Introductory ~ Guide to Wa =6Conveyor Z BeltingIntroductory Guide to Conveyor Betting 1 Vi. VIL. 1 VIIL Table of Contents Introduction Some “Basics” on Conveyor Belting... The Elements of a Conveyor Belt... A The Textiles B. The Elastomers C. The Covers, Plies, and Saturants D. The Carcass Construction Conveyor Systems... A. Heavyweight Systems B. Lightweight Systems Conveyor Belt Application Engineering... A. Heavyweight Systems B. Lightweight Systems Belt Installation/Maintenance/Training A. Heavyweight Conveyor Belting B. _ Lightweight Conveyor Belting Fabricated Belting Trouble-Shooting Conveyor Belt or System Problems Appendix - Glossary NIBA| a eae q Introductory Guide to Conveyor Belting An Introduction... The Introductory Guide To Conveyor Belting has been developed by the NIBA Technical Committee, in conjunction with the other committees of NIBA, as well as it’s members. Itis intended to provide a quick but accurate overview of both the basic, as well as the more detailed or advanced components of the conveyor belting industry. We begin by looking at, in depth, the elements that makeup conveyor belting, and include detailed discussion on Belt Fabrication, With the aid of various photographs and illustrations, ‘we explore the world of Conveyor Systems as they relate to belting, detailing common conveyor configura- tions that are found in the industry. Once a ground-work level of knowledge has been established, we continue to dive deeper, looking closely at Application Engineering, and eventually on to the processes involved in Belt Installation, Maintenance of Conveyor Belts, and Tracking or Training Conveyor Belts, Finally, we will take a look into the skill of “Trouble-Shooting” a conveyor or conveyor belting problem. The “Guide” will make references to more detailed technical information which is available from NIBA. ‘The detailed support information and the Introductory Guide To Conveyor Belting will help anyone.to become versed on the principles of conveyors and conveyor belting. Also, at the end of this “Guide” you will find a Glossary of Terms that will help to define much of the terminology used throughout this text. Words that are highlighted in maroon can be found in this Glossary. Inaddition, this “Guide” will help the reader to gain a better understanding of the methods used in conveyor engineering, such as determining belt strength, etc. It will also provide the reader with suggestions on where to find NIBA information ona variety of topics related to conveyor belting and the associated equipment that it is used on, Remember, however, that there is no substitute for experience. Whether you are a novice or professional, as it relates to conveyor belting, you will find the information contained in the “Guide” extremely helpful. Introductory Guide to Conveyor Belting 3 Some “Basics” on Conveyor Belting... There are many types of conveyor belts-used today in a variety of industries, and with the dramatic advances in technology, that number is increasing daily. You can find lightweight belts in the food industry, package handling, agriculture, airport baggage handling, automotive, warehousing, and a number of other areas. Lightweight belts, for the purpose of this “Guide”, will refer to belts that have tension ratings of equal to or less than 160 Ibs. per inch of width (PIW) or less. fe Heavy weight belts will refer to those rated over 160 Ibs. PIW. Heavy weight belts are found in industries such as ag- gregate, grain, wood products, metals, minerals, ores, power plants, to name a few. For mote detail, see NIBA Video Tape #42 ‘Heavy Duty Conveyor Belting” Conveyor belts are typically produced in long lengths and wide widths called slabs ‘These widths are typically 60 or 72 inches wide in domestic production, and 1500 mm to 2 meters wide in European production. Popular slab lengths range from 500 feet in domestic production, to 100 meters in European production. The NIBA distributor will usually purchase these full or half-slabs, slitthem to width, and sell smaller individual belts that satisfy the requirements of their customers. NIBAIntroductory Guide to Conveyor Belting 5 The Elements of a Conveyor Belt... | ‘Most conveyor belts are a combination of tension bearing warp yarns, lateral fill or weft yarns, and rubber or plastic components. In traditional conveyor belts, this consists of a carcass that includes textile (Figure ‘A) or metallic tension bearing elements that are impregnated with rubber or plastic material, and also have rubber or plastic covers on both sides. | “Straight Warp Fabric | | Illustration of a Carcass Cross-Section ‘The complexities of lightweight belting, as it relates to many demands, make it the most interesting. Light- | ‘weight belting has numerous construction characteristics related to it to match the demands of the overall | ‘end-user requirements. Belts may be plied, interwoven, and constructed on multifilament ormonofilament yarns which have been fully impregnated with PVC or plied with rubber or other elastomers that are com- ‘monly used by the belting manufacturers. ] ‘The Textiles - The textiles used in modern converyor belts are usually synthetic, with polyester and nylon being the msot common. Almost all téxtile carcass structures ate woven in one of several types of configurations, although there are some belts made with non-interwoven parallel cords (Figure B). Cover + | Figure B i t | | Non-Woven Segment Illustration of “non-Interwoven Belt Cross-Section” Inaddition, some solid-woven cotton belts are manufactured and used without any elastomeric impregnate.P) Introductory Guide to Conveyor Betting The Elastomers (Rubber or Plastic) - The rubber or plastic components in the carcass serve to impregnate and bind together the textile structures both within themselves and between plies. Most modem conveyor belt textile structures are treated with an adhesion promoting chemical material before the elastomer compound is applied to them. Conveyor belt covers provide a sacrificial wear surface and protect the carcass from the abusive materials being conveyed. Covers may not be included on belts where-a low coefficient of friction to a slider bed support surface or the material being conveyed is needed. The types of rubber used may be natural andjor one of the many types of synthetic rubbers. Plastic-usually means thermoplastic and refer to PVC or urethane. Thermoset urethanes are also used. For mare detail, see NIBA Video Tape #42 “Heavy Duty Conveyor Belting” “Breakers” are another element of conveyor belts that deserve to be mentioned, although their use is becom- ing rare. These structures, usually woven textiles, are included in one or both covers to enhance cover adhesion, and in some cases add impact, tear, or burn resistant properties. The high adhesion in modern synthetic textile reinforced conveyor belts has rendered breakers nearly obsolete. The Covers, Plies, and Saturants - A variety of types of rubber compounds for conveyor belts are available, designed for specific service conditions and materials to be conveyed. ‘These include wear resis tance, elevated temperatures, oil resistance, fire resistance, and many others. NIBA Introductory Guide to Conveyor Belting: ‘Some rubber compounds made specifically for resistance to oils, for example NBR (Nitrile Butadiene Rubber) come in varying degrees of oil resistance. ‘The degree of oil resistance is directly related to the amount of acrylonitrile in the formulation. PVC can also be formulated for oil resistance. PVC is generally described as either monomeric (having poor oil resistance) or polymeric (hav- ing good oil resistance). ‘Therefore, selection of the right fabric and elastomer are critical in providing the correct belt for the job. Elastomers are also used to ply fabric together in the production of plied belting. The Carcass Construction - The textile carcass components are usually woven structures, in a single or in multiple ply configuration. Metallic tension components used in conveyor belts usually are individual parallel steel cables. ‘There are however, woven steel cord structures that are used toa very limited degree. Finally, some low tension conveyor belts consist simply of a sheet ofa strong, high modulus, wear resistant plastic. Solid Woven Fabric Steel cable belts are made with a single layer of steel cables as a tension element. In the fabric reinforced type, one or more plies of woven fabric may be provided above and below the steel cable layer, and the carcass is then covered with the appropriate cover and breaker arrangements. ‘The all gum type eliminates the fabric and breaker and is made with the cable and the rubber only. Insulation Layer and Stee! Cables Illustration of Steel Cable Belt Cross Section In sumniary, there is an endless combination of fabrics and elastomers. When it comes right down to it, ‘one needs to work closely with the end-user to determine the best belt for the application. NIRAIntroductory Guide to Conveyor Belting i) 2» 3) 4) 5) 6) j | (Questions ) Which segment of a belt fabric design supports the bearing or tension load? A Fill B. Binder C. Both Fill and Binder D. Warp Do all belt fabrics use only polyester? O Yes No ‘What type of woven designs are used today? A. Plain B. Interwoven Cc Twill D. — Allof the Above ‘An elastomer can serve as: A. Binder B. Cover Cc Fabric Protection D. All of the Above Steel cables are used in all belt designs. true False Some rubber elastomers are formulated for a wide variety of uses. Some formulations are better for oil resistance than others. One of these types is: A. BBR B. SBR CNBR D. —_ None of the Above Introductory Guide to Conveyor Betting 9 Conveyor Systems... Heavyweight Conveyor Systems Heavyweight Conveyor Systems are described as those generating tension on the conveyor belting equal to or greater than 160 pounds per inch of width during normal operation. Heavyweight conveyor systems are employed in the continuos haulage of bulk materials and are largely found in industrial applications where ‘mined materials such as coal are conveyed out of the ground and to another area. A good example of this might be a rock quarry or electric generating power plant, The principal components of these systems are the conveyor belt, the pulleys and idler rolls used to support and move the belt, and the motors and controls that provide and regulate the necessary power to drive the system. These can be further described as follows. The Conveyor Belt - This is an endless band that transfers the material conveyed between two points. Basically, a conveyor belt is comprised of a reinforced member, ot carcass, and a protective covering. As mentioned in the previous chapter, conveyor belts are generally a composite of rubber or some elastomer such as PVC and fabric or some other reinforcement such as steel cords. The elastomer is the external covering which provides wearability and protection from the handling environment such as high or low temperatures, moisture, oils, chemicals, or highly abrasive materials, ‘The fabric car- cass internally serves as the strength bearing member for supporting the load and to control stretching of the For more detall, refer to Section II; Elements of Conveyor Belts For, more detail, see NIBA\Video Tape #30,"Introduction to Belting” and NIBA Vidéo Tape #31 ‘Let’ Talk Conveyor Belting” Pulleys and Rollers - These mechanisms, usually standard steel rolls on shafts with bearings, drive and support the belt and material conveyed. The bead pulley is usually at the top or near the point where the material discharges. The tail pulley is generally at the bottom or near the area where material loads onto the belt. The driving roll is motorized and moves the belting. The drive could be located at the head, the tail, or placed at some other point along the conveyor system depending on the layout ofthe system. NIBAa ba introductory Guide to Conveyor Belting ‘Sometimes a snub roll is placed near the drive to provide a controlled degree of wrap preventing belt slippage. Lagging, or a soft rubber covering, is often applied to the drive roll to assist in the prevention of belt slippage. Many times, pulleys are crowned, or have a slightly larger diameter in the center to help the belt run in the center of the conveyor system. Carrying idler rolls help support the belt and material conveyed. They are usually in a trough configuration to prevent spillage while increasing the capacity of the material able to be conveyed. A series of transition idlers gradually shape the belt in to and out of this, troughed position when flat rolls are within a certain distance. Retum idler rolls support the belt on it’s way back around the conveyor on the bottom side after the material discharges.’ The take-up roilis part of a device used to prevent slack in the belt as it stretches due to starting and stopping or loading and unloading. Usually, there is a counterweight or spring attached to the take-up roll for this purpose. Occasionally, the take-up roll extends using a serew-like device to tension the belt. Bend pulleys are sometimes used in the take-up area for additional belt support. Motors and Controls - These are components that are used to generate power, as well as regulate it’s use in driving the system. Proper selection of motors to drive the conveyor must be preceded by a determination of the system horsepower requirements, This can be carried out through a calculation involving many factors. For more detail, refer to the NIBA Engineering Manual - Section I! “Carcass Selection” ‘Torquecharacteristics, forces that produce rotation or torsion, must be analyzed to select the motor which will adequatély start the conveyor into motion without exceeding the elastic properties of the conveyor belt. Reduced voltage is frequently used to achieve a smooth start by beginning slowly and then accelerating up to full speed. Modem conveyor systems use computers to control many functions of operation. Sensing devices can electronically feed information to the computer such as material weight or system speed, etc., for analysis and determination as to whether or not changes should be made to allow for more efficient operation. Many safety devices are incorporated into the average conveyor system, These include emergency stop switches, closed circuit television monitoring, and warning horns and alarms. Electrical interlocking techniques are used to stop a series of conveyors, should one of those require emergency shut down. Introductory Guide to Conveyor Belting u Other Elements - There are potentially many other elements of heavyweight conveyor systems. The materials and mechanisms used to make the belt endless are of great importance. Usually, these are either a cement-like chemical bonding system or fastening devices made of metal. Loading chute designs reduce abrasion of the belt surface and provide a controlled material flow onto the belt. Rubber skirting is placed around the loading area to further prevent spillage. Scrapers or wipers placed against the belt surface help remove fine par- ticles that remain on the belt after material discharges. Sometimes electronic rip detection systems are utilized to provide automatic shut-off should the belt become severely damaged. Systems with high angles of incline such as grain elevators use buckets or other devices attached to the belt to carry the load. Shown below is a typical diagram of a heavyweight conveyor system. Elements of a Heavyweight Conveyor System +—Loading Chute apn Carry Idler Snub Roller Tail Pulley —> Seu Ral Illustration of a heavyweight belt conveyor system NIBAi Introductory Guide to Conveyor Belting Introductory Guide to Conveyor Belting 3 Lightweight Conveyor Systems Lightweight Conveyor Systems are described by NIBA as having “a belt with a working tension of equal or Jess than 160 pounds per inch of width”. In general, lightweight belting is used in a wide range of conveying applications. Some examples of where these products are used are in the conveying of automotive parts, ' baggage handling, the graphics and computer industry, finished wood products, medical distribution, to- | bacco processing, confectionery, distribution centers, canneries, cattlefeeder lots, and sortation systems, just to name a few. Belting used for these applications come in a variety of widths, lengths, colors, and 1) Heavyweight conveyor Systems generate this much tension on the conveyor belt. configurations. Speed, weight, and coefficient of friction are but some physical considerations necessary to A. Equal or greater than 175 Ibs. per inch of width, B. Atleast 175 Ibs. per of width support lightweight demands. C. Less than 160 Ibs. per inch D. Greater than 160 pounds 2) "The purpose of a drive roll in a conveyor system is to: A. Protect the conveyor belt. Protect the material being conveyed, C. Move the conveyor belt. D. Move 160 Ibs. 3) A counteiweight is usually attached to: Protect the material being conveyed. ‘The take-up roll. ‘Add 160 pounds. ‘The return idler rolls. pap> 4) Torque describes the following type of force: Rotational The take-up roll 175 pounds. All of the above except for 160 pounds pomp 5) You would probably find a heavyweight conveyor system here: A bakery A discotheque A movie theater An electric generating plant pomp Conveyor designs that utilize the lightweight belt vary in size and purpose. lightweight conveyor system can be as complex as a computerized distribution center several stories tall and filling approximately one million square feet of space. Others can be quite simple in relationship to moving the product ata slow speed through an X-ray machine in an airport. NIDA NIRAea et, = wr 7 Introductory Guide to Conveyor Belting Introductory Guide to Conveyor Belting 15 The Conveyors - Lightweight conveyors are many times incorporated into machinery that process goods Conveyor Types - These conveyor systems can be complex in their own right where they incorporate of all types. The belts.are supported with either a slidet bed, roller bed, live rollers or are suspended bends, crowned pulleys, Scrapers, return idlers, lagged rollers, actuating systems, ete. In addition to the above, some end-users require that these lightweight belts have the ability to fun over small radius nose bars, be v-guided, cleated, and made endless. The end result may be something as simple as conveying your weekly supply of groceries to be tallied by the checkout person in yout local super-market, or as complex as j flipping and turning envelopes at blazing speeds in a fully automated mail/sortation system in postal service facilities. without support. Iustration of Roller Red Conveyor IMlustration of Sortation Conveyor Ilustration of Live Roller Conveyor NIBA= Introductory Guide to Conveyor Belting Qu sd ee estions ) 1) How many types of conveyor systems are there? A. One B. None C. More than one D. None of the above 2) Koware conveyor systems defined by NIBA? Light and Heavy Pw NBR ABC pow> 3) Where are lightweight systems found? are A. Distribution B. Baggage Handling C. Confectionery D. — Allof the above 4) Whattype of conveyor is used with lightweight conveyor systems? A. Roller B. Incline C.— Sortation D. —_Alltypes E. — Allof the above NIBA Introductory Guide to Conveyor Betting 7 NIBA CONVEYOR BELT ENGINEERING MANUAL LIGHTWEIGHT BELT DATA SHEET Date: Conveyor Number: __ Conveyor Specification ‘Manufacturer: ‘Type Cirele One): Horizontal Incline Decline Degree of Incline or Decline: Slider Bed (Circle One): Metal - Pickled Stainless Wood Plastic Rollers/idlers (fon Rollers or Idlers): Distance Between Idlers: Dimension of Rollers: Distance Between Pulleys: Pulley Size: Bare or Lagged?, Shape and Size (Crowned, Trapezoidal, ete.): Drive Location (circle one): Head Pulley ‘Tail Pulley Scraper or Cleaning Blade ‘Type: Position: ‘Type of Take-Up (cirele one): Serew Gravity Others, NIBAEE eee ——=us 18 Introductory Guide to Conveyor Belting. Belt Specifications (continued) Width of Belt Length of Belt: Color of Belt Top-Cover: ___ Circle One: FDA Approval Required USDA Approval Required None Required Overall Gauge: ‘Tension (PIW): # of Plies; ‘Cover Profile: —___ Belt Speed (ft./min.):___ Coefficient of Friction: ___ Fabrication Mechanical Lacing (Type / Number): ___Cirele one: Std. Hidden Flap Endless? (If yes, circle one) Finger Splice Step Splice Skived Splice Other Cleats: Yes No ‘Type: Height: __ Centers: = Circle one if applicable: Indented Tapered Sidewalls: ‘Type: Height: Material Being Conveyed Type: Shap Bulk Density (Ibs./sq. ft.):, —______ Circle One: Wet Dry ‘Temperature: ______ Abrasion: __ Circle if Applicable: Oily (Note type of Oil Chemicals ‘Tacky Operating Conditions Circle One: Indoors Outdoors Environment Temperature: 7 ae ‘Chemicals used in Cleaning: Steam used in Cleaning: __ Static Conductive: Non-Static Conductive: —————____ Dusty Environment: Yes No Does Product Accumulate on Belt: Yes No System is in (cirele one): ContinuousUse Intermittent Use Note Hrs/Day: NIBA Introductory Guide to Conveyor Belting 19 —COC_ee Conveyor Belt Application Engineering. Heavyweight Applications Heavy - As the introduction states, heavyweight belts are those rated over 160 Ibs. PIW. In Application Engineering, the person calculating the tension per irich of width (PIW) of the particular conveyor is deter- ‘ining the power requirements and the belt tension by using engineering formulae. pl ‘The power required to drive a conveyor belt is composed of three (3) major parts: (1) The power to drive the empty conveyor (horsepower). (2) The power required to move the material horizontally. (3) The power required to move material vertically. This would be a plus vvalue for an ineline conveyor, and a minus for a declined conveyor. Selection Process - Before beginning any discussion, emphasis should be given to the importance of obtaining accurate conveyor operating data. Data sheets (NIBA Engineering Manual - Data Sheets, Pages 17-21) area valuable tool to use in getting all ofthe pertinent information required. Usually available to the belt engineer is the original prints found in the plant’ files or by “walking” the system and obtaining the information from actual observation and measurements. With this data, the belt engineer can calculate tensions, required take-up, motor horsepower, and the PIW strength, along with many other pertinent considerations. First, the Effective Belt Tension (TE) must be calculated. TE is the sum of the tension required to move the empty belt (TC), the tension required to move the load horizontally (TL), and the tension required to lift the load (TH). NIBAPe eee Le, he 22 Introductory Guide to Conveyor Belting en (continued) Head Pulley Diameter (inches): Face (inches): ___ Is Pulley Lagged? Yes No Boot Pulley Diameter (inches): Face (inches): __ Is Pulley Lagged? Yes No Bucket Data ‘Type or Style: __ Number of Rows: Spacing in One Row (inches): __ Weight per Bucket (Ibs.): ____ Punching Data Attached? Yes No ‘Capacity (Cubic Ft): —_ Length: Depth: Width (projection): Bolt Size: _ Previous or Current Belt Specificatio Reason for Replacement or Existing Belt: ‘Years of Service (existing belt): Recommendations: = a Signed NIBA Introductory Guide to Conveyor Belting 23 NIBA CONVEYOR BELT ENGINEERING MANUAL HEAVYWEIGHT BELT DATA SHEET Date: Conveyor Number: Specifications Width of Belt:__ Length of Belt: ‘Type of Splice: Center to Center Distance Between Pulleys: Lift or Drop (cirele one): ‘Trough Angle (degrees): Discharge To: Material Being Handled ‘Type of Material Being Handled: ‘Weight (Ibs. per cubic ft.): Percent of Fines: ‘Temperature of Material (F): Drive Information ‘Type of Drive (cirele one): Single Pulley Lagged? (circle one): Yes No ____ Chute Length: Horizontal Centers (ft.): Length of Splice: : Slope Degree: (ft) Loads from: Belt Speed (FPM): Chute Angle: Maximum “Lump” Size: Circle One: Wet Dry Other. Other Information: _ Double Other Degree of Belt Wrap: NIBA24 introductory Guide to Conveyor Betting (continued) Location of Drive: Drive Horsepower: RPM: Starting Method: Pulley Information ‘Type of Surface on Head Pulley: Diameters: Head Pulley ‘Tail Pulley __ Take-Up Take Bends Drive (if separate) Take-Up Information Location of Take-Up: Amount of Take-Up (Ft): ‘Type of Take-Up:__ If Gravity, Total Weight (Ibs.): Load Area Information ‘Type of Rollers: Idlers: Diameter__Style___ Spacing Previous Belt Information (Describe Type) Belt Failure Information (Describe) Calculated Operating Tension (PIW) _ NIBA Cr rrr rnc c ccc creer cceccennnnnnnn nnn en Introductory Guide to Conveyor Belting 25 CONVEYOR BELT TENSION CALCULATION Calculations TC=FIXLXCW FL = —_.035” (Normal friction factor for average conditions (over 20 degree F) to move empty belt). L = _ Beltlength (feet). CW = Weight of conveyor belt components (See Table A in Engineering Handbook). TL=F2XLXMW F2s- = —_.04” (Normal friction factor to move load horizontally). L = __ Belt length (feet). MW = — Material weight (Ibs. per lineal foot) MW = —3337PH — or MW= Total Material load in Ibs. Belt Speed (fpm) L H = __ Difference between elevation of terminal pulleys (ft.) TH=- HX MW TE=1C+TL+TH Second, additional tension must be added to the effective Belt Tension (7) to prevent slippage on the drive pulley. This is called Slack Side Tension (73), or commonly called 72. Ts=DXTe D = Drive factor (See Table B in Engineering Handbook). Next, the total tension To-Te+ To is the total operating tension, or commonly called Allowable Working Tension, and is expressed in PIW (pounds per inch of width). To is sometimes referred to as TL. NIBAa ee ee ee oo le, 26 Introductory Guide to Conveyar Belting Introductory Guide to Conveyor Betting Long, complicated, overland conveyor systems may require steel cable tension members and extensive belt engineering expertise; however, a percentage of conveyars do not involve tension (PIW). That is ‘when the actual operating tensions are low, a much higher PIW belt may be required to satisfy the load support, troughability, and impact resistant requirements that are found in the belt manufacturer's manuals. Heavy black belt “engineering” can often be very compli- cated. After considering all of the calculations and consider- ations, the following important question should always be asked before making a new recommendation: “How did the old belt fail?". This can spotlight on where the old belt was ‘weak and where the new belt should be reinforced. On new systems, in general, the belt should be as narrow as possible (depending on lump size) and run as fast as possible, within acceptable limits, to convey the required tonnage. 27 NIRAee E—x«€_ = Introductory Guide to Conveyor Betting inlroductory Guide to Conveyor Betting 29 OC) Gui fo Conveyor ting Comer Bt appatonageawe comumeg nN Questions > Lightweight Applications 1) What are three other considerations in engineering a belt recommendation besides actual tensions? is i 7 ‘di 4 particular application, 2) The power required to drive a conveyor belt is ‘composed of what three (3) major parts? 3) What is one of the most important tools for getting all the operating details of a conveyor belt 4) One of the most important questions to ask a buyer of replacement belts is... 5) Name just three (3) ways operating information ‘can be obtained on a particular conveyor belt. A. B. com Baked Goods Conveying NIBAnn 30 “There are many components and factors of a conveyor system which ms be considered in order to tnaxitnize the performance ofthe conveyor system and get the optimam life out of the conveyor belt. Remember that the conveyor belt is just one component ofthe entre convey" system, and that the performance ofthat belt will be affected by the other components of the system and it's operating environment. “The following are some of the components of a conveyor system which are key factors when choosing the proper conveyor belt: © Width distance between both edges of the conveyor belt total length of belt, end to end (consider pulley diameter) diameter, type, lagging, size, etc, ‘weight, abrasion, size, density _ feet per minute ; of incline _ degree of decline “flat system parallel to ground roaterial that supports or caries belt; usually wood, steel or plastic rollers carrying or supporting the belt Rollers (idlers) 4 Fabrication any cleats, V-guides, or sidewalls, ete. 4 Oils andjor chemicals if the belt is exposed to oils or chemicals 4 Temperature emperature of the material being conveyed & the working environment -There are other factors which may also be considered such as notse restrictions FDAJUSDA ot Canadicin Food Approval, cleaning methods and conveyor operating time: Introductory Guide to Conveyor Beltin y dv 3) 4) 5) 6) 7 Does every conveyor system operate under the same environmental conditions? Yes No 4 All conveyor belts are oil resistant? Tue False Special fabrication such as cleats, v-guides; and sidewalls, can perform on both rubber and thermoplastic belts? Tue + False Generally speaking, lightweight conveyor systems require the minimum amount oftensionin order to drive an unloaded belt without the belt slipping? Tue O False ‘Understanding as many aspects about the conveyor system as possible, is important when recom ‘mending the proper belt? True False Lagged pulleys or crowned pulleys are required on all lightweight conveyor belt systems? Tue Falsetin 33 Introductory Guide to Conveyor Belt Installation, Tracking, & Maintenance... Heavyweight Conveyor Belting The Installation of a Heavyweight Belt - can range from sinall belt that is readily man handled, to a belt literally miles Jong hauling bulk ‘materials over variable terrain. Regardless of size, four essential items must be achieved in proper belt installation: 4 Protect the belt from injury during installation, 4 Obtain intended orientation, ie. right side-up, texture or cleats facing in correct direction, threaded as designed over all pulleys, idlers, slider beds, etc. 4 Engage drive and take-up systems correctly (no excess tightness ot slack) 4 Apply secure splice, appropriate for intended operating conditions “Advancements in technology continue to provide us with a wide array of tools that aid us with belt instal- lations, such as steel cord stripping machines and automatic heated-rubber compound dispensers. Belt Tracking - Few conveyor belts run perfectly centered at all points around their operating path, especially when newly installed. Most belts require a break-in period to obtain acceptable tracking. ‘Acceptable tracking or training usually means following a path that neither loses the load being carried not permits belt edge damage from rubbing against fixed elements of the conveyor system. NIRACe EE” & 34 Introductory Gulde 19 Conveyor Belting. The tracking or training of a belt consists of the application or removal of belt steering forces to obtain an acceptable central path on the conveyor. Tracking/training procedures include consideration of the following among others: % Recheck of conveyor for freedom from tilt, sag, bend, or other structural misalignments. ‘Recheck of pulleys and idlers for misalignment or build-up. % Recheck of belt splice accuracy and straightness. ‘% Observation of belt operation empty and loaded for any specific mistracking tendencies or locations along the conveyor Use of training idlers or idler adjustments (skew, tilt, etc.) to overcome any observed mistracking. This is often a” trial and error” procedure. 4 Variation of belt tension within a controlled range to determine if tracking is affected. ‘ Elimination of factors detrimental to good tracking such as random spillage, off-center loading, build-up of materials on idlers and pulleys, excess wetness or lubricants on conveyor components, malfunctioning scrapers or wipers, wind load, frost or other environmental conditions. Conveyor and belting care and maintenance - are important factors in any plant that has to move significant tonnage of bulk or unit materials with reliable consistency. ‘Unfortunately, conveyors are sometimes taken for granted until a breakdown happens. To avoid such circumstances, various plans and programs are available to the conveyor operator. ‘The core of all of these programs is a periodie inspection plan, ‘These are relatively inexpensive to perform and they can be tailored to the specific need of individual plants. The purpose of these inspections is twofold: % Identify and apply “stiteh-in-time” repairs to minor problems before they become major. # Provide a forecast and planning basis for larger, but inevitable maintenance operations or replacements. | Introductory Guide to Conveyor Belting 35 A typical inspection checklist would include: ‘® Belt condition (overall & specifics) Belt tracking and training ‘Drive unit condition and operation ‘Take-up, type, function and setting All other pulleys and idlers Scrapers, wipers and other accessories Loading or spillage problems (if any) Housekeeping and lubrication, etc. Safety problems (if any) eooees Alter inspection and reporting, a management directed follow-through and repair protocol is necessary for optimum results. In-plant personnel of outside contractors can perform these services as they ate re- quired. Programs as described should be set at time intervals according to individual plant needs. NIBABoe ee es Fr Introductory Gulde to Conveyor Belting 37 Belt Installation, Tracking, & Maintenance... Lightweight Conveyor Belting Installation of Lightweight Belt - is covered by the same guidelines as heavy black belt: Protect the belt from injury during installation. + Obtain intended orientation, iz. right side-up, texture or cleats facing in correct direction, threaded as designed over all pulleys, idlers, slider beds, etc. Engage drive and take-up systems correctly (no excess tightness or slack) Apply secure splice, appropriate for intended operating conditions Since lightweight belts handle foods and other sensitive ‘materials, care should be taken to keep the belt clean during installation. Tracking - As with heavy black belt, a lightweight belt will usually require some break-in and adjustment to obtain central tracking and training, NIBA,Ce EEE 39 38 Introductory Guide to Conveyor Belting troductory Guide to Conveyor Belting Unlike troughed black belts, many lightweight belts ran on flat rollers or sliderbeds. This eliminates the Lightweight belt maintenance - unlike heavy black belt, ightwaight conveyor belts do not lend themselves to major hot vulcanized repairs. Relatively minor injuries can be sealed or bonded with self training option of skewing troughing idlers to steer the belt. cure cements depending on the economics and other factors. ‘Adjustments to track lightweight belts (assuming conveyor structure and splice are not misaligned) are made at terminal pulleys and retur rollers, if any. Adjustable snubber pulleys are also effective in guiding lightweight belts, especially on reversible conveyors. Some package and unit handling conveyors have side ribs which prevent the belt from shifting excessively to one side or the other. ‘A typical unit handling or food handling conveyor would appear as below: In some cases, lightweight belting can be repaired by. insertion of a “saddle” section with either metal assistance or vulcanized splices. In general, the most effective maintenance for lightweight belting is protection from damage or injury, or “Preventative Maintenance”. Often, a damaged lightweight belt is replaced rather than repaired. ‘The belt tracking sequence is to start on the return side behind the drive and work toward the tail, Return rollers (if any) can be skewed or tilted to center the belt. If the belt is square going over the tail pulley, it will usually'run true on the cartying strand. Snubber and take-up adjustments can also be used to track the belt. NIBA NIBA40 Introductory Guide to Conveyor Belting fn to = C Questions ) db ‘What achieves proper belt installation? A. Correct belt orientation. B. __ Proper belt protection during installation. C. Proper splice installation, D. All of the above. 2) ‘Tracking of a belt on a conveyor is obtained by removal of? AL Paint. B. Steering forces. Cc Load. D. Belt. 3) ‘What two items should one look for as typical inspection items to maintain good belt care? AL Condition of idlers. B. Lubrication of motor. C. Loading or spillage problem. D. _ Not necessary to inspect. NIBA Introduciory Guide to Conveyor Belting a Fabricated Belts... Fabricated belting - consists of a wide variety of value-added profiles and/or operations that add value to manufactured flat belting. Fabricating belt can improve conveyor belting ability to do special job func- tions that a conveyor belt would otherwise be unable to do. Profiles - Simple fabrications may require nothing more than techniques to vulcanize splices, install ‘mechanical lacing, or punch holes for anchoring attachments. More complicated fabrication uses heating processes to melt or fuse profiles like thermoplastic guides, cleats, and sidewalls onto belting. Rubber profiles are also vulcanized, either by heat and pressure, or by chemical bonding. Such profiles may be more elaborate and include herringbone chevron styles, transverse cleats, v-guide tracking configurations, curbed flanged edges, or angular profiles to prevent material roll-back from steep angles. Special fabricated belting with complex designs include high angle steep incline conveying and profiles blending technology from both, vulcanizing and bonding of two or more surfaces together. Corrugated sidewall belting, with or without cleats, are popular fabrications of growing importance and wide-spread use. Together with molded belting operating at extreme speeds, high heat, and tensions, fabricating experts make belts available which can handle very complicated tasks. NIBA= Introductory Guide to Conveyor Belting Fabricating belt s an art. Businesses schooled in various fabricating techniques depend on them to repair cnisting belts, gain wider customer confidence, create innovative ways to solve customer conveying prob- Tans and increase profitable sales. Limited only by imagination, fabricators develop new concePts © get materials to flow easily in applications which may not have utilized belting previously. Fabricated belting occupies an expanding market. These belts are found in food and industrial markets. ‘They may be used in either light or heavy duty applications and may be made from commet materials or rae ney orlike compounds oF thermoplastics. The diversity of fabricated belting tems and the applica- tions where they can be used show no sign of becoming mature. [As long as new approaches to materials handling are sought, fabricated belting will be needed. Introductory Guide to Conveyor Belting 43 Trouble Shooting Conveyor Belt or System Problems... Belt Tracking and Training 1) Before installing a belt - All palleys, stubs, idler, and structure must be square for proper belt alignments. 2) Insall belt - Operate under tension for about two (2) hours before making adjustments (unless there isa severe problem). This will alow temporary mal-distribution of tension in belt to even itself out. 3) Adjust idlers - Pulleys and snubs have a very positive effect in training (unless the problem is obvious). 4) Train ortrack the belt by knocking ahead the end of the idler to which the belt rides. This should be done over a reasonable length of the conveyor preceding, the problem area. 5) Inorder to obtain the expected life & performance of a conveyor belt - many factors should be investigated before, during, and after installation, as well as during the operation of the system. If the above references do not solve your problem, see Chapter V of the Introductory Guide To Conveyor Belting. “The chapters in the Introductory Guide To Conveyor Belting will also familiarize you with other refer- ‘ences on belting, systems, maintenance, and operation. Problem Cause & Solution Vulcanized splice delamination or failure. 1) Pulley toosmall. Cheek recommended minimum size for belt. 2) Belt running wrong direction. Check for manufacturers arrow ot make sure that leading edge of splice contacts pulley first. 3) Reverse bend. Use thinner belt. 4) Too much tension for belt. Use heavier construction.Introductory Guide to Conveyor Betting a4 Introductory Guide to Conveyor Belting Problem Belt does not track properly. (See NIBA Video on Tracking) Cleat delamination ‘V-Guide delamination Fastener pullout Severe Edge Wear Excessive belt stretch Excessive belt slip NIBA, Db 3) 4) 5) 6) 1d 2) 3) 4) 5) dy 2) 3) iy 2) 3) 4) yy 2) 3) 4) 5) dy 2) ) 2) 3) 4) Cause & Solution Problem Cause & Solution Pulleys andjor idler NOT squared. Elevator belt pull-out 1) Bolts not tight; tighten monthly, ‘New belt not “un in” long enough. 2) Bucket hung-up on boot. Uneven loading; load off-center. 3) __ Belt tension too low causing elongation of holes. Structure not square. 4) Adverse conditions - heat, oils, acids, ete. Lacing or splice not square. Bow in belt. Cover and/or ply delamination 1) Adverse conditions - heat, oils, acids, etc. 2) Pulley too small for belt type. Pulleys too small, Check minimum cleat type, 3) System misaligned causing poor tracking; edges Retum idlers hitting cleats, hitting the conveyor frame. Material conveyed affecting bond (oils, acids, etc.) 4) Improper belt splice techniques. Product Overload, 5) Manufacturing error Poor tracking. Cleat edges repeatedly hitting j conveyor frame, Pulley too small. Notch V-guide for small pulleys, Severe misalignment, Wrong size cross-section for pulley groove. Wrong size fastener. Fastener not installed properly. Obstruction touching splice area. Poor tracking. Splice hitting conveyor frame. Pulleys, idlers, or structure not square, ‘Wom pulley lagging. } Offset loading conditions. Load off center. See section on Training Belt. Too much tension for belt used; use a stronger belt. Insufficient take-up. Over-tightening of take-up. Tighten take-up or pulley, Lag or replace worn lagging. Pulleys too small; not enough wrap. Use lighter belt or larger Pulley. Material spillage. Lag pulleys and/or install cleaning devices. NIRA48 Introductory Guide to Conveyor Belting. Acknowledgments Thank you to all of the member companies of N.I.B.A. for the input and support that went into the publishing of this introductory Guide To Conveyor Belting. ‘A special thank you to the following member companies that provided the artwork and photographs used throughout: Apache Hose and Belting, Ine. Beltcraft Equipment Corpoation Belt Maintenance and Supply, Inc. Boston Industrial Produets / Dana Corp. Chiotino, Inc. Flexible Steel Lacing Company Georgia Duck and Cordage Mill Globe International Inc. Goodyear Tire and Rubber Company Lewis-Goetz and Company, Inc. Pang Rubber Company Rubber and Accessories, Inc. Rubber Plus, Inc. Scandura, Inc. Shaw-Almex Fusion: Siegling America, Inc. Vis USA, LLC@NIBA Answer Key: Introductory Guide to Conveyor Belting The following are the correct answers to the questions found in the Introductory Guide to Conveyor Belting: Questions on Page #8: 1)D 2)No 3)D 4)D §)False 6)C Questions on Page #12: 1)D 2)C 3)B 4)A 5)D Questions on Page #16: 1)C 2)A 3)D 4)E Questions on Page #28: 1) Required take-up, motor horsepower, and PIW strength 2) Drive empty conveyor, move material horizontally, move material vertically 3) Data Sheets 4) ‘How did the old belt fail?" 8) Original system prints, walking the system, and doing the calculations Questions on Page #31: 1)N 2)F 3)T 4)T 5)T 6)F Questions on Page #40: 1)D 2)B 3)A&C ‘Questions on Page #48: 1)C 2)E 3)All 4)B,C,D,&E