Custom Workshops

Belt Conveyor Systems
Training Workshop Outline

1. How a Belt Conveyor Works

   a. Major Components (Introduction)   

   i. Belting

   1. Function

   2. Components

   a. Carcass Constructions
   b. Rubber Covers

   ii. Troughed Idlers

   1. Function
   2. Components
   3. Types

   iii. Pulleys

   1. Function
   2. Components

   a. Shaft
   b. End Disk
   c. Rim
   d. Locking Device
   e. Bearings
   f. Lagging

   3. Types

   iv. Take-up

   1. Function
   2. Types

   v. Drive

   1. Function
   2. Components

   a. Motor
   b. Reducer
   c. Couplings
   d. Brakes
   e. Holdback
   f. Starter
   g. Controller

   b. The System – Putting it all together

   i. Volume (Capacity)

   1. Belt Width, Idler Configuration and Velocity = Throughput

   ii. Belt Tension Diagram (Tension Cycle)
   iii. Power Requirementsc. Starting and Stopping

   i. Torque vs. Time
   ii. Dynamic affects of Belt Elasticity

   1. Tension Fluctuations- High and Low
   2. Take-up Travel

2. System Design

a. Calculations

i. Belt Tensions

1. Friction (CEMA 5th and 6th Comparison)

a. Idler Drag
b. Alignment
c. Rubber Indentation
d. Material and Belt Flexure

2. Lift
3. Secondary Losses

ii. Power
iii. Take-up Weight

1. Slip
2. Sag

b. Conveying Profile (Route)

c. Load Variations

i. Constant vs. Sporadic Loading
ii. Normal vs. Peak Overloads

d. Drive, Brake and Take-up Locations
e. Selecting Components

i. Belting

1. Tension
2. Load Support
3. Troughability
4. Flex (Pulleys)
5. Impact

ii. Idlers

1. Load Rating
2. L10 Life

iii. Pulleys

1. Shaft Deflection
2. Stress
3. Bearing Life

iv. Take-up

1. Location
2. Weight
3. Travel
4. Type, Gravity/Winch/et cetera

v. Drives

1. Horsepower
2. Types of Starting Devices

a. Fluid Couplings
b. VFD
c. Wound Rotor
d. Et cetera

3. Types of Stopping Devices

f. Loading and Unloading

i. Chutes
ii. Cleaners
iii. Plows
iv. Impact Idlers / Beds

3. Installation, Operation and Maintenance

a. Belt Tensions affect…

i. Belt Life

1. Belt Tension Cycle

a. Transitions
b. Turnovers
c. Concave Curves
d. Convex Curves
e. Pulleys

2. Cycle Time
3. Splice Life
4. Cover Wear (Life)
5. Tracking

ii. Pulley Life

1. The T1/T2 Ratio
2. Lagging Wear
3. Crowning
4. Alignment

iii. Idler Life

1. Installation Tolerance
2. Transitions
3. Convex Curves

iv. Take-up Requirements

1. How fast it moves…
2. How far it moves…
b. Component Installation

i. Idlers
ii. Pulleys
iii. Belting
iv. Drives

c. Maintenance Concepts

i. Unplanned
ii. Preventive
iii. Predictive
iv. Proactive- Route Cause Failure Analysis

1. Belt Tracking
2. Belt Damage
3. Belt Splices
4. Transfers
5. Motor Overload
6. Idlers
7. Pulleys
8. Take-ups
9. Fluid Couplings
10. Wound Rotor
11. Reducers- Drive Components

4. Advanced Design Considerations

a. Energy Efficiency

i. Low Rolling Resistance Rubber
ii. Low Resistance Idlers
iii. Alignment
iv. Material and Belt Flexure

b. Dynamic Analysis

i. Basics of time based transient analysis
ii. Stopping a high incline conveyor- Location of take-up important
iii. Stopping a long conveyor- Take-up Performance important
iv. Starting a long conveyor

1. Time vs. Torque
2. Breakaway vs. acceleration

v. Starting with Fluid Couplings, et cetera
vi. Starting with VFD, et ceterac. Fast Conveyors (How Fast?)

c. Distributed Power

i. Head Tail Drives
ii. Intermediate Drives

d. Horizontal Curves

e. Specialty Conveyors

i. High Angle Conveying

1. Pocket Belts
2. Sandwich belts

ii. Pipe
iii. Cable Belt
iv. Others

g. Transfer Chute Design using Discrete Element Simulation

i. Virtual Prototyping

5. Project Management

a. Conceptual Design

i. Definition of Need and System Requirements
ii. Development of Design Criteria
iii. Functional Requirements
iv. General Specification

b. Preliminary Design

i. System Considerations
ii. Evaluation of Alternatives
iii. Trade-off Studies
iv. Preliminary Design
v. Component QA/Testing Requirements
vi. System Specification and Component Requirements/Performance Specifications

c. Detail Design

i. Select Component Suppliers and supplier activities
ii. Collect component characteristics and performance data from manufacturers
iii. Evaluate manufacturer alternatives
iv. Verification of Component Design
v. Verification of System Design
vi. Final Design Review by Team including manufacturers, integrators, etc
vii. Detailing

d. Manufacturing

i. Confirmation of Component Quality
ii. Confirmation of Component Performance
iii. Review Manufacturing Discrepancies to determine system design sensitivity

e. Installation

i. Structural Alignment
ii. Horizontal Curve Alignment
iii. Belt Splicing
iv. Drive Alignment
v. Control Software

f. Operation

i. System Performance Verification

g. Maintenance