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History of Conveyor Belts

Conveyor belts might be one of the most well-known pieces of equipment in the manufacturing sector. When someone imagines a factory, they likely picture works in progress, traveling down a conveyor belt through an assembly line. Conveyor belts are commonplace at grocery store checkout aisles, airport security checkpoints and baggage claims, treadmills at the gym and industrial facilities alike. They&#;ve become so closely associated with manufacturing and production because of their incredible efficiency, versatility and long-standing history.

When Were Conveyor Belts Invented?

Historians debate over when the first conveyor belts appeared. Many believe the earliest hand-operated, wood-and-leather belt conveyors first cropped up in the late s. The first heavy-duty conveyor belt appeared in to carry coal, ore and similar products. Historians credit their invention to Thomas Robins, who developed a series of designs that eventually produced the heavy-duty belt.

Leading to , a series of inventions contributed to the technology. The American inventor Oliver Evans, best known for inventing the automated mill, included a wooden conveyor belt system in his patented design in . His invention, which also included bucket elevators and modified Archimedean screw conveyors, yielded a flour mill capable of continuous manufacturing with zero human labor. After the mill saved Joseph Tatnall, the leading miller at the time, $37,000 in its first year, inventors across industries realized the conveyor belt&#;s potential to increase efficiency.

Steam-powered conveyor belts arrived in  when the British Navy began using them in their kitchens. In , when Charles Goodyear invented vulcanized rubber, belt conveyors became more durable and powerful. Vulcanized rubber conveyor belts were more heat-resistant than previous models. Steam remained their primary power source until Robins invented what we would consider the modern conveyor belt.

The Swedish engineering company Sandvik AB invented steel conveyor belts, which came on the scene in , shortly after Robins&#; invention. Steel allowed these simple systems to withstand the stress demands of industrial use. Since then, many companies have continued to improve on conveyor belts&#; initial designs. Over the years, conveyor belts have taken on new materials, improved shapes and increasing popularity.

History of Conveyor Belts

The conveyor belt has come a long way since the s. Since their beginning, conveyor belts have improved efficiency. Each iteration has offered distinct productivity benefits. Innovations have allowed more industries to take advantage of conveyor belts, and today, almost every sector of the industrial market has used conveyor belts in some form. Here&#;s how conveyor belts have evolved throughout their history:

Primitive Conveyor Belts

We know the earliest conveyor belt systems have been around since because they are included in Oliver Evans&#; flour mill design. It&#;s unclear who their original inventor was or when they first appeared. In these primitive designs, the conveyor frame was a simple flat wooden bed with a belt running over it. They were hand-operated using hand cranks and a system of pulleys. The belts themselves consisted of leather, canvas or rubber, with the earliest ones made from leather.

These primitive conveyor systems were short compared to the incredible lengths we see today. Farmers used these first conveyor belts to transport grain over short distances. They were often employed at shipping ports, where they conveyed agricultural products onto ships. They were also used in flour milling.

Steam Powered Conveyor Belts

Steam engines had been around long before hand-crank conveyor belts, so it didn&#;t take long for the technologies to merge. With steam power&#;s introduction, belt conveyors no longer needed hand cranks or human labor to keep the belt moving. This innovation aligned with the British industrial revolution in the 18th century.

The first recorded use of a steam-powered conveyor belt was in the British Navy, which integrated them into their kitchens in . The machinery was used to streamline baking &#; in particular, baking biscuits. This innovation made it much more efficient to feed the many sailors enlisted in the world&#;s largest navy.

After the navy found success with steam-operated conveyor belts, it didn&#;t take long for other industries to follow suit. Not surprisingly, bakeries were one of the first industries to accept steam-operated conveyors. Many slaughterhouses also adopted the technology.

Heavy-Duty Conveyor Belts and the Industrial Revolution

The invention of vulcanized rubber in was a significant milestone. While even primitive belt conveyors used rubber, they were much more sensitive to temperature changes. They became rigid and brittle in cold environments and melted in the heat.

Thomas Robins invented the heavy-duty conveyor belt in . He began his series of inventions in  to develop a more efficient way to carry coal and ore. He created what we consider the modern conveyor belt for Thomas Edison&#;s company, the Edison Ore-Milling Company, in Ogdensburg, New Jersey. The resulting conveyor used steel idler rollers and rubber-covered belting. These heavy-duty materials could convey heavy, abrasive materials such as iron ore efficiently.

After his invention&#;s success, Robins formed the Robins Conveyor Belt Company and patented the three-roll idler in . The company has changed hands many times over the years and still exists today as ThyssenKrupp Robins. His heavy-duty conveyor belt won the grand prize at the Paris Exposition and first prizes at the Saint Louis Exposition and the Pan-American Exposition. It was a massive boon to the industrial revolution already underway, and many industries began implementing the technology.

When Sandvik&#;s steel conveyor belts arrived in , they were another popular option for coal and aggregate mining operations. Within a few years, the food production industry adopted steel conveyor belts. The first European manufacturer to adopt conveyor belts was probably the coffee production company Kaffee HAG, also known as Coffee HAG. The world&#;s first decaffeinated coffee producer began production in  in Bremen, Germany. Thanks to their belt conveyors, Kaffee HAG could process 13,000 pounds of coffee every day.

As steel belting took off in food production, rubber-covered belts became the industry standard for mining, quarrying and mineral processing for their flexibility and superior durability.

Underground Conveyor Belts

The next major innovation was the underground conveyor belt, which mining engineer Richard Sutcliffe invented and patented in . While conveyor belts already had applications in the mining industry, they weren&#;t yet used underground. They needed some adaptations to survive the harsh environments and operate in confined spaces. Sutcliffe&#;s solution was a belt made from layered cotton and rubber.

The preferred method for transferring coal from the source to surface operations was a rail car. A belt conveyor was a major improvement because they were more affordable and easier to maintain than rail cars. When a mine reached the end of its life, a conveyor could be packed up and brought to the next site, unlike permanent rail cars. While he&#;s credited with inventing the underground conveyor belt, Sutcliffe called his manufacturing company &#;Universal Works&#; because the systems were suitable for both above- and below-ground applications.

Henry Ford&#;s Conveyor Belt Assembly Line

While not their inventor, Henry Ford might be the name most often associated with conveyor belts. When he became the first car manufacturer to introduce belt conveyors in , he made the invention famous. Innovations didn&#;t spread fast in those days, so his headline-making implementation helped popularize conveyor belts across more manufacturing sectors. He got the idea after studying how their use in slaughterhouses in Chicago and Cincinnati improved efficiency and productivity. He then built on the Oldsmobile brand&#;s continuous assembly line and introduced a conveyor belt to speed up the process.

While it took five full years to changeover his factories at the Ford Motor Company, the results were astounding. He slashed the time it took to manufacture a Model-T from around 12 hours to just an hour and 33 minutes. In , Ford introduced a new mechanized belt that moved as fast as 6 feet per minute. By , conveyor belts were industry standard for the automobile manufacturing industry. After Ford&#;s sensational introduction, belt conveyors became more widespread throughout the s. Meanwhile, in the coal mining industry, they grew to nearly 5 miles long.

Synthetic Fabric Belting

While the Second World War (WWII) slowed the mining and quarrying industries, it was an excellent time for conveyor belts. To support the war efforts, America placed restrictions on many natural materials, including rubber, canvas and cotton. To adapt, manufacturers developed several synthetic fabric belts. In the mid-20th century, urethane and synthetic rubber belts arrived to replace other belting materials.

By the s, lightweight, fully synthetic belting became widespread. The benefits of synthetic belting are still being realized today. The synthetic material is lightweight and flexible. This quality lets belt conveyors operate with smaller pulleys and can handle high speeds. Today, cotton, canvas, rubber and steel belts haven&#;t gone away. Now, with no material shortages to worry about, manufacturers can select the conveyor belting material best for their particular application, whether it&#;s synthetic or natural.

Another wartime and post-WWII improvement was the V-belt assembly. The V-belt is a massive improvement over the traditional flat belt. While flat belts can easily slip out of place on their pulleys, V-belts have sidewalls that fit into place along designated grooves. Their unique shape allowed conveyor belts to move higher loads, which significantly improved efficiency.

Plastic Modular Belting

The s marks the transition into the modern era of conveyor belt history. Manufacturers introduced many innovations that made the systems quieter, longer-lasting and cheaper to maintain during this decade. Some of the developments included precision bearings, quiet and internally powered rollers and motorized gearboxes and pulleys.

One of the most groundbreaking innovations of the &#;70s, plastic conveyor belts, solved the food processing industry&#;s unique need. Since rust and corrosion built up on metal belts, food processors needed a food-safe material for their belt conveyors. In , the Louisiana-based company Intralox designed and patented a modular plastic conveyor belt. Rather than a continuous loop of fabric, these belts use small, interlayed plastic bricks.

Today, modular plastic belts consist of polypropylene, polyethylene or acetal thermoplastics. Plastic conveyor belts offer some distinct advantages that have revolutionized the industry. As low-tension systems, plastic modular conveyor belts can be wider than they are long. They can travel around corners and along inclines and declines more efficiently than traditional belt conveyors. Because they are simple to take apart and clean, they&#;re the industry standard for food processing plants to this day.

Conveyor Belts Through the Ages &#; and Into the Future

Since their original use in agriculture to transport grain and other materials, conveyor belts have been adapted to many applications across many industries. Today, belt conveyors transport goods throughout production facilities in food processing, bottling and canning, automotive manufacturing, printing, logistics and warehousing, paper goods, textiles and more. Here are some examples of conveyor belts throughout history and their specialized uses:

&#; The First Underground Conveyor Belts

In , conveyor belts were adapted for underground mining applications. The first six underground belt conveyors were installed in the Glass Houghton Colliery Company. The belts were 20 inches wide and 110 yards long. They moved at 200 feet per minute and together moved 500 tons of coal per day.

&#; The Mobius Strip Conveyor Belt

Another improvement came with the Turnover Conveyor Belt system, which the B. F. Goodrich Company patented in . The conveyor belt was shaped to form a Mobius strip rather than a loop. By incorporating a half-twist into the belt design, the belt formed a one-sided shape, rather than the two sides formed with a regular loop. Since the belt could expose its entire surface area to wear and tear, it had a longer lifespan than traditional belt conveyors.

While the Mobius conveyor belt was an important innovation, they&#;re no longer manufactured today. Now, belt conveyors can achieve longevity through more durable materials and more layers, making the twisted design obsolete.

&#; The First Sushi Conveyor

Conveyor belt sushi restaurants today are a fun novelty experience, born out of a need for efficiency. Inventory Yoshiaki Shiraishi had trouble staffing his sushi restaurant and couldn&#;t run the establishment by himself. The conveyor let him serve customers quickly without increasing his staff. He opened his first restaurant and patented the concept in  before moving on to open 250 franchises throughout Japan.

&#; The World&#;s Longest Conventional Conveyor

Stretching for 61 miles, the current world record-holder for longest conveyor belt was built in in the Western Sahara. It runs from the Bou Craa phosphorus mines to the coastal city of El-Aaiun. It transports 2,000 tons of rock per hour to the port for loading onto cargo ships. It&#;s length combined with the distinct white phosphorous ore make this conveyor belt visible from space.

The Present Day &#; Smart Conveyor Belts

The Internet of Things (IoT) and other smart manufacturing technology has been transforming the industry over the last several years. As with much of the other equipment found throughout the shop floor, manufacturers are now equipping conveyor belts with smart technology. The technology allows the belt conveyor to communicate with other machines in the production facility and uses a system of sensors and artificial intelligence (AI) to make smart, automated decisions.

For example, smart conveyors can analyze their power usage to reduce consumption when full power isn&#;t needed and shut themselves down when not in use. They can also detect safety hazards, such as an item being caught in the belt. They can inspect themselves while in operation and use statistical analysis to predict when and where the conveyor might fail before it causes unnecessary downtime.

The Future of Conveyor Belts

While the IoT is already here, the conveyor belt will improve as AI gets more sophisticated. Still, there will always be a place for traditional belt conveyors. Not all industries need to implement smart conveyor belts, and these sectors will continue to benefit from innovations in belting material and more sophisticated designs. For example, adjustable width belts are growing in popularity since they allow producers to handle multiple different product types and sizes on a single system.

Trust SEMCOR for Your Custom Conveyor Belt Needs

SEMCOR provides conveyor belts and belting services to clients throughout Illinois, Indiana, Kentucky, Iowa, Kansas and Missouri. Besides our off-the-shelf belting solutions, we also offer extensive modification and fabrication expertise. We assist with installation, inspection, repair and alignment, and custom fabrication of conveyor belts. We strive for belting solutions that lower your maintenance needs, extend your service life and address the specific concerns your company faces.

If you need conveyor belt customization or repair for your facility in our service area, contact us for more information or to request a quote.

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Introduction

This article will take an in-depth look at belt conveyors.

The article will bring more understanding on topics such as:

• Belt Conveyors and their Components
• Types of Belt Conveyors
• Design and Selection of Belt Conveyors
• Applications and Benefits of Belt Conveyors
• And Much More&#;

Chapter 1: What are belt conveyors and their components?

This chapter will cover the basics of belt conveyors and their various components.

What is a Belt Conveyor?

A belt conveyor is a system designed to transport or move items such as materials, goods, or even people from one point to another. Unlike other conveying methods that use chains, spirals, or hydraulics, belt conveyors utilize a belt to move the items. This system consists of a loop of flexible material stretched between rollers, which are driven by an electric motor.

Since the items being transported can differ significantly, the belt material used in the conveyor system also varies. Typically, it is made from polymers or rubber, depending on the specific requirements of the application.

Components of a Belt Conveyor

A standard belt conveyor system includes a head pulley, tail pulley, idler rollers, the belt itself, and the frame.

Head Pulley

The head pulley is connected to the actuator and the electric motor, providing the pulling force that drives the conveyor. Located at the discharge end where the conveyor offloads its materials, the head pulley is crucial for system operation. To enhance traction, the outer surface of the head pulley is often covered with a rough jacket known as a legging.

The head pulley usually has the largest diameter of all the pulleys. Sometimes a system can have multiple pulleys that act as drive pulleys. The pulley at the discharge end, is a drive roller usually with the biggest diameter, and will be identified as the head pulley.

Return or Tail Pulley

The tail pulley is situated at the loading end of the belt conveyor. It often has a wing shape to help clean the belt by directing materials away from the support members.

In a basic belt conveyor setup, the tail pulley is typically mounted on guides with slots to adjust the belt&#;s tension. In other conveyor systems, as we will explore, tensioning is managed by a separate component known as the take-up roller.

Idler Roller

Idler rollers are positioned along the length of the belt to support both the belt and its load, prevent sagging, ensure proper alignment, and remove carryback (material that sticks to the belt).

While idler rollers can perform all of these functions or just one, their primary role in any conveyor system is to support the belt.

Various types of idler rollers are designed for specific functions, as outlined below:

Troughing Idlers

Troughing idlers consist of three rollers arranged to create a "trough" shape for the belt. These idlers are positioned on the side of the conveyor that carries the load. The central idler is fixed, while the two end idlers can be adjusted to modify the angle and depth of the trough.

These idlers help reduce spillages and maintain a consistent cross-sectional area along the length of the belt conveyor, which is crucial for stability.

Rubber Disk Idler

This idler features rubber disks spaced along the roller's axis. The rollers at the extreme ends are positioned closer together to support the belt edges, which are more susceptible to tearing. The spaced disks help dislodge any carryback or leftover material, reducing buildup on the underside of the belt. This buildup is a common cause of mistracking, where the belt shifts to one side and causes misalignment.

Screw Idler Roller

In some cases, the disks are arranged in a helical pattern, resembling a screw, and the idler is referred to as a rubber screw idler roller. Despite the different design, its function remains the same. An example of a screw idler roller is shown below.

The screw idler can also be constructed from a rubber helix. Screw idlers are particularly useful in situations where a scraper for removing carryback isn't practical, such as on mobile belt conveyors.

Trainer Idler

Trainer idlers ensure the belt runs straight and counteract mistracking. They feature a central pivot that redirects the roller back to the center if the belt drifts to one side. Additionally, they include two guide rollers to help guide the belt.

Conveyor Belt

When setting up a belt conveyor, the belt itself is often the most intricate component. Its tension and strength are crucial, as the belt endures significant stress during loading and transporting materials.

The increasing demand for longer conveyor lengths has spurred research into new materials, though this often comes with significant costs. Stronger belts that comply with environmentally friendly regulations can be prohibitively expensive, sometimes making the costs difficult to justify. Conversely, opting for a more economical approach can lead to belt failure and higher operating costs. Typically, the cost of the belt should be less than 50% of the total cost of the belt conveyor.

A belt is comprised of components such as:

Conveyor Carcass

Since this is the skeleton of the belt, it has to provide the tensile strength needed to move the belt and the lateral stiffness for supporting the load. It must also be capable of absorbing loading impact. The belt is a loop so it has to be joined; this is known as splicing. Because some of the splicing methods require the use of bolts and fasteners, the carcass must be able to provide an adequate and firm base for these fasteners.

The carcass of a belt is typically constructed from steel cord or textile ply. Textile ply consists of fibers such as aramid, polyamide, and polyester. A single-ply carcass may also be PVC-coated. Carcasses can be built up to six layers thick and often include edge protection, which is essential for bulk conveyor belts.

Conveyor Covers (Top and Bottom & Sides)

The covers of a belt are made from flexible materials such as rubber or PVC and are exposed to weather elements and the working environment. It is important to carefully select the covers based on their intended use. Considerations typically include flame resistance, low-temperature resistance, grease and oil resistance, anti-static properties, and food-grade suitability.

The carrying side of the conveyor is designed based on the load, angle of inclination, and overall use of the belt. It may feature special configurations such as corrugated, smooth, or cleated surfaces to suit different requirements.

In applications such as scrap conveyors in CNC machines, steel belt conveyors are used because they are more durable and resistant to wear compared to conventional materials.

In the food processing industry, PVC, PU, and PE belts are utilized to preserve food quality and minimize contamination.

Plastic belts, while relatively new, are gaining popularity due to their numerous advantages. They are easy to clean, have a wide temperature range, and exhibit excellent anti-viscosity properties. Additionally, they are resistant to acids, alkaline substances, and saltwater.

Conveyor Frame

The frame of a conveyor system varies based on factors such as loading, operational height, and the distance to be covered. It can range from a simple cantilever setup to more complex trusses for handling larger loads. For simple and lightweight operations, aluminum extrusions are also commonly used.

The frame design is a crucial aspect of conveyor construction. An improperly designed frame can lead to:

• Belt running out of track
• Structural failure which results in:
  • Long downtimes which translate to delays in production
  • Injuries and casualties
  • Costly Spillages
• Expensive fabrication methods and installation.

Additional accessories, such as walkways and lighting, can be mounted on the frame, as shown above. Lighting installations often require sheds and guards to protect the material. Loading and discharge chutes may also be added. Understanding these potential add-ons is crucial to prevent uncalculated overloading.

Chapter 2: What are the types of belt conveyors?

This chapter will cover the various types of belt conveyors, including:

Roller Bed Belt Conveyor

In this type of conveyor belt, the surface just beneath the belt consists of a series of closely stacked rollers. This arrangement minimizes belt sagging.

These conveyors are suitable for both long and short-distance conveying. In some cases, they can be so short that they use only two rollers for the entire system.

When utilizing gravity for loading, a roller bed conveyor is an excellent choice. Manual loading can cause damage to the rollers due to the internal bearings they typically have. These bearings, combined with the generally smooth surface of the rollers, significantly reduce friction, making conveying easier.

Roller bed belt conveyors are primarily used for hand sorting, assembling, transporting, and inspection tasks. Examples include:

• Airport baggage handling
• Courier items sorting including postal offices

Flat Belt Conveyor

The flat belt conveyor is one of the most commonly used types of conveyors. It is typically employed to transport items within a facility. Internal conveyance relies on a series of powered rollers or pulleys to move the belt.

The belts used in flat belt conveyors can range from fabrics and polymers to natural rubbers, making them versatile for transporting various materials. They are also easy to align, with the tail pulley typically mounted to allow for adjustments. Generally, flat belt conveyors operate at low speeds.

Applications of flat belt conveyors include:

• Slow assembly lines
• Washdown applications
• Light dusty industrial assembly

Modular Belt Conveyor

Unlike flat belt conveyors, which use a continuous flexible belt, modular belt conveyors employ a series of interlocking rigid pieces, typically made from plastic or metal. They function similarly to a bicycle chain.

This design provides significant advantages over flexible belt conveyors, including greater durability and the ability to operate across a wide range of temperatures and pH levels.

When a section of a modular belt becomes damaged, it is easy to replace just that section, unlike flexible belts, which require replacement of the entire belt. Modular belts can navigate corners, straight lines, inclines, and declines using only one motor.

While other conveyors can also perform these tasks, they often involve increased complexity and cost. Modular belt conveyors are particularly advantageous for applications requiring unusual dimensions, such as widths greater than lengths.

Due to their non-metallic nature, ease of cleaning, and porosity to gases and liquids, modular belt conveyors are suitable for applications including:

• Food handling
• Fluid handling
• Metal detection

Cleated Belt Conveyor

Cleated belt conveyors are designed with barriers or cleats that segment the belt into distinct sections. These cleats help to prevent particles and materials from rolling back or falling off the conveyor, particularly during inclines and declines.

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The cleats come in various shapes and sizes, including:

Inverted Capital T

This cleat stands at a 90-degree angle to the belt, providing support and flexibility for delicate items. It is ideally suited for light-duty applications, including handling small parts, packaged goods, and food products.

Forward- Leaning Capital L

Due to its orientation, this cleat effectively resists leverage forces and can scoop granules while holding them against gravity. It is suitable for handling light to medium-weight granules.

Inverted V Cleats

These cleats, typically less than 5 cm in height, function similarly to a trough. Their design allows them to transport heavy or bulky materials effectively, as the short cleat height can endure high impacts.

Lugs and Pegs

These cleats assist in draining liquids after washing items like vegetables and fruits. Lugs and pegs provide a cost-effective method for conveying items that don&#;t require full-length support, such as large cartons or rods. They can also selectively move products that exceed a desired size and secure individual items in place.

Additional applications of cleated belt conveyors include:

• Escalators are a modification of cleated belt conveyors in a sense they carry loose materials up an incline that is steep.

Curved Belt Conveyor

This conveyor features a pre-fabricated curved frame designed to transport items around tight corners. It is ideal for situations with limited space where space-saving winding conveyors are needed. The curves can accommodate angles of up to 180 degrees.

Modular plastics with interlocking segments are used when the conveyor has a straight run before curving. Flat flexible belts are utilized if the conveyor primarily consists of curved sections.

Incline/Decline Belt Conveyor

Incline conveyors require tighter tension force, higher torque, and traction on the belt surface to prevent items from falling off the belt conveyor. Thus, they will incorporate a gear motor, a center drive, and a take up. The belt must also have a rough surface to allow for greater traction.

Similar to cleated conveyors, these conveyors are designed to transport items up a gradient while preventing them from falling off. They can also enhance the gravitational flow of fluids.

Sanitary Washdown Conveyor

In the pharmaceutical and food industries, stringent sterilization and washing procedures are required to comply with health and safety guidelines. Washdown and sanitary conveyors are specifically designed to handle these sanitary processes. Typically, these conveyors use flat belts that are relatively thin to accommodate the cleaning requirements.

Sanitary wash-down belt conveyors are designed to handle items exposed to extreme temperatures, such as those from freezers or furnaces. They can also operate in hot oil or glaze. Due to their robustness in greasy environments, they are sometimes used to offload oil drums and crates from ships.

Troughed Conveyors

A troughing belt conveyor is not a separate type of conveyor but rather a feature that can be incorporated into various types of conveyors.

It uses a belt that takes on a trough-like shape due to the troughing idler rollers positioned underneath it.

The troughing idler rollers feature a central roller with a horizontal axis of rotation, while the two outer (wing) rollers are angled upward, typically at around 25 degrees. Troughing occurs only with the top idler rollers and not with the bottom ones.

Excessive troughing angles can cause permanent damage to the belt. If the belt is curved at steeper angles, it may retain a cup shape, making it difficult to clean and track, and potentially damaging the belt carcass. This can also decrease the surface contact with the idler rollers, ultimately reducing the efficiency of the belt conveyor system.

Trough belts generally operate in a single plane, either horizontal or at inclines of up to 25 degrees. The belt must have a sufficiently large radius to ensure full contact with all the rollers in the troughing idler. If the troughing angle is too steep, the belt may fail to make contact with the center idler roller, which can compromise the belt's structural integrity and reduce the overall efficiency of the conveyor system.

Magnetic Belt Conveyor

Magnetic belt conveyors are designed to position and control ferrous metal pieces and parts. They utilize ferrite or neodymium magnets to transport materials and are especially useful for handling small parts that might not fit on traditional belt conveyors. While they operate similarly to conventional belt conveyors, their distinguishing feature is the use of magnets to exploit the magnetic properties of materials.

The magnets on a magnetic belt conveyor are positioned along the conveyor bed with sufficient strength to counteract gravity. The size of the materials has little effect on the conveyor&#;s performance, as the magnet strength can be adjusted to meet varying conditions and requirements.

Types of Magnetic Belt Conveyors

Magnetic Belt Conveyors - Magnetic belt conveyors are the most prevalent type of magnetic conveyor due to their ease of construction and operation. They are equipped with a magnetized sheet metal belt featuring either permanent magnets or a series of electromagnets that attract ferrous materials to the conveyor belt.

Besides the presence of magnets, magnetic belt conveyors function like traditional belt conveyors. They are used for moving cans, parts, ore, and other magnetic materials, and can handle products vertically, up inclines, and even upside down.

Magnetic Separator Belt Conveyors - Magnetic separator belt conveyors are designed specifically to separate ore from loose dust and debris. As material travels along the belt, non-magnetic materials fall off to the side, while magnetic materials adhere to the belt. These conveyors are available in dry and wet types. The dry type does not require the material to be wet for separation, while the wet type does.

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Chapter 3: How should belt conveyors be designed and selected?

Key parameters to consider when designing a conveyor belt include:

• Motor and gearbox selection
• Speed of belt
• Tension and take-up
• Material to be conveyed
• The distance over which to be transported
• Working environment e.g. temperature, humidity, etc.

Motor and Gearbox Selection

To select the appropriate motor, it is essential to first determine the effective pulling force required for the conveyor.

For a simple horizontal conveyor, the effective pulling force is determined using the following formula:

Fu=µR · g(m+ mb+ mR)

Where:

Fu=Effective pulling force

µR =Friction Coefficient when running over roller

g = Acceleration due to gravity

m =Mass of goods conveyed on the whole length of the conveyor

mb =Mass of Belt

mR =Mass of all rotating rollers minus mass of drive roller

For an inclined conveyor system, the effective pulling force is calculated using the following formula:

Fu=µR · g · (m + mb+ mR) + g · m · sina

Where

Fu =Effective Pulling Force

µR =Friction Coefficient when running over roller

g = acceleration due to gravity

m = mass of goods conveyed on the whole length of the conveyor

mb =Mass of Belt

mR =Mass of all rotating rollers minus mass of drive roller

a =Angle of inclination

Once the pulling force is established, calculating the required torque becomes straightforward, which in turn helps in selecting the appropriate motor and gearbox.

Speed of Conveyor

The conveyor speed is calculated by multiplying the circumference of the drive pulley by the number of revolutions per unit time.

Vc=D · F

Vc =Speed of conveyor belt in ms-1

D =Diameter of drive pulley in meters.

F =Revolutions of drive pulley per second

Tension and Take-up of the Belt

Take-up is a crucial component for maintaining and achieving optimal belt tension, which significantly contributes to the process and its mechanical stability.

A properly tensioned belt will wear evenly, contain material uniformly in the trough, and run centrally over the idlers.

All conveyors will experience some degree of stretch in their length and width. Typically, a new belt will stretch up to an additional 2 percent of its original length. This added length creates slack in the belt, which must be taken up to maintain optimal tension.

The degree of stretch increases with the length of the conveyor. For example, a 2-meter long conveyor may stretch 40 mm, whereas a 200-meter long conveyor could experience up to 4 meters of slack.

Take-up mechanisms are also advantageous during maintenance. By releasing the take-up, personnel can perform maintenance more easily.

Types of Belt Conveyor Take-Ups

Various take-up configurations each offer distinct advantages and disadvantages. Common types of belt conveyor take-ups include the gravity take-up, screw take-up, and horizontal take-up.

Screw Take-Up

The screw take-up configuration uses mechanical force to take up all the slack in the belt. It achieves it by adjusting a threaded rod that is attached to one of the rollers, especially the tail roller. This threaded rod will be on each side of the roller so it can also work as an alignment procedure. Since this is a hands-on manual approach, screw take-up is often called manual take-up.

Another type is the top angle take-up. While it is popular, it requires a large and heavy tail frame to be effective, and the guards also need to be substantial.

Screw take-ups are an inexpensive and efficient method for controlling belt tension in relatively short conveyors and are a common and straightforward choice for many applications.

Gravity Take-Up

Screw take-ups are generally unsuitable for managing the stretch in conveyors longer than 100 meters. In such cases, a gravity take-up system is the more effective solution for maintaining belt tension.

A gravity take-up assembly consists of three rollers: two are bend rollers, and one is a gravity or sliding roller that continuously manages belt tension. A counterweight attached to the gravity take-up roller exerts downward force on the belt, maintaining tension through gravity. The bend rollers guide the belt slack around the gravity take-up roller.

The complete take-up assembly is mounted at the bottom of the conveyor frame, ensuring consistent belt tension. This self-tensioning mechanism allows the take-up to adapt easily to sudden changes in tension or load.

The gravity take-up method effectively maintains proper belt tension and prevents damage from sudden spikes in load or tension. Because gravity tensioners are self-adjusting, they require less maintenance compared to screw take-ups. Maintenance is typically needed only when the belt reaches the end of its lifespan, at which point the take-up assembly may be at its maximum travel distance. In such cases, the belt may need replacement or repair. Gravity take-up systems are also known as automatic take-ups due to their self-adjusting nature.

Maintenance for gravity take-up systems is typically required when the belt reaches the end of its useful life, which occurs when it has stretched enough for the assembly to reach its maximum travel distance. At this point, the conveyor belt may need to be replaced or cut and vulcanized. Gravity take-up systems are often referred to as automatic take-ups because they adjust themselves automatically.

Horizontal Take-Up

The horizontal take-up serves as an alternative to the gravity take-up, especially in situations where space is constrained.

This take-up operates similarly to the gravity take-up, but instead of being positioned below the belt, the assembly is mounted vertically behind the tail roller. This configuration is particularly advantageous when the conveyor is installed on a slope or in locations where there is insufficient space underneath the conveyor.

Unlike the gravity take-up, the horizontal take-up does not extend below the conveyor. Instead, it uses a system of cables and pulleys to tension the belt with a weight box. Cables connected to the tail pulley move along a carriage, enabling the take-up to be adjusted in and out to maintain proper tension.

Chapter 4: What are the applications and benefits of belt conveyors?

This chapter will cover the applications and benefits of belt conveyors, as well as common issues encountered with belt conveyors, their causes, and the impact of environmental factors on their performance.

Applications of Belt Conveyors

Conveyor belts are used in various industries for a multitude of applications, including:

• Mining Industry
  
• Bulk handling
• Processing plants
• Taking ores from the shaft to the ground level
• Automotive Industry
  
• Assembly line conveyors
• CNC machines&#; scrap conveyors
• Transport and Courier Industry
  
• Baggage handling conveyors at airports
• Packaging conveyors at courier dispatch
• Retailing Industry
  
• Warehouse packaging
• Till point conveyors

Other conveyor applications are:

• Food handling industries for grading and packaging
• Power generation conveying coal to the boilers
• Civil and construction as escalators

Chapter 5: What are the types of belt conveyor pulleys?

Pulleys play a crucial role in belt conveyors by providing drive tension and altering the direction of the belt's movement. Belt conveyor pulleys are categorized into several types, including drive, tension, motorized, snub, wing, and bend pulleys. These pulleys can come with various surfaces, such as smooth, rubber-coated, or cast rubber.

Motorized Pulley or Motor Drum

Motorized pulleys serve as the driving mechanism for belt conveyor systems. They feature a sealed motor and a protective exterior drum, which the motor drives. This drum provides the necessary traction to move the conveyor belt. Motorized pulleys come in various configurations to accommodate the diverse needs of conveyor systems.

Drive Pulley or Head Pulley

The drive pulley, or head pulley, is responsible for supplying traction to the conveyor belt. It typically has a surface coated with chevrons or diamonds to enhance friction between the belt and the pulley, ensuring effective movement. Drive pulleys can be single or double-sided and may have one or two drives, depending on the size and requirements of the conveyor system.

Bend Pulley

Bend pulleys are used to redirect the belt conveyor, creating a continuous loop. They function as the tail roller in a tensioning device and help change the belt's direction. Bend pulleys resemble return pulleys but are designed with a smaller diameter.

Tension Pulley

A tension pulley, also known as a return pulley, creates tension in the conveyor belt, increasing the force exerted on it. These solid pulleys are built to withstand significant forces and can be placed anywhere along the belt, although they are most effective when positioned close to the drive pulley.

Snub Pulley

The snub pulley works in conjunction with the drive pulley to increase the contact area between the belt and the drive pulley. By enhancing friction, snub pulleys are ideal for conveyor systems that require high drive power or operate under contaminated conditions.

Wing Pulley

Wing pulleys are designed to clear material from the return belt and continuously clean themselves. They offer excellent traction and come in various types, including spiral, heavy-duty, and herringbone.

Magnetic Pulley

Magnetic pulleys are integral to magnetic conveyor belts, used to separate ferrous materials from non-ferrous ones. Constructed from steel and enclosed with permanent magnets, these pulleys effectively remove both large and small ferrous debris.

Crowned Head Pulley

A crowned head pulley features a cylindrical middle with tapered ends to ensure stable operation of the conveyor belt. By guiding the belt back to the center, crowned head pulleys improve stability and are typically used with flat belt drives.

Chapter 6: What are the advantages and problems associated with belt conveyors?

Belt conveyors are widely recognized for their convenience and efficiency in moving, sorting, packing, and shipping goods and products. Having been in use for many years in various forms, they have significantly improved supply chain efficiency.

Advantages of Belt Conveyors

Belt conveyors offer several advantages, including:

• It is a cheap way of moving materials over long distances
• It doesn&#;t degrade the product being conveyed
• Loading can be done at any place along the belt.
• With trippers, the belts can offload at any point in the line.
• They do not produce as much noise as their alternatives.
• Products can be weighed at any point in the conveyor
• They can have long operating times can even work for months without stopping
• Can be designed to be mobile as well as stationary.
• Have less dangerous hazards to human injury
• Low Maintenance costs

Common Belt Conveyor Problems

Despite their advantages, belt conveyors are complex systems that require careful monitoring and management. Key concerns to address include:

Problem 1: The Conveyor Runs to One Side at a Certain Point in the System.

Possible causes of these issues include:

• Material building upon the idlers or something causing the idlers to stick
• Idlers no longer run square to the path of the conveyor.
• Conveyor frame tilted, crocked, or no longer level.
• Belt was not spliced squarely.
• Belt is not loaded equally, probably loaded off-center.

Problem 2: The Conveyor Belt Slips

Potential causes of this issue include:

• Traction is poor between belt and pulley
• Idlers stuck or not rotating freely
• Worn out pulley legging (the shell around the pulley that helps increase friction).

Problem 3: Overstretching of the Belt

Possible reasons for this include:

• Belt tensioner is too tight
• Belt material selection not done properly, probably &#;under belted&#;
• Conveyor counterweight is too heavy
• The gap between idler rolls is too long

Problem 4: The Belt Wears Excessively at the Edges

This can be attributed to factors such as:

• Belt is loaded off-center
• High impact of material on the belt
• Belt running against conveyor structure
• Material Spillage
• Material is trapped between belt and pulley

Environmental Effects On Belt Conveyors

Factors such as water, petroleum products, chemicals, heat, sunlight, and cold can all impact the performance and lifespan of a belt conveyor.

The effects and causes of these factors can be categorized as follows:

Moisture Effects

• Belt rots and cracks
• Belt loose adhesion
• Causes slippage
• Steel carcasses can rust

Effects of Sunlight and Heat

• Rubber will dry out and weaken
• Rubber will crack
• Rubber may have more slack and thus reduce belt tension

Cold Effects

• Belt stiffens and becomes harder to guide and train
• On incline systems, frost can build up and cause slippage
• Ice can build up in chutes and clog them

Effects of Oil

• Rubber will swell
• Rubber will lose tensile strength
• Rubber will lose tensile strength
• The belt will wear quicker
• Rubber will lose adhesions

Conclusion

A belt conveyor is a system designed to transport or move physical items like materials, goods, even people from one point to another. Unlike other conveying means that employ chains, spirals, hydraulics, etc., belt conveyors will move the items using a belt. It is critical to be cognizant of the design considerations and applications of various belt conveyors depending on the intended use.

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