, tail and inspection points of the belt conveyor.

Pull switch: it is a protective device for conveyor-site emergency stop when an emergency occurs, anywhere in the field to pull the switch, can be a warning signal, and then self-locking and stop. Generally pull switch mounted on both sides every 60m of belt conveyor.

Chute block switch: used to detect chute blockage of belt conveyor system. When occurs blockage, the controller will give an alarm and shut down. 

Slip detector: used to detect the difference of linear speed between shaft belt and driving idler. It can give an alarm and achieve automatic tension and normal shutdown.

Overspeed detection device: used for downstream transport or transported under conditions. When the conveyor speed reaches 115% -125% of the specified belt speed, it will give an alarm and emergency stop.

Minimum run out of idler rollers for belt conveyor

Most of the drivers understand that proper wheel alignment for your vehicle is paramount to your safety and extends the life of your tires, provides better mileage and gives more comfortable ride. Similarly, proper alignment of the “scale area” is paramount to satisfactory operation of a belt conveyor scale. Most scale manufacturers have established strict guidelines for installing and aligning belt conveyor scales. Failure to follow these guidelines may result in less than favorable scale accuracies and repeatability.

The idler alignment must be completed prior to placing a belt conveyor scale into operation. This alignment includes idler spacing, centering the idlers on the conveyor frame and adjusting the idler backing height. All of these dimensions must be held to a maximum tolerance of 0.030. The height and centering dimensions of alignment are verified by use of several “string lines”. It is recommended that a minimum of five string lines be used and on wide conveyors (≥42”) as many as 7 string lines be used. These lines will ensure that the idlers are level with one another, aligned on the same conveyor centerline and that the wing roll angles match within ± 1o.

It is recommend the usage of idler specially manufactured for use with a belt conveyor scale. These idlers are known as scale duty or scale quality ensure. The minimum Total Indicated Runout (T.I.R) tolerance is 0.015” and that the idler trough angle is within ± 1o. T.I.R is a measurement of the variance of a cylindrical item as it is rotated. Here’s a sketch to illustrate the measurement using a dial indicator.

Some manufacturers build a scale quality idler that has an adjustable plate built into the end stand to enable fine alignment of the trough angle during installation. The use of existing idlers (non-scale quality) is not prohibited, it may result in additional time being required for the alignment. In extreme circumstances, it may be necessary to modify the trough angle to meet the 1 degree tolerance, as well as adding bracing to the cross member and adding gusset supports to the end stands.

These “extreme” measures of idler modification may seem time-consuming and costly, but they will aid in long-term accuracies from the belt conveyor scale system.

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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.

Problems and solutions in the operation of belt conveyor

1) The motor too heat 

Reason: Due to overloading or conveyor belt was stucked, the running resistance increases, motor overload operation, lubrication conditions of driveline is poor, also can led to the increase power of motor. 

The solution: Relubrication the transmission parts timely

Reason: Accumulation of coal dust in the inlet of the motor fan or radial gasket, make the cooling conditions deteriorate.

The solution: Clean the coal dust. 

2) The problem of belt broken.

Reason: The material of the belt body is not fit,becomes hard and brittle when come across cold or water. 

The Solution: use the material stable in mechanical and physical properties to produce the core.

Reason: The strength of the conveyor deteriorates due to long-term use.

Solution: replacement the damaged or aging conveyor belt timely, observed the joint regularly find problems in time. 

3) the axis of the roller and belt conveyor centerline are not vertical. 

Reason: Roller axis is not perpendicular to the centerline of Belt conveyor in installation caused the conveyor belt deviation

Solution: Adjust the roller that run laterality to the the direction of the conveyor belt running .

4) The rotation of the idlers is not flexible or can not run.

Reason: Bad in seal and dirt into the bearing causing the rotation of the idlers is not flexible or can not run. 

Solution: replacement of the roller that does not rotate immediately.

Reason: There are dung on the rolls. 

The solution: removal the dung on the rolls timely .

5) Slipping of the belt.

Reason: The tensioning force of the conveyor belt is shortage cause the belt slip. 

The solution: re-adjust the tension, reduce the traffic. Reason: The coefficient of friction between the roller and the conveyor belt reduces because of watering. 

The Solution: eliminate watering, increasing the tension, use the drum with pattern rubber surface

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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.

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 the belt 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 the conveyor shut down. 

Reasons of Drifting of Belt Conveyor

 As one of the most common conveyors, belt conveyor is widely used in metallurgy, chemical, electricity, coal, mining, port, transportation and so on. In operation of belt conveyor, there is much drifting of the machine. The following is reasons of the phenomenon.

1. There is coal or other attachments in the surface of pulley or idler.

2. There is mistake in the degree of net post manufacture of driving pulley and bend pulley.

3. Driving pulley and bend pulley are not parallel.

4. Diameters of driving pulley and bend pulley are inconsistent.

5. Center line of driving pulley and bend pulley is not vertical with center line of machine body.

6. Feeding position is inappropriate.

7. Center of pulley is not in the center line of the machine.

8. Installation of idler is inappropriate.

9. Stiffness of frame is bad which causes the deformation of the machine.

10. Joint of belt conveyor is inappropriate or the belt conveyor is aging and deterioration.

11. Rotation of unilateral bearing is not flexible.

12. The damage of ware of the two side of driving pulley are inconsistent.

13. The adjusting device is damaged.

14. Girdle pulley in head and bend pulley are not parallel.

15. Center lines in both sides of belt conveyor are not consistent, or the margin of belt is heavily damaged.

16. Installation of feeder, unloader and sweeper is inappropriate.

17. Degrees of ware of two sides of coal unloading pulley are inconsistent.

18. Take-up tension of belt conveyor is not enough.

19. Feeding direction and height arrangement are inappropriate.

20. Support of idler is heavily damaged.

Introduction of belt conveyor

Henan pingyuan mining machinery Co., Ltd provides different types of belt conveyor which are fixed belt conveyor,sidewall bell conveyor, portable belt conveyor, shuttle conveyor and tripper.

Fixed belt conveyor

Fixed Belt Conveyor is a friction drive conveyor transported materials continuously. Belt conveyor machine comprises the    rack,conveyor belt, pulley, rollers, tensioning devices, driving unit and other components. It not only conveys material but also can cooperate with various industrial equipments to form a rhythmic transport line.

Sidewall belt conveyor

            

Sidewall belt conveyor is continuous transporting equipment of loose bulk materials such as coke, coal,

 limestone, sand and gravel. It adopts high quality conveyor belt with corrugated sidewall and horizontal baffle.

 Sidewall belts are used to convey material up inclines. The sidewall increases the carrying capacity of the belt 

and prevents product from falling off the edges of the belt. Hot vulcanization provides a 5x greater adhesion 

between the belt and sidewall, eliminating the need for bolting the sidewall to the base belt. Greater adhesion

 also prevents the sidewall from lifting and separating from the base belt, extending the belt life.

Portable Belt Conveyor

DY Portable belt conveyor is lightweight continuous conveying equipment which has the features of high efficiency, good mobility, and convenient usage.
Movable belt conveyor is divided into rise-and-fall and non rise-and-fall conveyors.
      It is a kind of machinery that can transfer the material continuously by friction drive.
      According to different transport requirements, the transport system can be single belt conveyor or consist of several conveyors or be combined with other conveying equipments.
      It can be installed horizontally or aslant to meet the needs of different production lines. 

Shuttle conveyor

Shuttle conveyor is designed for conveying material moves along a transport direction on the steel track which is usually installed on the top of the storehouse.Reversible conveyor mainly used to discharge material constantly
 in multi-point when the discharging points could move.

Tripper

Belt conveyor tripper is a mobile device which can unload materials at the arbitrary point of horizontal section of the conveyor; it’s a single part of the conveyor. Movable tripper can be divided into light-duty type and heavy-duty type.

For more information, pls do not hesitate to contact us via : 

Web:http:www.pkmachinery.com

Mobilephoe:+86 18338953783

Tel: +86 373 579 9198

Fax: +86 373 507 1699

Address: 289 Yellow River Road, Xinxiang City, Henan Province, China