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Some time after that, belts made of cotton fabrics covered with rubber However, even stronger belts were sought and around 1970 rayon was
were used. The tighter the weave, the greater the strength. To standard- replaced by polyester. Since ’P’ was already being used as a designation
ize the types of fabric to some extent, they were designated in weight for polyamide, the letter ’E’ from ’ester’ was chosen. Of all belt types,
per surface unit. For example, 32 oz fabric meant that the weight of a EP-belts are the most common, in various applications.
fabric measuring 36” x 42” was 32 ounces (0.93 kg/m²). Breaking strength
of this fabric corresponded to about 63 N/mm width. Surprisingly, standards for the fabric strength were agreed upon at an
early stage. It was decided to use a number system, the so called Renard
In the late 1950s, fabrics made from rayon began to come into use. Since 10 system, which is based on the preceding number being multiplied
rayon is considerably stronger than cotton, it was difficult to use the by 10√ 10 (≈1.25). The series can be extended in both directions.
weight as criterion for the strength of the fabric. Instead the tension at
which breaking occurred was given and what textile was used. Thus,
B 63 means that the tensile strength of this cotton fabric is 63 N/mm in
warp direction, while R 100 means rayon fabric with a tensile strength of
100 N/mm.
To achieve high tensile strength in the belt, several layers of fabric had to
be used. The problem with several layers was that belts were difficult to
trough. To solve this, another textile material was used crosswise (weft 1. Upper cover plate
direction). Polyamide (Nylon®) showed itself to be sufficiently elastic for 2. Carcass
this purpose. 3. Textile armament
4. Skim rubber
5. Lower cover plate
Of course you also want to know the length and the width of the belt.
This information is put in front. For example 86 m 1200 EP 800/5 6:2 Y.
The complete belt designation is shown in the example below.
On the other hand, the EP-fabrics, which are fully synthetic, are purpose 2. The maximum force occurs in the middle of the transition zone
made for conveyor belts. Here, the material is adapted to the belts, not close to the drive pulley. Here the edges are stretched an extra 0.8%.
the other way around as it used to be with cotton. In recent years this
fact has begun to be misused. In practice this means that belts of one 3. During startup of the fully loaded belt the forces reach a maximum,
strength class lower were being used. EP 800/5 was replaced by EP especially for drives with high starting torque.
630/4 which lead to damages to the belt.
4. Worn lagging of the drive pulley or build-up of ice or dirt have an ad-
A sufficient safety factor is necessary not only for the fabric but ditional negative impact.
especially for the dynamic strength of the splice.
If a customer was to use a belt with a low safety factor, already at point
3 which can occur even with good maintenance, the layers of fabric can
be stretched to an extent that permanent elongation with damages to
the belt occurs.
To prevent the safety factor from being lowered even further, splicing has
to be performed carefully. To ’lose’ a ply due to the step splice is bad
enough. Careful work is required so the knife does not cut through the
next fabric, which in practice would leave you with only two layers of
fabric in the splice. The old argument that ’I feel when I’m through’ is
of no value. It might have worked with cotton belts where the layers
of fabric were 1.5 mm thick but not with modern fabrics which have a
thickness of less than 1 mm.
Make sure that the drive pulley and the tail pulley do not have a build-up
of material.
Stretching Stretching
The only thing keeping the two layers of fabric together is the rubber
layer in between them. Before and after the splice all the traction forces
are concentrated in one single layer of fabric. In the splice they are
divided between two layers of fabric.
Cleanliness. No matter how good the material may be, it will adhere
badly to greasy or dusty fabrics.
If using hot vulcanization, the pressure, time and the temperature must
be according to the manufacturers guidelines to obtain the best strength
and adhesion.
As the most stretched part of the rubber gets damaged, this damage
moves further and further into the splice until it opens completely.
If you bend a phone book and imagine the covers as two layers of fabric,
you will observe that the ’outer layer of fabric’ is displaced in relation to the
’inner layer of fabric’. The pages in between symbolize the rubber layer.
Usually the conveying speed is restricted by the conveyed material. The carcass that is responsible for transmitting the forces needs to be
Heavier materials can be conveyed at a higher speed than dusty materials. protected from damages and wear. This is the task of the top and bottom
The maximum volume capacity therefore is mostly determined by the belt cover. The thickness depends on the conveyed material. It is recommend-
width and troughing angle while the influence of the conveying speed is ed to use thicker covers for heavy or abrasive material than for light, less
limited. Since the tension forces are spread over the full width of the belt, abrasive material. It is often said that doubling the thickness of the cover
a wider belt can have a lower tensile strength than a narrow belt if both plate does not mean doubling the price, but perhaps quadruples the life
convey the same mass flow at the same speed. of the belt.
Once the width of the belt is chosen, the correct tensile strength needs Slight wear /Wood chips, grain etc. 2:1
to be determined. It is important to choose a belt that is neither too weak Normal wear /Sand, coke etc. 3:1
nor too strong since both cases could cause problems. Most national Wearing /Gravel, crushed stone etc. 5:2
Standards for belt calculations refer to the corresponding DIN/EN, which Heavy wear /Ore, rock etc. ≥6:≥2
determines the forces due to running resistance (friction), lifting resistance
and pretension. The latter is needed to avoid slippage at the drive pulleys
and sagging of the belt.
If the distances are shorter there is a considerable risk that a tunnel effect Instead, a longitudinal fold is created, i.e. the belt folds itself into a ‘z’ over
will be created, i.e. the belt center will rise. Since most conveyors today the drive pulley. Along this path permanent stretching and deformation
are equipped with tilted idlers that steer the belt edges towards the of the fabric occurs. All stability is lost along this path, making the crea-
center, the ’tunnel’ has great difficulties in disappearing on its way to the tion of a new tunnel easier on the next turn.
drive pulley. When it arrives at the drive pulley and passes over it, the
friction between belt and pulley is so high that the belt has difficulty in
flattening out.
Belt type A B C A B C A B C
EP 160/2 250 200 160 200 160 125 160 160 125
EP 250/2 250 200 160 200 160 125 160 160 125
EP 315/2 250 200 160 200 160 125 160 160 125 The table gives the smallest pulley diameter for three
EP 315/3 315 250 200 250 200 160 200 200 160 different types of pulleys:
EP 400/2 315 250 200 250 200 160 200 200 160
EP 400/3 315 250 200 250 200 160 200 200 160 A: Drive pulleys or other pulleys in which the belt tension is high
EP 500/3 400 315 250 315 250 200 250 250 200
EP 500/4
B: Pulleys in which the belt tension is relatively low
500 400 315 400 315 250 315 315 250
EP 630/3 500 400 315 400 315 250 315 315 250 C: Angle pulleys in which the angle change of the belt is ≤ 30°
EP 630/4 500 400 315 400 315 250 315 315 250
EP 800/4 630 500 400 500 400 315 400 400 315
EP 800/5 630 500 400 500 400 315 400 400 315
EP 1000/3 630 500 400 500 400 315 400 400 315 Note! The diameters given are the smallest recommended
EP 1000/4 630 500 400 500 400 315 400 400 315 and should never be less! The choice of pulley diameter
EP 1000/5 800 630 500 630 500 400 500 500 400 is determined by the following factors:
EP 1250/4 800 630 500 630 500 400 500 500 400
EP 1250/5 800 630 500 630 500 400 500 500 400
EP 1600/4 1000 800 630 800 630 500 630 630 500 1. The stretching properties of the belt
EP 1600/5 1000 800 630 800 630 500 630 630 500 2. The flexibility of the belt
Ep 2000/5 1250 1000 800 1000 800 630 800 800 630 3. Utilization of max. recommended working tension (T1)
4. Wrap angle
Note! Belts with profiled cover plates may need larger pulley diameter.
Contact Metso for information.
Look carefully at the space between the center roller and the side roller,
<10 mm <10 mm
which should not exceed 10 mm. A larger setting makes the belt tend
to press down and get jammed. High risk areas are the idlers in convex
curves and the troughing zones.
A large amount of sagging result from too great a distance between the
idlers in combination with large gaps, leads to direct damages of the
belt.
The rubber discs have a relatively small contact surface against the belt,
which makes their lateral steering capability insignificant. By covering
the rollers with Trellex Roller Sleeves, the steering capability is improved B
as the lateral friction between belt and roller is increased.
Since shrinking forces occur in the rubber after the belt is vulcanized, the
upper cover plate will contract more, due to its thickness, than will the
lower one, which is usually thinner. This means that the belt edges ’dip’.
This is especially noticeable on belts that have been in use for a long RIGHT
time. For this reason it is of utmost importance that the belt edges are
always supported when passing the return rollers. A belt with its edges
’dipping’ outside the rubber rings cannot center itself.
Tolerances for the straightness and width of a belt have been mentioned. B
It is obvious that the rubber rings must be positioned to cover the belt
edge even within these tolerances. Unfortunately this is often not the
case. The return rollers are in contact with the dirty side of the belt. When
abrasive material is transported on the belt, the wear on the shell of the
return rollers increases. By mounting Trellex Roller Sleeves on the rollers
the wear is reduced, which considerably increases the life of the rollers.
WRONG
RIGHT
Material spillage around the conveyor means extra maintenance and T-Cleaner
cleaning. The many variants and solutions which have existed and do
exist on the market demonstrate this. Descriptions of some frequently The Fine-Cleaner is available in a number of different designs. They
occurring types are given here: all have one thing in common, they are installed immediately behind
the drive pulley. Two common models are the T-Cleaner and the Arm-
Cleaner. The T-Cleaner is pushed straight up towards the belt, while the
Arm-Cleaner has a twisting motion. For best efficiency, Fine-Cleaners are
normally used in combination with a Pre-Cleaner but can also be used
by themselves if fine, dry material is being transported.
Pre-Cleaner
The friction between pulley and belt is the prime determining factor A common misunderstanding is that larger pulley diameters give higher
when it comes to operating the belt without slippage. A steel pulley friction than smaller ones. Because friction forces are only affected by
which is not lagged requires about five times higher belt pretensioning two things, surface and pressure, the total force is the same. Any differ-
than one with rubber lagging. The installation of the correct pulley ence that might be noticed depends more on the qualities of the belt.
lagging is the cheapest and most effective measure to minimize risk of A heavier belt has a larger bending resistance than a thin belt, which
slippage. Using a conveyor without pulley lagging on the drive pulley is means that a full wrap angle is not achieved on very small pulleys.
Tilted troughing idlers are designed in such a way that the side roller
brackets are somewhat displaced ahead in the belt direction. This
creates an angle against the belt edge of 1.5-3 degrees, which in its
turn, through the friction between belt and side rollers creates a force,
directed towards the centerline of the belt. The more the belt wanders
Subject to alteration without prior notice Brochure No. 2422-05-10-SBL/Trelleborg-English © 2013.08 Metso Printed in Sweden