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Application Design Manual-June 17, 2002

Application Design Manual-June 17, 2002

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APPLICATION DESIGN MANUAL

5100 West 12th Street Sioux Falls, SD 57107-0514 605-332-3200 PHONE 605-332-1107 FAX WATS 800-328-1785 www.hiroller.com email – sales@hiroller.com

Notice: Instructions, Designs and Specifications are subject to change without notice!

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Conveyor Components
Conveyor Orientation - Standard
The conveyor Left(LH) and Right(RH) Side is determined by assuming that one is standing at the Tail Section and looking in the direction of the belt toward the Head Section. The Left(LH) Side is on your left hand. The Right(RH) Side is on your right hand.

Conveyor Orientation - Reversible
The conveyor Left(LH) and Right(RH) Side is determined by assuming that one is standing at the Non-Drive Section and looking in the direction of the Drive End Section. The Left(LH) Side is on your left hand. The Right(RH) Side is on your right hand.

Head Sections & Discharges
Head Sections are typically in the two different types as shown below. The Discharge(Overshot) is bolted to the Head Section as shown below. Discharges have inspection hatch at the top. A four-sided frame is typically included for discharge transitions.

Standard Discharge
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Snubber Head Section Discharge
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Motor & Drive Mountings
Hi Roller mounts all motors and reducers that are supplied by the factory. All of the manufacturer's specifications are followed. The photograph below illustrates a right hand mounted drive. Motor & Drive Mountings Shaft Mount Drive w/Synchronous Cog-Belt (Shown) is the most common type of Drive. In-Line Drive w/Synchronous Cog-Belt Final Drive and In-Line Drive w/Direct Coupled Drive (NOT Shown) are not as common.

Trunking Sections

Head/Drive End Trunking Sections Distinguished by High Leg End Channel, Inspection Door Location & Special Flanges(Shown). Tail/Non-Drive End Trunking Sections – Distinguished by High Leg End Channel, Inspection Door & two other equal flange channels in the middle and opposite end of the High Leg End Channel(NOT-Shown). Intermediate Trunking Sections Each Intermediate section has two equal flange channels. Each section has an equal flange channel on the end and the other in the middle of each section. NOTE: Sections are labeled & numbered starting with #1 at the Tail Section.

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Inspection Doors –Trunking

Channels & Clamps - Trunking

Cover Clamps & Wing Nuts - Inlet/Loader

Inspection Door Clamps & Wing Nuts - Trunking, Head, Tail & Inlet/Loader

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Tail Sections - Standard Tail Section w/Inner & Outer Box Take-Up

Tail Section Back Cover Removal & Installation The Tail Cover Clamps(Below, Top-Right) release the Tail Cover. Handles on the Tail Cover(Below, Bottom-Center) should be used to pull the Tail Cover back and down to release from Tail Section. The Safety Chains(Below, Center) will stop the Tail Cover from dropping too far down. Lift the Tail Cover to release the Safety Chains. Then, slowly allow the Tail Cover to swing down until it releases from the channel on the bottom of the Tail Section as shown(Below, Top-Left). The installation is in reverse order of the removal procedure.

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Loaders/Inlets-Extremely Important Loading Considerations!
The loader must be installed on the conveyor to load the same direction of belt travel. The loading point of a belt conveyor is the critical point. Here the conveyor belt receives major abrasion and practically all of its impact. The ideal condition is to have the material pass from the spout to the belt at the same speed and direction of belt travel. This must be done with a minimum amount of impact and loaded centered on the belt. Improper loading can cause damage belt, idlers, bearings, pulleys, shafting, and other components. An off-centered load will cause belt alignment problems in that the belt will run off center. Standard Inlets - Flat Top w/Matching Flange & Control Gate

Loading Considerations! • Control Gate Orientation • Turbulent Flow Problems • Controlled Flows from all spouts • Belt Speed vs. Proper Loading • Side Loading Problems • Level/Even Loading Problems • High Velocity Flow Problems • Poor Loading = Belt Tracking Problems • Straight Down Flow Problems Side Loading Problems!! Hi Roller’s Engineering Department must complete a proper design to eliminate Side Loading Problems.

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Standard Inlet - 45 Degree w/Matching Flange & Control Gate

Gate Orientation & Proper Operation = Flow Controlled Properly

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Loading Goals: 1. Material must flow evenly on to the belt and at the speed and direction of the belt. 2. Control Gate and Spouting must be installed so that the material flows down the Back Plate of the Loaders as shown on the illustrations on the previous page. 3. Control Gates must be installed to open from the back(tail end) of the Loader to the front(head end) so the material flows down the Back Plate. This must be done for proper loading. 4. Material speed is very important to proper loading. Material flowing too fast will cause the material to splash as it contacts the belt. This will cause the material to boil and loading will be a problem. Material dropping from more than 3-4 feet must be slowed down with a control gate, dead box, or another type of material slow down device. 5. The material must be evenly spread across the full width of the Back Plate of the Loader. 6. Spouting from the side will cause material flow problems in the Loader. A control gate, baffle, or another means to turn the material flow must be included in the design of the Loader. 7. Bi-Directional Loading is very feasible with a properly designed Loader. Contact Hi Roller’s Engineering Department for assistance with this design.

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Covers
Covers are made to fit over the width of the conveyor and 5(five) feet of a section. Note: Do not weld any items to the covers. Covers must be removable. parts can be obtained from Hi Roller to attach devices to top of conveyor so that covers will still be removable. Standard 5 foot Covers

Cover Clamps & Wing Nuts - Installation

Covers can be cut to length in the field during the installation. Cover End Channels are provided with the conveyor so the contractor can cut the covers and weld on a new channel to the correct length. NOTE: Covers can be “Cut to Length” at the factory if they are ordered to specific lengths. These specific lengths must be measured and sent to Hi Roller’s Engineering Department as soon as these measurements can be completed during the installation. The order for these special length covers will be expedited to ship them out within the shortest possible time.

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Take-Up Sections
Tail Take-Up Sections w/Rods & Leveling Rods The Tail Take-Up Rods are used to tighten the belt. There is one TakeLeveling Rod Up Rod on each side of the Take-Up Section. The Take-Up Rods are located on the centerline of the Tail Shaft Bearings. The rods are to be tightened equally to prevent misalignment of the pulley causing belt tracking problems. The top rods Take-Up Rod are used to level the Tail Section. Do not use these rods for tightening the belt. Special Take-Up Sections: Head Take-Up Sections w/Rods & Leveling Rods The Take-Up Head Section works in the same manner as a Sliding Box Tail. The take-up rods located on the sides tighten the belt. The rods are to be tightened equally to prevent misalignment of the pulley-causing belt tracking problems. Head Take-Up Sections w/ Sliding Bearing Mounts & Rods The Sliding Plate Take-Up Head Section utilizes a sliding plate to mount the Head Pulley Bearings. The conveyor belt is tightened with the take-up rods mounted directly behind the bearing mounting. The rods must be tightened equally to prevent misalignment, which can cause the belt tracking problems. The Motor Drive Belt will have to be adjusted when tightening the conveyor belt.

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Application Design Considerations
The Proper Installation of the Hi Roller Conveyor is very important! Basic Rules and Understandings must be used for the installation. Plan ahead to make sure that the conveyor will be properly installed. Start-Up Problems will be reduced dramatically if the conveyor is installed correctly. Please take the time to plan and follow the Basic Rules. Clearances that must be considered: • Idler Bearing & Shaft Removal = Clearance to the Wall or Structure! • Idler Removal = Clearance above the conveyor cover. • Tail Shaft & Bearings = Much wider than standard Trunking Sections! • Take-Up Section = Clearance to access Take-Up Rods! • Head Section = Much wider than standard Trunking Sections! • Motor & Drive = Depending on type, much wider than Head Section! • Tripper Sections = Much wider than standard Trunking Sections! • Bottom Clearances for cleaning & Bottom Removal • Inspection Doors & Top Cover Removal • Tail Cover & Inspection Door Removal Clearances - Head & Discharge

Clearances - Bottom & Covers

Clearances – Tail Section Width

Clearances – Tail Take-Up Extended

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Extremely Important-Trunking installed in a Straight Line!

must

be

Check with Laser, Transit or Wire Line – The Trunking must be installed in a Straight Line. Trunking that is not installed straight and true with cause belt tracking problems. The Trunking must be installed installed in a true straight line!

Trunking must be straight and true from the Tail Section to the Head Section.

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Monitors: • Motion Monitor/Speed Slow-Down Monitor must be properly installed. • Discharge Spouting or “Overshot” Plug Monitor must be properly installed. • Other required Monitors required must be properly installed.

Motion Sensor Installed & Tested = Extremely Important!
A Motion Sensor must be Properly Installed and Tested. Head Pulley slippage must be detected before damage to the belt occurs. This is very important during the start-up period when the belt may stretch and cause Head Pulley slippage.

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Plug Switch Installed & Tested = Extremely Important!
A Properly Installed and Tested Plug Switch or Switches must be included in the design.

Discharge Considerations: • Spouting angles – Materials flow differently in spouting. The proper angle must be maintained so that the material will freely flow in the spout. • Spouting sized properly – Flow characteristics are different for each type of material. Properly sized spouting must be installed to handle the capacity of the discharge flow from the conveyor! Inclines: • Gradual – Hi Roller Conveyors can be installed with a Gradual Upbend. This is the lowest cost, horsepower and maintenance option. Hi Roller’s Engineering Department must complete design calculations to determine the amount of Gradual Upbend that can be installed on a specific application. • Sharp Upbends – Hi Roller Conveyors can be installed with a Sharp Upbend Section. This is the highest cost, horsepower and maintenance option. Hi Roller’s Engineering Department must complete design calculations to determine the amount of increase horsepower and cost of this option for a specific application. • Horsepower – Inclined conveyors of any type require additional horsepower. A Straight, Gradual or Sharp Upbend Inclined conveyor will require additional horsepower to simply lift up the material. This additional horsepower will be calculated by Hi Roller’s Engineering Department. • Capacity – Inclined conveyors of any type will not convey the same amount of material as a flat horizontal conveyor. Hi Roller’s Engineering Department will calculate the capacity of a specific application.

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Aspiration: • General-Dry-Ambient Material

• Hot Moist Material

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Condensation Prevention: • Bin Venting Problems – Warm Air = Warm and moist air must not be allowed to vent through the conveyor. This will cause condensation to form on the inside of the conveyor enclosure as the dew point of the air is reached. The condensation or water can freeze inside the conveyor and caused many major problems. • Warm/Hot Moist Materials = Warm or hot moist materials will create warm moist air inside the conveyor enclosure. This will cause the same problems discussed above. • Proper Insulation = The outside skin of the conveyor enclosure may have to be insulated to eliminate the formation of condensation from the cold outside temperatures. • Vapor Isolation = Warm and moist vapors can cause the same condensation problems discussed above. The conveyor enclosure must be isolated so that these vapors cannot circulate through the conveyor enclosure. Product Characteristics • Multiple Products – Make sure that the conveyor is designed and installed to handle all of the different types and sizes of the materials. • Bulk Density, i.e. pounds per cubic foot, pounds per bushels, metric tons per cubic meter, kg/cubic meter, etc. • Abrasive Materials – Design considerations must be reviewed with Hi Roller’s Engineering Department. • Corrosive Materials – Design considerations must be reviewed with Hi Roller’s Engineering Department. • Sticky Materials – Design considerations must be reviewed with Hi Roller’s Engineering Department. • Moist Materials – Design considerations must be reviewed with Hi Roller’s Engineering Department. • Hot Moist Material – Design considerations must be reviewed with Hi Roller’s Engineering Department. • Hot Oily Moist Material – Design considerations must be reviewed with Hi Roller’s Engineering Department.

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Capacity Considerations: • Capacity – Inclined conveyors of any type will not convey the same amount of material as a flat horizontal conveyor. Hi Roller’s Engineering Department will calculate the capacity of a specific application. • Multiple Products – Make sure that the conveyor is designed and installed to handle all of the different types and sizes of the materials. • Bulk Density, i.e. pounds per cubic foot, pounds per bushels, metric tons per cubic meter, kg/cubic meter, etc. • Belt Speed = Min. for proper Reloading = 350 fpm(granular materials) & 400 fpm(powders/fines/meals) Options: • Heavy Duty Idlers • Heavy Duty Return Liners(1/2”) • Etc?? Splices: • Mechanical – Flexco splices are standard on all Hi Roller Conveyors. We recommend different types of Flexco splices depending on the application. • Vulcanized – We recommend that the first year of operation be with a Mechanical splice before a Vulcanized splice is installed. The belt should be stretched and stabilized before the permanent Vulcanized splice is installed. This is because of the limited length of the Take-Up Section of the conveyor. Supports: • Supports must be installed at least every twenty (20) feet of the length of the conveyor. • Support Legs or Hangers should always be bolted to the trunking vertical or bottom flanges. Supports should never be welded to the trunking sides. Motor and Drive: • Motor, Drive, Couplings, and other Drive Components must be securely mounted in place and properly aligned. • Proper Belt, Chain, Couplings, Cooling Fan or other required Guards must be properly installed. • Lubrication – Has the Drive lubrication oil been properly filled? The Drive DOES NOT arrive at the jobsite filled with lubrication oil. The Drive MUST BE FILLED at the jobsite with lubrication oil.

Hi Roller’s Engineering Department should be contacted with any further questions or required information.
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