CONVEYOR BELT

CONVEYOR BELT IS THE CARRYING MEDIUM OF CONVEYOR BELT SYSTEM.IT HANDLES

MATERIAL FROM ONE PLACE TO ANOTHER .
A BELT CONVEYOR SYSTEM CONSISTS OF TWO OR MORE PULLEYS WITH A CLOSE LOOP OF
CARRYING MEDIUM- THE CONVEYOR BELT – THAT ROTATES ABOUT THEM.
CONVEYOR BELT IS MADE UP OF THREE LAYERS TOP COVER ,CARCASS AND BOTTOM COVER.
THE PURPOSE OF CARCASS IS TO PROVIDE LINEAR STRENGTH AND SHAPE.
CARCASS IS MADE UP OF TWO THINGS 1. SKIM 2. PLY
SKIM :- LAYER OF THIN RUBBER PROVIDE ADHESION,LOAD SUPPORT AND IMPACT
RESISTANCE
PLY :- IT IS THE WOVEN NET OF NYLON OR METTALLIC WIRES.
•IN PLY THE WARP REFERS TO LONGITUDINAL CORDS WHCH PROVIDES TENSILE
STRENGTH,TRANSVERSE TEAR ,IMPACT RESISTANCE.
•WEFT REPRESENS THE WHOLE SET OF TRANSVERSAL CABLES ALLOWING THE BELT SPECIFIC
RESISTANCE AGAINST CUTS,TEARS AND IMPACTS AND AT THE SAME TIME HIGH FLEXIBILITY.
USUALLY IN INDUSTRY WE USE 3 OR 4 PLY CONVEYOR BELT.
IN SHANTI GD WE USE 3 PLY CONVEYOR BELT AND BELT WIDTH 800mm AND THICKNESS IS 10
mm.
PULLEYS:- THERE ARE SIX TYPES OF PULLEYS WE USE WHICH ARE AS FOLLOWS:-
1. HEAD PULLEY
2. TAIL PULLEY
3. SNUB PULLEY
4. TAKEUP PULLEY
5. TWO BEND PULLEY
HEAD PULLLEY:- THE HEAD PULLEY IS LOCATED NEAR THE DISCHARGE POINT OF
CONVEYOR.IT USUALLY DRIVES THE CONVEOR AND OFTEN HAS A LARGER
DIAMETER THAN OTHER PULLEYS .FOR BETTER TRACTION THE HEAD PULLEY IS
USUALLY LAGGED ( WITH EITHER RUBBER OR CERAMICS LAGGING MATERIAL).
TAIL PULLEY:-THE TAIL PULLEY IS LOCATED AT THE LOADING END OF THE BELT,IT
COMES WITH FLAT FACE.
SNUB PULLEY:- A CONVEYOR PULLEY USED TO INCREASE ARC OF CONTACT BETWEEN
BELT AND HEAD PULLEY,TYPICALLY FOR THE PURPOSE OF IMPROVING TRACTION.
TAKEUP PULLEY:-A CONVEYOR PULLEY USED TO REMOVE SLACK AND PROVIDE
TENSION TO A CONVEYOR BELT,AND ALSO HAVE EXCESS OF BELT .
BEND PULLEY:- THE BEND PULLEYS ARE CALLED THAT BECAUSE THRE BELT BENDS
OVER THEM TO FORM A LOOP FOR THE TAKEUP PULLEY TO SIT IN.
IDLERS:- IDLERS ARE VITAL TO CONVEYING PROCESS.THEY SUPPORT THE BELT AND
CONVEYED MATERIAL ALONG ITS FULL LENGTH PREVENTING IT FROM
STRETCHING,SAGGING AND EVENTUALLY FAILING.
THERE ARE SIX TYPE OF IDLER WE USE IN SHANTI GD
1. CARRYING IDLER
2. RETURN IDLER
3. SELF ALIGNING CARRYING IDLER
4. SELF ALIGNING RETURN IDLER
5. IMPACT IDLER
6. GUIDE ROLLER
DIMENSIONS OF IDLER WE USE:-
7. CARRYING IDLER –O.D -114 mm ,L – 315 mm
8. RETURN IDLER – O.D – 114 mm, L – 950 mm
9. IMPACT IDLER – O.D – 114 mm, L – 315 mm
10. GUIDE ROLLER – O.D – 60 mm ,L – 100mm
TROUGHING ANGLE:-THE GROUP OF 3 IDLERS ARE FITTED IN FRAME IN WHICH THE
MIDDLE IDLER IS IN FLAT CONDITION AND THE OTHER TWO MAKES AN
INCLINATION ANGLE WITH HORIZONTAL WHICH IS CALLED TROUGHING ANGLE.
IN SHANTI GD WE USE 35 DEGREE TROUGHING IDLERS.
SAFETY EQUIPMENT IN CONVEYOR BELT :- THERE ARE THREE SAFETY EQUIPMENT
USED :-
1. BELT SWAY SWITCH
2. PULL CORD
3. ZSS(ZERO SPEED SWITCH)
4. CANOPY( COVER FOR BELT)
• BELT SWAY SWITCH :-BSS IS A PROTECTIVE SWITCH FOR DETEECTING THE SWAY
OR DEVIATION ,AND SENDS OUT AN ALARM SIGNAL AND AN EMERGENCY STOP
SIGNAL.
• PULL CORD:-AN EMERGENCY SWITCH TO STOP THE CONVEYOR INSTANTLY WHEN
AN ACCIDENT HAPPENS. THE CORD CAN THEN BE PULLED AT ANY POINT ON THE
CONVEYOR AS AN EMERGENCY STOP.IT IS MOUNTED AT THE SIDE OF CONVEYOR
TO THE FULL LENGTH.
• ZSS:- IT IS ALSO KNOWN AS SPEED ACTUATING SENSING SWITCHES ARE USED TO
DETECT WHETHER A ROTATING SHAFT IS TURNING ( EVEN AT VERY SLOW SPEEDS).
IN SHANTI GD WE HAVE 12 CONVEYOR BELTS ARE AS FOLLOWS:-
1. CBC1-COAL HOPPER TO SCREEN
2. CBC2 –CRUSHER TO CBCI
3. RBC1 – HUSK HOPPER TO SCREEN
4. RBC2- AFTER SCREENING WAY FORWARD
5. BOTH CBC1 AND RBC2 WILL DROP MATERIAL ON FBC1
6. AFTER FBC1 IT TRANSFER TO FBC2 AT TRANSFERING TOWER
7. COAL COMES TO RC FROM FBC2
8. BUT HUSK DIVIDE BY A TWO WAY DIVISION AND DIRECTLY GOES TO BUNKER
9. COAL GOES TO BUNKER FROM RC
10. AFTER BUNKER WE HAVE FOUR FEEDER CONVEYOR BELT TWO FOR COAL TWO
FOR HUSK.
11. AND ALSO ONE BED ASH CONVEYOR BELT.

LOAD SHELL :-THERE IS A ELECTRICAL DEVICE WHICH IS CONNECTED BETWEEN BELTS

WHICH TRANSMITS THE SIGNAL TO CONTROL TOWER ABOUT HOW
MUCH LOAD IS PASSED PER HOUR
CONVEYOR BELT TRIP REASONS(SUDDENLY STOPS):-
1. DUE TO MATERIAL OVERLOAD
2. DUE TO BELT SWAY
3. DUE TO GEARBOX FAILURE
4. DUE TO MOTOR BEARING JAMMED
5. DUE TO MATERIAL JAMMED NEAR DISCHARGE POINT
6. DUE TO PULL CORD

CONVEYOR BELT SWAY REASONS :-

7. LOCKING OF SELF ALIGNING CARRYING IDLER FRAME
8. LOCKING OF SELF ALIGNING RETURN IDLER FRAME
9. DUE TO DISTURBANCE IN LOCKING POSITION OF BEARING BLOCK OF ANY PULLEYS
10. DUE TO INCRESE BEARING CLEARANCE
11. DUE TO DAMAGE OF BEARING WHICH CAUSES SHIFTING OF PULLEY TO ONE SIDE
12. DUE TO BUILDUP OF MATERIAL ON PULLEYS AND ROLLERS.
CONVEYOR BELT SLIPPPAGE:- CONVEYOR BELT RELY ON A PRECISE BALANCE OF
TENSION TO WORK CORRECTLY.IF THERE IS TOO MUCH OR TOO LITTLE THE BELT
CAN SLIP.
• IF THE HEAD PULLEY BREAKS DOWN OR EVEN BECOMES OVERLY WORN ,THERE
WILL NO LONGER BE ENOUGH TENSION TO KEEP THE BELT FROM SLIPPING
AROUND.
CAUSES OF BELT SLIPPAGE :-
1. OVERWEIGHT LOAD
2. LOW TEMPERATURE
3. POORLY INSTALLED LAGGING
4. PULLEY PROBLEMS
5. SEIZED ROLLERS
6. MATERIAL SPILLAGE
7. BELT TEAR
IMPORTANT THINGS TO DO TO KEEP CONVEYOR SYSTEM SMOOTHLY:-
1. CHECK FOR BUILDUPS
2. CLEAN YOUR SYSTEM REGULARLY
3. DO CLEANING AND GREASING OF PLUMMER BLOCKS OF ALL PULLEYS
4. MAKE SURE THE FRAME IS SQUARE AND LEVEL
5. MAKE SURE THE END PULLEYS ARE EVEN
6. KEEP THE IDLERS RUNNING SMOOTHLY
7. REPLACE ANY WORN OUT PARTS

ADVANTAGES OF CONVEYOR BELT:-

8. SAFETY- OPERATES WITH AN EXTREMELY HIGH DEGREE OF SAFETY
9. FEW PERSONNAL ARE REQUIRED FOR OPERATION AND THEY ARE EXPOSED TO
FEWER HAZARDS THAN WITH OTHER MEANS OF TRANSPORTATION
10. LOW LABOR COSTS
11. LOW MAINTANENCE COSTS
12. LONG DISTANCE TRANSPORTATION.
BELT JOINING PROCESS :-
• FIRST WE HAVE TO LIFT THE TAKEUP WITH THE HELP OF CHAIN BLOCK
• THEN REMOVE THE CARRYING IDLER FRAME AND MAKE SPACE FOR BELT JOINTING
• THEN PUT PLYBOARD UNDER THE BELT FOR BASE SUPPORT AND CLAMP THE BELT AT
THE BOTH SIDES
• NOW CUT THE BELT WITH THE HELP OF CUTTER IN HALF.
• AND FIX TWO PARTS WITH THE HELP OF NAILS SO THAT IT NEVER MOVES WITHIN THE
BELT JOINING PROCESS
• IN SHANTI GD WE HAVE THREE PLY CONVEYOR BELT SO WE HAVE TO CUT THE BELT IN
TWO PARTS
• WITH THE HELP OF CHALK AND MEASURING TAPE MARK 400mm AND AT THE END OF
400mm.
• NOW WITH THE HELP OF SUTLI AND CHALK MARK AN ANGULAR LINE TO THE END OF
TOP CUTTING EDGE
• NOW AT ANOTHER 400mm MAKE PARALLEL LINE,AND ANOTHER PARALLEL LINE AT
ANOTHER 400mm.
• NOW FULL CUT THE FIRST PART AND REMOVE TWO PLY FROM NEXT AND ONE PLY
FROM LAST
• REPEAT OPPOSITE FOR OTHER SIDE OF BELT
• NOW WITH THE HELP OF BUFFER GRINDER REMOVE ROUGH SURFACE AND EXTRA OIL
ON THE CUT SURFACE
• BUFFER GRINDER HELPS TO PREVENT VULCANISATION OF RUBBER
• NOW MIX 1 LT THEJO TC310 SOLUTION AND 45ml HARDNER HC
• APPLY ONE COAT ON BOTH SIDES TO BE JOINT AND WAIT TO 3-5 MINUTES
• THEN REPEAT THIS PROCESS TWO MORE TIMES
• NOW WITH PROPER CARE OVERLAP THESE JOINTS ON ONE ANOTHER
• NOW HAMMER THE JOINT LIGHTLY
• ATLAST GRIND THE JOINT FOR LONG LASTING
• REMOVE THE NAILS AND CLAMP FIX THE IDLER FRAMES
• RELEASE THE TAKEUP NOW IT IS READY TO CONVEYING
GENERAL PURPOSE CONVEYOR BELTS CAN BE CLASSIFIED INTO TWO GRADES :-
1. M24 GRADE
2. N17 GRADE
• M24 GRADE:- WHERE 24 REPRESENTS TENSILE STRENGTH,THIS TYPE OF
CONVEYOR BELT ARE EXTRA ABRASION RESISTANT,CUTS AND GOUGES RESISTANT
FOR THE SPECIFIC TYPE AND SIZE OF MATERIAL TO BE HANDLED.
• SUITABLE FOR CONVEYING SHARP ,LARGE LUMPS AND RUGGED MATERIALS
UNDER ADVERSE LOADING CONDITION.
• N17 GRADE:- THIS TYPE ARE ABRASION RESISTENT BUT INFERIOR TO GRADE M24
IN CUT AND GOUGE RESISTENCE.
TENSILE STRENGTH:- IT IS THE MAXIMUM STRESS THAT A MATERIAL CAN WITHSTAND
WHILE BEING STRECHED OR PULLED BEFORE BREAKING .
UNIT :- N/mm*2
IN SHANTI GD WE USE M24 GRADE OF CONVEYOR BELT
INCLINE ANGLE OF CONVEYOR BELT:-THE INCLINATION ANGLE OF CONVEYOR BELT
FOR COAL IS FROM 16-20 DEGREES.