Conveyor Belts

Definition
A mechanical
apparatus
consisting moving
belt that transports
material from one
place to another.
 Types of conveyor belt system
1) Troughed belt conveyor
2) Flat belt conveyor
3) Pipe belt conveyor
 Troughed belt conveyor

• Belt forms a trough

on the carrying side
while running over
idler rollers
• in set of 5 rolls, 3
rolls or 2 rolls.
• The troughing angle
adopted are: 15°, 20°
, 25° , 30° , 35° ,
40° , 45°.
 Flat belt conveyor
• Belt runs flat on
the carrying side
over straight roller
type idler or a set
of idlers.
• Suitable for lower
capacity, low
speed
requirement .
 Pipe belts
• Used where bulk materials
must be conveyed along
horizontal and vertical
curves in confined spaces
• Used where spillage must be
avoided.
• The belt can negotiate tight
horizontal and vertical
curves.
 Belts
Conveyor belts
consists of 3 elements:
1)Top cover
2)Carcass
3)Bottom cover
 Types of conveyor belts
1)Steel cord belt
2)Textile belts
 Steel cord belt
1)Consists of top cover
layer
2)Adhesive component
3)carcass(steel cord
mesh)
4)bottom cover layer
 Steel cord belt
1) They ensure maximum
conveying performance
under grueling stress
conditions.
2) High tensile strength.
3) Excellent impact
resistance.
 Textile belts
1)Various cover stock
properties according
to applications.
2)Low price .
3)Easy maintenance.
 Types of textile belts
1)Temperature resistance belts
2)Oil & grease resistance belts
3)Slit protection belts
4)Dirt repellent cover belts
 Belt designation

1. Driving pulley
2. Tail roller at end of installation
3. Slider bed
4. Carrying rollers on the carrying side
5. Snub roller
6. Tail roller
7. Tension roller
8. Carrying roller on the return side
Belt nomenclature
 Steel cord belt conveyor
2000 m DIN 22131 AB 1200 St 1600 7T/5 X
2000 m Length
DIN 22131 Applicable standard/norm
AB Manufacturer's acronym
1200 Belt width in mm
St Carcass material (steel cords)
1600 Belt's minimum breaking strength in N/mm *)
7 Top cover thickness in mm
T Textile reinforcement (in top cover) **)
5 Bottom cover thickness in mm
X Rubber Cover grade
 Textile belt conveyor
E.G 1000 m DIN 22102 AB 1000 EP 630/4 6/2 Y

1000 m Length
DIN 22102 Applicable standard/norm
AB Manufacturer's acronym
1000 Belt width in mm
EP Carcass material (polyester warp / polyamide weft)
630 Belt's minimum breaking strength in N/mm
4 Number of plies
6 Top cover thickness in mm
2 Bottom cover thickness in mm
Y Rubber cover grade
 Failures in belt conveyor system
• Drive unit failure
• Pulley failure
• Idlers and belts failure
 Drive unit failure
• Drive unit consist of
electric motor, damping
coupling, two or three
stage gear-box and
coupling that connect
output shaft with pulley
• Failures occurs mainly
in Pulleys and gear box
Pulley
failure

Actual Pulley

Failed pulley
 Idler & belt failure
• Due to over load Side
idler may fail.
• Due to foreign Pointed
bodies belt may cut
along its length.
• Bearings in the idlers
may fail
Belt conveyor troubleshooting
Problem Cause solution
1) Conveyor belt runs One or more idlers not Advance the end of
to one side at a at idler
particular point on the right angles to to which the belt has
conveyor. longitudinal shifted in the direction
centerline of belt. of
belt travel.

Build up of material on Improve maintenance.

idlers. Install scrapers.

Sticking idlers. Replace or free idler

Problem Cause Solution

2) Excessive wear on Slippage between belt Lag drive pulleys,

bottom side of belt. and drive pulley or renew
pulleys. (Cont.) worn-out lagging.
Sticking troughing
idlers. Increase arc of contact
drive pulley with snub
pulley or use tandem
drive.
Material ground Replace or free stuck
between idlers.
pulley and belt.
Install scrapers in front
of tail pulley or return
belt.
Problem Cause Solution
3) Excessive wear on Dirt, frozen or Install belt-cleaning
carrying side of belt. misaligned return plows at head end and
idlers. tail end.
Excessive sag between Clean, repair and align
troughing idlers return idlers.
causing load to move Increase belt tension if
and shift on too low.
belt as it passes over
idlers. Reduce idler spacing.
Use rubber skirt
material.
Avoid use of old
belting.
Problem Cause Solution

4) Short breaks in Impact of lumps falling Use impact idlers.

carcass on belt at loading
of belt parallel to edge station.
and star breaks in
carcass.
Material trapped Install plows or
between scrapers
belt and pulley. ahead of pulley.
Problem Cause Solution

5) Belt running off at Build up of material on Remove material

tail pulley. return idlers. provide better
housekeeping.
Return rollers out of Adjust at right angle to
line. frame.
Unequal loading. Adjust loading chute to
properly center the
load.
Preventive maintenance of belt
conveyor system
 Daily preventive maintenance
1) Check operation of conveyor controls. Ensure
that all "STOP" pushbuttons operate properly.
Also ensure that all limit switches function
properly
2) Clean any accumulation of dust
3) Never touch a moving belt or rotating part.
4) Keep large lumps of material off belts
5)Note and mark “frozen” or damaged idlers for
repair or replacement.
 Daily preventive maintenance
6) Check scrapers and plows for proper
operation.
7)Watch for material to build up on decking or
floor under idlers or pulleys. This is especially
important at training idlers.
8)Prevent large lumps from dropping onto
unprotected belt.
 Weekly preventive maintenance
1)(Conveyor Drive) Check reducer (gearbox) oil
level, Check reducer for oil leaks, Inspect
drive coupling , Check oil level in backstop
and inspect for leaks , Ensure all safety guards
for drive are in place and in good condition.
never touch a moving belt or rotating part.

2)(Safety Switches) Inspect cables for correct

tension, Ensure flags are free from material
build up. do not touch loose wires.
 Weekly preventive maintenance
3)Head pulley) Inspect belt cleaners for worn or
missing blades, Inspect belt cleaners for
cleanliness of frames and blades , Check belt
cleaner tension according to manufacturers
recommendation , Ensure belt is cantered on
pulley.
4)(Tail pulley) Ensure belt is centered on pulley,
check V-plow blade for wear, Check V-plow
mounting , Check V-plow tension
How to avoid spillage over
conveyor?
Spillage over the conveyor occurs mainly at
three different areas:
1)Loading point containment
2)Preventing the escape of material from the run
of conveyor
3)Managing the discharge of the materials being
conveyed.
Use of pipe conveyor belt
 Scrapper
1)Scrapper cleans belt after
belt discharges material
from it.
2)Material carry back and
reduce spillage.
3)Avoid material built up on
snub pulley and return idler.
 Skirt rubber
1)Prevents material
falling down.
2)Avoids spreading
dust in atmosphere.
3)It also serves
purpose of guarding.
Methods of conveyor belt joining
 Belt splicing
Definition:
Conveyer belt
splicing is the
process of joining
together two pieces
of conveyer belt.
 Mechanical splicing

It involves use
of several types of
metal fasteners

It is a quick and
versatile method
used in dirty and
confined
environments

Relatively
inexpensive
 Vulcanization
1)Vulcanization creates a splice by using
heat and/or chemicals.
2)Requires special tools, expertise, and a
clean, temperature- and moisture-
controlled environment.
3)Splice is smoother and typically more
durable than a mechanical splice
 Types of vulcanization
Hot vulcanization Cold vulcanization
1)splices by using heat and 1)Use of chemicals that bond two
pressure through use of a pieces of belt.
vulcanizing press.
Safety
How to avoid accidents in belt
conveyor?
 Guarding
1) Each workplace must be examined at least once in each
shift for conditions which may adversely affect safety.
2) Prompt action must be initiated to correct hazardous
conditions.
3) Moving machine parts must be guarded to protect persons
from contacting them.
4) Guards must be securely in place while machinery is being
operated .
5) New employees must be indoctrinated in safety rules and
safe work procedures
 Best practice

1)Maintenance should not

be performed unless the
power is off and
machinery components
are blocked against
hazardous motion.
2) Moving machine parts
should be guarded to
protect persons from
contact that could cause
injury.
3)Maintenance should not be performed unless
the power is off and machinery components are
blocked against motion.
4)Visible or audible warnings should be
provided before conveyor start-up when the
entire length of the conveyor is not visible from
the starting switch.
5)Machine operators should take measures to
assure all personnel are trained in safe work
procedures.
 Guard comparison

Bad guard Better guard

Bad guard Better guard
Thank you