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Screening and Conveyor Solutions

Trellex Conveying – theory and practice

EN
Contents

The conveyor belt ............................................................ 1


Fabric strength ................................................................... 2
Belt designation ................................................................ 3
Tolerances .............................................................................. 4
Safety factors ..................................................................5-6
What happens in the splice? ...............................7-8
Choice of belt ...................................................................... 9
Transition distance ............................................... 10-11
Pulley diameters .............................................................12
Idler design .........................................................................13
Return rollers .....................................................................14
Loading .......................................................................... 15-17
Belt cleaning .............................................................. 18-20
Slippage ................................................................................21                                                                                  
Belt guiding ................................................................ 22-24
Questions and answers .................................... 25-28
Our products .....................................................................29
The Conveyor Belt
The first written evidence about conveyor belts, made of leather or belt To show that there was polyamide in the fabric, the letter ’P’ was used
duck, can be found in a report in the US from 1795. (Millers Guide’ by conforming to the original material designation. Such a belt designation
Oliver Evans). could be, for example, RP 100.

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

Screening and Conveyor Solutions 1


Fabric strength (per fabric) N/mm (kp/cm)
B 50 For practical reasons, EP-fabrics are produced no stronger than 700 N/mm.
B 63 The thickness makes it difficult to obtain enough strength in the splice.
B 80 RP 80 EP 80 Instead other materials are chosen, for example D-/DP-fabrics made of
RP 100 EP 100 Aramid (Kevlar®/Twaron®) or steel (St / STW). As explained earlier, the
RP 125 EP 125 numbers indicate the tensile strength of the fabric in N/mm (kp/cm).
RP 160 EP 160
RP 200 EP 200 Obviously the price increases with the strength of the belt. Adding a
EP 250
little extra for stronger belts therefore is more expensive but necessary
EP 315
to achieve a suitable safety factor.
EP 400
EP 500 D 500 ST 500
EP 630 D 630 ST 630 Today, the strongest fabric is Aramid. Belts are produced at a strength
EP 700 D 800 ST 800 of up to 3150 N/mm using only a single ply. If it was possible, a cotton
D 1000 ST 1000 belt of this strength would have to consist of approximately 40 layers of
D 1250 ST 1250 B80 fabric! The carcass would have a thickness of about 95 mm instead
D 1600 ST 1600 of 3 mm for the Aramid belt. This highlights the fact that it is of the
D 2000 ST 2000 utmost importance that the splicing is carried out perfectly. The splice of
D 2500 ST 2500 this belt has to transmit all forces in only one ply.
ST 3150
ST 4000
ST 5000
ST 6300

2 Screening and Conveyor Solutions


Belt designation
To make it possible to identify a belt, there is a standard on how the If, for example, a breaker is being used this will be shown after the
description has to look like. In the past the number of layers of fabric digit for the corresponding cover thickness. Depending on the material
used was declared first, followed by the type. For example, 5 EP 160. an “S” for a steel or a “T” for a textile breaker is being used. 1200 EP800/5
Today the belts total strength is declared first, followed by the number 6T:2 Y, shows that the breaker is vulcanized into the top cover. 1200
of fabric layers. The former 5 EP 160 is now described as EP 800/5. EP800/5 6:2T Y means that the breaker is vulcanized into the bottom
This is followed by the thickness of top and bottom cover as well as the cover. 6S:2T would mean that the top cover includes a steel breaker
cover grade. Top and bottom cover is divided by a colon. The first while the bottom cover includes a textile breaker.
digit states the top and the second digit the bottom cover. At the end,
the quality of the covers is stated, for example: EP800/5 6:2 Y.

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.

86 m 1200 EP 800/5 6:2 Y


Quality of the cover plate
Thickness of the cover plate
over/under (mm)
Numbers of fabric layers
Tensile strength (N/mm)
Type of fabric
Width (mm)
Length (m)

Screening and Conveyor Solutions 3


Tolerances
A conveyor belt consists of ’living’ material – rubber and fabric. It is quite Elongation
obvious that such materials are subject to fluctuation . The requirement that a belt should only elongate slightly has become
For this reason the following tolerances are used: more and more common over recent years.
Width over 500 mm: ±1 % example: 1200 mm ±12 mm
Width up to 500 mm: ± 5 mm The DIN-standard has increased the elongation demands and the follow-
ing values are valid:
This means that a belt with a width of 1188 mm can be spliced with a
belt of 1212 mm. up to EP 500/x max 1,5 %
EP 630/x - EP 1250/x max 2,5 %
Belt length: open length + 2 % EP 1600/x - max 3,0 %
endless ± 0,5 %
Note that the elongation percentages are related to the total strength of
Thickness of the cover plate: Up to 4 mm - 0.2 mm. the belt, not to the individual layers of fabrics.
There after -5%. For example 6/2 can be 5.7/1.8.

However, the plus tolerance is free.


Belt thickness: <10 mm ± 1 mm
>10 mm ± 10 %

Straightness: Permitted mistracking:


Up to 800 mm ± 40 mm 1000 mm ±50
1200 mm ±60
1400 mm ±70
1600 mm ±75
Example:
Permitted mistracking for 1200 EP800/5 6:2 = ± 60 mm.

4 Screening and Conveyor Solutions


Safety factors
The ’ten-times security’ against breaking dates from the era of the cotton What can happen in practice?
belts, which is not so long ago. Cotton is a natural material and its quali- The belt needs to be calculated for the worst case scenario, for which
ties can vary in an uncontrollable way. They can vary with the time the following points need to be taken into consideration for a 4-ply belt:
and place of the cotton picking. The method of storage can have an
effect, and moisture can have a negative effect on quality. For these 1. In the step splice, only three layers of fabric are transferring the forces,
reasons, it was desirable to have real safety margins from the beginning. the safety factor in the splice is therefore lower than in the belt.

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.

Screening and Conveyor Solutions 5


Safety Factors
What can we learn from this?
A calculation is only as good as the given data. Variations of the “real”
conveyor from this data may occur which might lead to a smaller safety
factor.

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.

It is often possible to move an idler so that the transition zone is lengthened.

Even a perfect splice can be exposed to so much strain that it breaks.


Sometimes the margins are very small and especially the stronger,
longer and more qualified a belt is, the smaller the margins become.

6 Screening and Conveyor Solutions


What happens in the splice?
To make it simpler, let’s say that two layers of fabric have been vulcanized Then we expose the fabric to traction forces.
together. It is not important whether it was by cold or hot vulcanization.

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.

As there is a difference in tension, there is also a difference in stretching.


This difference in stretching is absorbed by the rubber layer. Once the
forces become too high the rubber will either break or it will come off.
Whatever the case, the result is the same.

Screening and Conveyor Solutions 7


What happens in the splice?
What can we learn from this?
We can’t oppose the laws of nature, but we can prevent their conse-
quences.

Always follow the manufacturer’s instructions regarding vulcanized


materials. These have always proved to give the best results. Don’t ignore
drying and curing times, even if someone is ’breathing down your neck’.

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.

If the pulley diameters are too small there is also a displacement in


every ’splice step’, which can become unfavorably large and cause
permanent damages.

8 Screening and Conveyor Solutions


The choice of belt
Before deciding which tensile strength is needed, it is necessary to look at Depending on the tensile strength and the length of the conveyor, the
the general conditions. On which route does the material need to be con- right type of tension member for the carcass needs to be chosen. EP-
veyed? How many curves with which radii? What kind of material is to be Fabric, Steel or Aramid are the most common materials. It needs to be
conveyed? What is the maximum inclination of the conveyor? Whichever checked if the troughing as well as the load support of the chosen carcass
type of belt should be used, it is necessary to find out at which dimensions is suitable for the installation. Also concave curves need to be calculated
(e.g. belt width, troughing angle and belt speed) the mass and volume for belt lift and convex curves for force peaks in the edges or omega folds
capacity can be conveyed. due to compression in the middle of the belt.

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.

Screening and Conveyor Solutions 9


Transition distances
For reasons of space, there has been a tendency for the conveyor to be as
compact as possible. Quite often this reduces the transition distance.
The old belt types, which had relatively high elongation and a thick,
cross-rigid, stable fabric package, had better properties for handling short
troughing distances. The belts of today, which require low elongation
and high flexibility, need longer distances between pulley and troughing
idler.

Without going into complicated calculations, it is generally recommend-


ed that the shortest acceptable distance for EP belts should be 1.9 x
the belt width at 45° troughing and 1.3 x belt width at 30° troughing.

Troughing angle 30° L = 1.3 x B


Troughing angle 45° L = 1.9 x B

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.

10 Screening and Conveyor Solutions


Transition distances
Another strange thing that can occur, the result of which has surprised Under no circumstances must the upper edge of the pulley be lower
many people, is that the ‘z’ shaped fold moves closer and closer towards than that of the center roller. This creates constant splice problems
the edge of the belt. When it reaches the belt edge, the ‘z’ is transformed among other effects.
into a ’U’ lying on its side, whereupon the lower leg of the ’U’ begins to ‘walk
back’ towards the center. After running completely folded for a short time, In the table below the following applies
the belt then proceeds to ‘walk’, and it ends up with the belt having turned h : troughing depth
itself inside out. The whole episode is complete after about ten turns. hTR = 0 : the upper edge of the pulley is on the same level as the upper
edge of the center roller in the support frame
As mentioned above, the transition distance should be 1.3 - 1.9 x the belt hTR = h/3 : the upper edge of the pulley lies at 1/3 of the troughing
width. This is valid if the upper edge of the pulley is on the same level as depth over the upper edge of the center roller in the support frame
the upper edge of the center roller in the support frame. It is much better if
the upper edge of the pulley is elevated above the center roller of approxi-
mately one third to one half of the troughing depth. This creates lower edge
stretch/tension.

Necessary length of transition distance L (B = Belt width)


Transition angle 30° 35° 40° 45°
Upper edge of the pulley hTR=0 hTR=h/3 hTR=0 hTR=h/3 hTR=0 hTR=h/3 hTR=0 hTR=h/3
EP-Belt 1.3 x B 0.9 x B 1.5 x B 1.0 x B 1.7 x B 1.2 x B 1.9 x B 1.3 x B
Trellex Aramid belt, regular elongation 1.5 x B 1.1 x B 1.8 x B 1.3 x B 2.0 x B 1.5 x B 2.2 x B 1.7 x B
Trellex Aramid belt, low elongation 2.1 x B 1.6 x B 2.4 x B 1.8 x B 2.7 x B 2.2 x B 3.1 x B 2.5 x B
Strongflex, STX 1.9 x B 1.6 x B 2.2 x B 1.9 x B 2.5 x B 2.1 x B 2.7 x B 2.4 x B
Steelcord, STR 2.2 x B 1.9 x B 2.5 x B 2.2 x B 2.8 x B 2.5 x B 3.0 x B 2.7 x B

Screening and Conveyor Solutions 11


Pulley diameters
Minimum pulley diameter ( mm )
Utilization of max. Recommended working tension

Group 60% - 100% Group 30% - 60% Group <30%

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.

12 Screening and Conveyor Solutions


Idler design
There are two principle types of support frame on the market: Unfortunately the damage to the belt does not show until it has been
These are fixed and suspension (Garland) support frames. As a rule most in operation for one or two years. By then it is too late to save the belt
of the support frames are manufactured with offset center rollers. These and also in this case it is the splice that suffers the most damage.
frames should be mounted so that the center roller meets the belt first.
The ’belt lift’ should be over this roller and not over the side rollers. This Suspension support frames give the same function as fixed ones but
creates better tension distribution in the troughing zone of the belt. they should not be used on downward conveyors. Because the belt has a
The tilting of the support frames is designed in such a way as to give tendency to drag the roller stands along, the side rollers tend to form an
the correct steering effect automatically. (On some older conveyors the angle towards the belt, which creates a steering problem.
support frames can be constructed the other way round. It is unusual,
but it happens). This problem does not occur on horizontal conveyor passages.

Another variation is for all rollers to be in line. There, it can be difficult


to see in which direction the support frame should be mounted, but
because the side rollers are angled it is usually easy to see.

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.

Screening and Conveyor Solutions 13


Return rollers
An area that is often neglected is the position of the rubber discs on
the return rollers. These rubber discs are used to prevent the build-up of
material on the return rollers.

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

14 Screening and Conveyor Solutions


Loading
Loading is one of the most critical points on the conveyor, where many There are certain criteria which must be fulfilled to eliminate spillage and
types of damage can occur. Here, the flow of material changes direction, carry out loading effectively:
impact is to be absorbed, the material will be slowed down and then
accelerated again and then guided until the turbulence from the loading 1. The belt must be centered
has stopped. A centered belt at the loading point is essential to avoid problems with
mistracking on the upper part of the belt. If the belt is allowed to wander
WRONG in the loading zone, the loaded material will not be positioned along the
centerline of the belt.

2. Loading of the material must be centered


A belt strives for balance. If the loaded material is not distributed evenly
around the centerline of the belt, the belt will be shifted sideways until
it reaches a position where the weight is equally divided. By installing a
horizontal load-centering plate in the loading chute a rocker box is cre-
ated which directs the material flow towards the centerline of the belt.

A common mistake in the past was to replace worn-out side shirting


with strips of worn-out belts. The idea was that you would get a stable,
wear-resistant shirting for free. The fact that these belt strips functioned
as an abrasive material against the belt was overlooked. The result was
two parallel grooves along the belt, which sometimes became so deep
that the belt split. Today, there are modern sealing systems which use
material with somewhat lower wear strength than that of the belt. In this
way you can concentrate the wear to the sealing strip and prolong the
life of the considerably more expensive belt.

Screening and Conveyor Solutions 15


Loading
3. The material to be loaded should travel in the same create a straight, smooth surface to tighten towards. The most effective
direction and have the same speed as the receiving belt way to do this is to use impact or glide bars surfaced with low friction
When the material leaves one belt and falls on another one, or when it plastic. These are installed on a special cradle under the belt or mounted
falls through a chute, the air around it will be dragged along and a flow on a bent plate which replaces the side rollers in the idlers. By choosing a
of air created. If the speed of the material or its direction differs from that somewhat larger troughing angle on the cradle than given by the idlers
of the receiving belt, the change of air flow makes the material bounce gives an effective support for the belt edge.
and dust will be released. The risk of spillage increases dramatically. Since
it can be complicated, or impossible, to correct this later on, it should be 6. The sealing system should be easy to adjust
taken into consideration when the loading point is designed. A common reason for spillage at the loading point is that the exist-
ing tightening sealing is complicated and time consuming to adjust.
4. The sealing system must be free of material pressure It is therefore important to choose a system that is easy to adjust and
If the material to be loaded is allowed to press against the sealing maintain. Common rubber strips function properly when they are new,
system, the material will work itself underneath the seal. By mounting a but since they are mounted vertically towards the belt they get worn out
wear liner in the lower part of the chute, the material is deflected from relatively quickly, and the fastening, which often consists of flat steel and
the sealing system. It greatly reduces the risk of spillage and prevents bolts, is hard to adjust, resulting in neglected maintenance.
material from getting stuck, this would result in increased wear and dam-
age to the belt. The opening towards the belt is made wedge-shaped to 7. The kinetic energy from the loaded material must
further reduce the risk of material getting stuck. be absorbed
Material that is large and heavy, or demanding in other ways, can cause
5. The underneath of the belt edge must be supported temporary puncturing pressure, which damages the belt. Unfortunately
A loaded belt always hangs down between the carrying rollers. The alien objects can also appear in the flow of material. These objects
extent to which it hangs down depends on the characteristics of the sometimes have a remarkable ability to get stuck and rip the belt. To
belt, the belt tension, the load and the distance between the frames. To reduce the risk of such damage, the impact idlers should be replaced
ensure that the sealing system can function at its best, it is necessary to with a fixed mounted cradle with impact bars. This will protect the belt

16 Screening and Conveyor Solutions


Loading
by absorbing the high puncturing pressure which occurs when coarse operational reliability is increased. A roller breakdown at the loading point
material with high kinetic energy hits the belt. When the belt is sup- normally happens very suddenly and can, in worst case, result in serious
ported from below, the risk of a rip caused by the belt being punctured belt damage. When an impact cradle is used it is very important that it is
is practically zero. If traditional rollers are used, the risk of puncturing is installed correctly. The top surface must be 20-25 mm below the upper
high as an alien object may get stuck with no possibility of breaking loose. edge of the middle roller. Permanent contact between the impact bar
From an economic point of view an impact cradle is better than impact and the back of the belt results in increased wear and much shorter life.
idlers. The demanding work of changing wrecked rollers is avoided, and

RIGHT

Screening and Conveyor Solutions 17


Belt cleaning
Belt cleaning is one of the most difficult problems encountered within
the conveyor sector. After the material has left the belt, particles that
remain must be removed to prevent contamination and build-up of
material on the return rollers, otherwise the result may be mistracking
leading to damage to the edge of the belt.

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 Pre-Cleaner is normally positioned against the drive pulley immedi-


ately below the flow of material. A rule says that the lower the belt speed,
the lower the cleaner should be mounted, and the higher the belt speed,
the higher the cleaner. This is to ensure that the cleaner does not get into
the flow of material. The pre-cleaner has a tough task. It removes most of Arm-Cleaner
the material that remains after unloading. The pre-cleaner is especially suit-
able when coarse or moist, sticky material is transported.

18 Screening and Conveyor Solutions


Belt cleaning
No matter how sophisticated a belt cleaner may be, there are certain require-
ments that have to be fulfilled to give it a fair chance to work well. The follow-
ing factors affect the effectiveness and length of life of the belt cleaner:

The condition of the belt. In addition to the demands placed on the


condition of the belt cleaner, there are certain demands made on the
Belt brush belt. Cleaning efficiency is lower if the belt is old or if the surface is worn
or damaged. It is important to check that the belt splice is smooth to
The Belt brush is a suitable method for cleaning cleated belts. Scrapers avoid the belt cleaner getting stuck. If the belt is spliced with mechanical
will not work on these belts. The Belt brush can be mounted anywhere belt clips, it is important that these are well countersunk. If necessary the
on the return part of the conveyor, but the most usual place is immedi- splice can be covered with rubber strips.
ately behind the drive pulley. The brush must not be pressed against the
belt, but should only touch it lightly for best results and length of life. A Maintenance. Naturally, a belt cleaner does not perform better than the
Belt brush works best on material which is relatively dry. maintenance it gets. Like all other equipment in a plant, it is recommended
that you regularly check and clean the belt cleaner. If the blades are worn-
The Plow-Cleaner. Material that becomes stuck between the belt and out, efficiency is reduced and spillage increases. The blades should therefore
the tail pulley can cause a break in the framework and must be removed be replaced regularly. It is also important to maintain correct blade to belt
before the belt reaches the tail pulley. This can be done satisfactorily pressure. If the pressure is too low there is an increased risk that fine mate-
with a Plow-Cleaner. The Plow-Cleaner can be combined with a scraper rial will pass between the blade and the belt. When this happens, spillage
placed against the shell of the pulley, which takes care of material that increases along the conveyor and wear on the blade increases substantially.
has managed to pass the Plow-Cleaner. Rubber or polyurethane strips
are suitable for use as the scraper blade on the Plow-Cleaner. Transported material. Belt conveyors are used in many industries.
Everything from wood chips, recycled paper and garbage to iron pellets
and crushed rock are moved with the help of conveyors. Naturally, the
characteristics of the transported material affect the wear, life and ef-
ficiency of the belt cleaner.

Screening and Conveyor Solutions 19


Belt cleaning
Choice of cleaner Incorrect installation
As mentioned above, it is important that the correct cleaner is chosen A belt cleaner can only function if it is installed correctly and in the right
with respect to application. A wrong choice can result in a shortening of place. Wrongly installed, both efficiency and wear life can be reduced
its life or poor efficiency of the product. Available space or other factors, considerably. A guarantee of successful installation is to employ experi-
such as temperature and working environment may also determine the enced service technicians to install and adjust the belt cleaner.
choice.
Belt speed
Choice of wear material A high belt speed reduces the efficiency of the cleaner, as the time that
It is also important to choose the correct wear material depending on the edge of the cleaner is in contact with a specific point on the belt is
the material transported. Advanced wear material is more expensive and extremely short. The life of the cleaner suffers most. The combination of
can be unnecessary in lighter applications, whilst a cheaper wear mate- high speed and friction between the scraper and the belt can result in
rial does not give the long service interval required for more demanding temperatures so high that they reduce the wear life of the cleaner.
applications. A number of different materials are used in today’s belt
cleaners. Rubber shows good wear properties, but is usually too soft to Vibrations
be used as a cleaner. To get enough rigidity, the rubber strip must be A belt that runs unsteadily on the conveyor and which may jump and
made relatively broad or be reinforced. If the contact area against the shake due to uneven or damaged rollers or rubber discs reduces the pos-
belt is broad, efficiency will be diminished. Polyurethane is a good wear sibility of the belt functioning well.
material, offering long wear life and is nevertheless gentle on the belt. An
aggressive cleaning angle towards the direction of the belt can be used Obviously cleanliness of belts is not just a question of aesthetics but, to a
without risk of damaging it. Tungsten carbide offers good wear resist- high degree, contributes to better operational reliability, increases wear
ance, but it is important that the scraper edge is at a 90° angle to the belt life and reduces clean-up costs. For these reasons it is necessary to be
to avoid damage to the cover plate. Ceramics also give long wear life too, patient and to try out the best solution each time.
but are sensitive to impact, which can shatter the cleaning edge.

20 Screening and Conveyor Solutions


Slippage
There are three factors that can cause slippage: pretensioning being like driving a car with worn tires. The more difficult conditions become,
too low, the wrap angle being too low or the friction coefficient being the greater the risk of loose grip. Therefore it is important to have pulley
too low. One of the most common causes of slippage is the belt be- lagging that secures operation in adverse conditions as well, including
ing tensioned too loosely. This may be because the belt has become for example, rain, snow, ice and mud. The pulley lagging should have a
permanently elongated. New belts especially, must be retensioned after pattern in order to create a draining effect and be flexible on the belt at
a short time, usually 1-2 weeks after installation. Counter-balanced belts the same time.
compensate for elongation automatically.
There are many types of pulley lagging. The most common one is glued
To achieve the lowest possible wear on belts, pulleys and rollers, preten- to the pulley and functions well on most drive, brake and turn pulleys.
sioning should be as low as possible, which means that the friction co- This type is also suitable for small pulleys and reversible conveyors. There
efficient and wrap angle should be as high as possible. To increase the are also pulley bars, which are bolted to the pulley with self-tapping
wrap angle by rebuilding the conveyor can however be very expensive screws. These pulley bars have a robust design and are suitable for
and the improvement only limited. If there is no snub pulley, it is recom- inclined or vertical conveyors during heavy operation. Another alterna-
mended that one be installed. Even if the wrap angle is only increased tive is bolted, self-cleaning pulley bars with an open pattern and free-
a few degrees it can be helpful, especially during startup. Strangely, the hanging design. These are excellent problem solvers in tough conditions.
actual contact surface is about 20 degrees smaller then the theoretical Bolted pulley bars also have the benefit of being easy to change without
one, this is due to the elasticity of the belt. having to lift the drive pulley out of the conveyor.

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.

Screening and Conveyor Solutions 21


Belt guiding
Once a new belt is spliced the only thing remaining is running it, which When the belt is moving on the return section, lateral forces very easily
can cause enough problems. affect it. It is therefore important to check the condition of the plow-
cleaner before any adjustments to the return parts are made. It is very
Bear in mind that an old belt has generally been working for several common for the wear to have become so severe that the belt is running
years. Adjustments have been made, rubber discs and rollers have been in a recess, which results in a ’locked’ position. The effectiveness of pos-
changed and the belt has been retensioned. sible adjustments further ahead on the conveyor will then be limited,
and may even be zero. Then, if the plow is adjusted subsequently, all the
Then a new belt with totally different properties from the old one is adjustments that have already been made to the belt create an exag-
installed. Suddenly the friction has been changed. A host of built-in ten- gerated effect, which can result in mistracking in the opposite direction.
sions will cause plastic elongation. Therefore, check that the scraper blade is not damaged and that the
plow is mounted correctly.
A good rule is to tension the belt hard from the start. Then begin by
checking the return parts. It is here that most damage will arise. Start at The most common causes of mistracking are in the following three areas:
the tail pulley and work your way towards the drive pulley. Remember
that a belt which enters the tail pulley centered, leaves it centered. If 1. The conveyor:
the belt is askew at the troughing zone, one of the belt edges will be A. The pretention is too low
stretched harder than the other one. This will then be longer than the B. The conveyor frame is not straight.
other. It can take time before the rest of the belt ’catches up’. Usually it C. Setting of the conveyor’s foundation.
will take 1-2 weeks before the plastic is fully elongated. Check that all the D. Rollers and idlers are not perpendicular to the belt
support frames are perpendicular to the belt. Especially important are or tilted in any direction.
the supporting frames and rollers which are exposed to high belt pres- E. Material not being loaded centered
sure. By studying damage on the old belt you can often estimate where F. The belt is stuck between the rubber discs.
adjustments must be made to the conveyor. This inspection usually G. Material build-up on idlers, rollers and pulleys.
takes a couple of minutes, but can save hours after the splicing job.

22 Screening and Conveyor Solutions


Belt guiding
2. The conveyor belt: the geometry of the belt guiding system, the distance between the
A. The belt splices are misaligned. edge rollers increases as it runs. This means that the edge rollers can be
B. Different types of belt have been spliced together. mounted near the belt edge and can react at an early stage if the belt is
C. The conveyor belt is misaligned or bent. mistracking, without the risk of pinching it. Tiny, rapid adjustments mean
that the belt can usually be kept within plus/minus 10 mm.
3. Environment:
A. The belt is exposed to side winds. Belt training idlers can turn around a point along the belt center. This
B. Rain or snow has altered the friction values. type generally has fixed mounted edge rollers, which are one or two dec-
C. The sun is heating the conveyor, which causes heat expansion. imeters in front of the turning point. When the belt edge is lying against
this roller a force is created which works to turn the whole support frame
Components which are normally used to make the steering of conveyor around. This function deteriorates relatively fast, as dust and dirt makes
belts more accurate: the turning center seaze.

Progressive steering systems are relatively new constructions which


use edge rollers to sense the belt’s lateral movement and link arms to
transmit the force to a steering roller. A link arm has a gear ratio, which
ensures a minimum of force is needed to center the belt. Because of

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

Screening and Conveyor Solutions 23


Belt guiding
to one side, the more the center forces increase on that side. At the same Crowned pulleys use the difference in tension created between the belt
time the forces on the other side are reduced. However, one should center and the belt edge due to the different diameters of the pulleys. On
calculate for increased wear on rollers and belts. To ensure any noticeable today’s belts modern reinforcement materials have to be considered, which
effect, several idlers of this kind are needed. With reversed belt direction are both strong, have low elongation properties and do not exaggerate
the effect is the opposite. the size of the crown. A calculation of a diameter difference between the
center of the pulley and its edge is the diameter divided by 150. This creates
a stretching difference of about 0.7%, which corresponds approximately to
the stretching at half the max. allowed working tension for an EP-belt. The
steering effect is, however, only valid over the pulley and a couple of meters
before and after it.

Inverted return idlers consist of a negatively troughed support frame


which presses the belt edges down between two straight return rollers.
By using the elasticity of the belt in this way, a centered steering effect is Fixed mounted edge rollers should not be used for belt guiding. In the
attained, which is always constant. The difference between stretching at past they were used for thick cotton belts. Today the only application is as
the edge and stretching in the center should be a maximum of 0.8% and protection of sensitive conveyor parts against damage from cutting, not for
a minimum of 0.4%. With higher stretching there is a risk that the belt will permanent guiding.
buckle in the center and the whole steering effect is lost. Any stretching
below 0.4% reduces the steering effect. It is assumed that both the right and Suitable, and necessary, places for mounting a belt guiding product are just
the left-hand sides are working under identical conditions for the system to before the tail pulley, before and after a convex curve and in a concave curve
function. where the belt often has a tendency to lift. Belt guiding products are most
suitably mounted approximately every 50 meters on long conveyors.

24 Screening and Conveyor Solutions


Questions and answers
Which is best – cold or hot vulcanization? special chemical resistant belts for those applications. The most common
In general you can say that a hot vulcanization is the best choice for a long reason however is heat. For temperatures above 60°C it is recommended
lasting splice. Anyway there are applications where cold splicing is enough to use special heat resistant belts to avoid cracks in the covers.
or where hot vulcanization is not possible. Cold vulcanizing has the big
advantage that it needs less time and less space than hot vulcanizing. For How fast can you run a conveyor belt?
special applications, for example heat resistant belts, cold vulcanization is For the belt there is really no limit. At speeds of more than 7 m/s balanced
not an option. For steelcord belts it is absolutely not possible. rollers and pulleys must be used, and they must be checked and main-
tained continuously which is being done for some special applications but
How high are the temperatures that cold in the long run becomes uneconomic for standard conveyors. Also the
vulcanization can take? material has to be taken into consideration. Light materials cannot be
The recommendations of the manufacturers (which you should always follow) transported as fast as heavy materials. Therefore, in practice, 6 m/s is the
state a maximum of approximately 70° Celsius. In practice, the limit is just maximum belt speed.
below 90° Celsius, but to go up to this limit continually is not recommended.
How cold can a belt get before it cracks?
How much do belts lengthen in hot conditions? For standard SBR based belts, the limit is about -35° Celsius. However,
In contrast to that the cord in the fabrics is twined at specially calculated Metso is able to provide special “Polar” cover grades that can resist low
angles, that causes a contraction force lengthwise. The overall change in temperatures down to -60°C.
length is so small as to be negligible.
Why does common wear rubber swell in oil while, for
Some belts get old and crack more than others. Why? example, nitrile rubber does not?
Cracks in the surface can have several reasons. In the past Ozone Wear rubber has, in principle, the same molecular structure as oil. This
was responsible for most of those cases. Today’s belts are well protected means that it is easy for oil to mix its molecules with rubber molecules
against Ozone. Especially cover grades for FLEXOPIPE® belts have a very with a resulting increase in volume. Nitrile rubber has a different struc-
high resistance against Ozone which is necessary for the stretched bot- ture and cannot absorb oil. The reason that there is still some swelling is
tom cover of the belt. Some chemicals can also make the covers age fast- that a rubber blend contains 15-20 different ingredients, of which some
er due to the extraction of softeners out of the covers. Metso can offer can absorb oil.

Screening and Conveyor Solutions 25


Questions and answers
ozone or UV-light are then reduced. After many years, it is possible that
Splicing problems there may be a slight tendency towards cracking at the belt edges and
Splicing problems can be caused by several factors. Contact the manu- on the outer wrapping of the belt. The quality of the fabrics, however, still
facturer and solve the problem together. As a rule, splicing should be remains the same. With longer storage, especially if the belts are long and
carried out in accordance with the manufacturer’s recommendations. heavy, each roll should be kept suspended through the wooden core. They
should also be rotated occasionally.
You often hear that less counterweight increases the
wear life of belt and splice. Is this really true? When you are skiving a belt when splicing, does it
No, it is not true. The task of the counterweight is to tension the belt matter whether you pull off the cover in
to avoid slippage, and also to prevent excessive sagging between the narrow strips or you pull off the full width?
idlers. This should not exceed 1%, as energy consumption then increases This depends on the adhesion values of the belt. If the adhesion is high
as well as wear, due to larger rolling resistance. Furthermore, the trans- and you pull the whole piece there is a risk that the belt ends will be
ported material will move up and down every time it passes the rollers. misaligned, which will result in a splice which is not straight.
This creates an unnecessarily large amount of belt wear, and at the same It is therefore recommended to always cut strips and pull in longitudinal
time the splice suffers from all the different stretching forces. Also, a belt direction. Due to the high risk of cutting a ply it is not recommended to
that is correctly tensioned is more stable in operation. cut and pull in cross direction. Belts with normal adhesion values can
have wider strips than belts with high adhesion values. Special care is
How long can you store a belt before it is used and needed when using the grinding machine. The fabric below the rubber
how should it be stored? must not be damaged.
There is no real answer to this question. A new belt always has better
properties than an old belt. There have been belts stored for over 10 years
with still very good properties but this depends on the way they were
stored. The best storage conditions are indoors, in the dark and at tem-
peratures around 15°C (not to exceed 25°C). The risks of damage due to

26 Screening and Conveyor Solutions


Questions and answers
How is adherence measured and what values are normal? In the old days there were rubber edges on the belts.
Pull a rubber strip or fabric strip straight back along the belt. The pulling Today many belts are delivered with a cut edge. Why
force needed is measured in N/mm (kg/cm). The DIN standard states a mini- is that?
mum value of 5 N/mm between the layers of fabric and 4.5 between cover Cotton belts were sensitive to moisture. That’s why the belt edges had to be
and fabric. If the cover is 1.5 mm or thinner the adhesion can be 3.5 N/mm. A protected against encroachment from moisture. The consequence was that
good value is around 5-7 N/mm. Skiving gets unnecessarily difficult if this is every belt had to be manufactured to an exact width. Modern belts are not
exceeded, and you do not gain any real advantage. At values of over 9 N/mm sensitive to moisture and can be manufactured to the most suitable and
you usually have to remove the cover plate in small pieces or grind it off. This economic width for production and then cut to the desired width. This
is common if you are re-splicing an older belt where the rubber may possibly method actually makes narrow belts cheaper. The carcass and the edges
have deteriorated. The grinding has to be done carefully so that the underly- however are not as well protected as with solid edges. For standard applica-
ing fabrics don’t get damaged. tions the adhesion values of these belts are more than enough and provide
enough protection to avoid damages in the edges. Wider belts that are
How much does a belt weigh? made to order usually still have a molded edge.
The density is approximately 1.1 g/cm3 for fabric belts. So, a belt which is
one meter wide and ten millimeters thick weighs approximately 11 kg/m. Which is the best troughing angle?
Steel cord belts however are heavier and their weight highly depends on the The most common troughing angle is 35° on a three-roller idler. A lot of new
strength class. Approx. weight values can be found in our product leaflets. installations use a 45° troughing angle which gives the highest and most
economic conveying capacity and, at the same time, the best belt steering if
Today one belt is as good as another. I mean, a belt is the conveyor is designed for this. Compared with older types of belts, it is even
a belt. So I can buy the cheapest alternative, can’t I? possible to use this troughing angle for very narrow belts today.
If you had said the same about car tires a number of opinions and
experiences would be proposed straight away. And naturally this is the How high is the cross strength in a belt?
same for belts too. The difference is that neither the knowledge nor the In the past, standards referred to 40% of the longitudinal strength in
discussions are especially extensive. Certain belt properties which are cross direction. Today there are no more rules. The cross strength of Met-
important can only be achieved by special treatment of the fabrics and so’s standard EP belts is approximately 30% of the longitudinal strength.
special rubber covers, which of course means extra costs.
Screening and Conveyor Solutions 27
Questions and answers
How long can a conveyor be if you use a screw take-up? How much can rubber be compressed?
The tasks of a take-up device include creating enough pretensioning to Rubber is easy to compress provided that it can expand in one direction
avoid slippage. With horizontal conveying there is little difference in load or another at the same time. If there is no room for expansion it is not
between an empty belt and a fully loaded belt. The usual opinion is that possible to compress it. This means that rubber, in fact, can be looked
the maximum length is approximately 50 m. However, there are exam- upon as uncompressible.
ples of conveyors as long as 150 m. For inclined conveyors, where there is
a high difference in tension, the limit is approximately 30 m.

Conveyor belts sometimes burn. How much energy


is there in a belt?
The energy value for a normal belt is about the same as for oil, 40 MJ/kg.
As a rough comparison you can say that the energy in a normal belt roll
(300m, 1200 mm width) corresponds to what you would need to heat
up a normal house for a year. But, in fact, a standard belt does not burn
quite like that. To start with it has to be a heated to 350° Celsius before
the inflammable gases are liberated, and then approximately another ten
degrees before it ignites. For natural rubber the equivalent temperature
requirement is 230° Celsius.

When do you have to use terpene-resistant belts?


Terpene resistant belts are very often used in the paper and pulp indus-
try to transport pitch and pine and bark. Terpene resistant belts become
slippery especially in cold conditions when the material is frozen.

28 Screening and Conveyor Solutions


Our products
Trellex conveyor belts are one of the most complete range of conveyor Trellex belt conductor is a simple and robust construction, which auto-
belts in the world, with capacity to fulfil every user’s need for reliability matically and continuously supervises the belt and prevents mistracking.
and economy. Reliability of operation increases and the risk of belt damage and spillage
is reduced.
Trellex impact bars replace impact rollers. They protect against loading
damage, prolong service intervals and reduce spillage and clean-up costs. Trellex belt cleaning system is a modular system designed to clean the
belt and prevent spillage under the conveyor in a maintenance-free and
Trellex glide bars support the belt edge by replacing side rollers and effective way.
make it possible for the sealing system to do a good job better.
Trellex sealing system keeps the loaded material on the belt. The
Trellex Griplag increases the coefficient of friction between belt and drive significance of this system is that it prevents wear to the belt, simplifies
pulley. It is bolted against the pulley, which makes replacement easier, and maintenance, reduces spillage and is easy to adjust.
has a self-cleaning design, which makes it suitable in tough conditions.
Trellex conveyor cover is a simple, low weight, modular system for
Traclag is a glued sliding pulley lagging with a broad field of application. sealing conveyors. The system protects against dust and the working
Suitable for most drive, brake and turn pulleys. Works well even on small environment is improved.
pulleys and reversible conveyors.
Trellex conveyor rollers offer long wear life and high load capacity at
Trellex pulley bars are a robust sliding protection, well suited for heavy- the lowest total cost. A well-balanced roller designed for tough condi-
duty inclined and vertical conveyors. They are bolted, which makes tions. An effective sealing system keeps moisture and dirt out.
installation simple and fast.
Trellex cold vulc is a glue which is easy to work with and ensures strong
Trellex roller sleeve is an elastic rubber sleeve which is mounted on the joints. It is excellent for gluing rubber to rubber as well as rubber to metal. It is
return rollers. It prolongs the life of the roller and protects against mate- also very suitable for splicing conveyor belts and for gluing pulley lagging.
rial build-up and mistracking.

Screening and Conveyor Solutions 29


Metso Germany GmbH
Conveyor Solutions
Grafenberger Alle 337a
40325 Düsseldorf
Germany
Phone: +49 211 2105 111
Fax: +49 211 2105 617

Metso Sweden ABTerminalsgatan 2


Conveyor Solutions
P.O. Box 132
SE-23122 Trelleborg
Sweden
Phone: +46 410 525 00
Fax: +46 410 526 02
www.metso.com

For contact or information about your


nearest sales office please visit:
www.metso.com

Subject to alteration without prior notice Brochure No. 2422-05-10-SBL/Trelleborg-English © 2013.08 Metso Printed in Sweden

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