Pulley | Belt Conveyor Pulley | Belt Conveyor Pulley Types | Belt Conveyor Power Calculationv

Pulley Belt Conveyor

Pulley:

The diameters of standard pulleys are: 200, 250, 315, 400, 500, 630, 800, 1000, 1250, 1400 and 1600 mm. pulley may be straight faced or crowned. The crown serves to keep the belt centered. The height of the crown is usually 0.5% of the pulley width, but not less than 4 mm. The pulley diameter D_p depends on the number of plies of belt and may be also be determined from the formula:

D_p > K.i (mm)

Where

K = a factor depending on the number of plies (125 to 150)

i = no of plies

The compound value should be rounded off to the nearest standard size. While selecting the pulley diameter it should be ascertained that the diameter selected is larger than the minimum diameter of pulley for the particular belt selected.

The drive pulley may be lagged by rubber coating whenever necessary, to increase the coefficient of friction. The lagging thickness shall vary between 6 to 12 mm. The hardness of rubber lagging of the pulley shall be less than that of the cover rubber of the running belt.

Pulley types:

Pulleys are manufactured in a wide range of sizes, consisting of a continuous rim and two end discs fitted with hubs. In most of the conveyor pulleys intermediate stiffening discs are welded inside the rim. Other pulleys are self cleaning wing types which are used as the tail, take-up, or snub pulley where material tends to build up on the pulley face. Magnetic types of pulleys are used to remove tramp iron from the material being conveyed.

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Typical welded steel pulley-Drum conveyor pulley

Spun end curve crown pulley

Spiral drum conveyor pulley

Welded steel pulley with diamond grooved lagging

Welded steel pulley with grooved Lagging

Spiral Wing Conveyor pulley

Power calculation for the drive unit:

The horse power required at the drive of a belt conveyor is derived from the following formula:

H.P = T_e . V

Where

T_e is the effective tension in the belt in N

V = velocity of the belt in m/s

The required effective tension T_e on the driving pulley of a belt conveyor is obtained by adding up all the resistances.

Conveyor Take Up Arrangement | Take Up Pulley | Screw Take Up Conveyor | Quick Take Up Master Cylinder

Conveyor Take up Arrangement:

All belt conveyors require the use of some form of take-up device for the following reasons:

• To ensure adequate tension of the belt leaving the drive pulley so as to avoid any slippage of the belt
• To ensure proper belt tension at the loading and other points along the conveyor
• To compensate for changes in belt length due to elongation
• To provide extra length of belt when necessary for splicing purpose.

Conveyor Take Up Types

Usually there are two types of Conveyor take up arrangements.

• Fixed take up device that may be adjusted periodically by manual operation
• Automatic take up devices for constant load type

Why Conveyor take up assembly required?

Conveyor take up is the tensioning of a conveyor belt. This avoids damage to the conveyor belt and other equipment as well as premature component wear.

This component is designed to regulate the tension of a conveyor belt. The design of this component varies depending on the conveyor system, but typically, it consists of a metal frame that connects to the conveyor frame, and one or more adjustment screws that move one or more cylinders.

Chain Conveyor Take Up

The conveyor take up may also be used to alter the tension of a drive system chain. As the chain stretches or wears from frequent usage, it must be adjusted.

Taking a link out of the chain may modify the conveyor take up, however it may create uneven wear or incorrect chain length. The conveyor pick up component adds or releases pressure on a chain guide pulley.

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Take Up pulley Belt Conveyor

When using the take up component to modify the belt tension, several units may be utilized. Each unit will be placed on each end of a customized take-up pulley. When the conveyor take up bolt is rotated one way, more tension is applied to one side of the pulley, and when it is moved the other way, less tension is added.

Belt Conveyor Take up system is used for tensioning the belt

The belt tension may be adjusted on either side of the pulley. To maximize adaptability, the pulley is typically placed out of line with the other cylinders or pulleys.

Advantages of Conveyor Take Up

Using a conveyor take up may prevent several kinds of harm. A belt that is overly tight may break or wear out prematurely, causing system failure. If it's too loose, it'll slide on the cylinders, preventing efficient belt movement. A slack belt may cause excessive wear and can become trapped in other conveyor components.

Conveyor Take Up pulley is used to adjust to new position

Conveyor Take up Bearings

In a screw take up system the take up pulley rotates in two bearing blocks which may slide on stationery guide ways with the help of two screws. The tension is created by the two screws which are tightened and periodically adjusted with a spanner. It is preferable to use screws with trapezoidal thread t decrease the effort required to tighten the belt.

Conveyor Take up system

The main problem with the use of manual take-up is that it requires a vigilant and careful operator to observe when take up adjustment is required. Perfect tension adjustment with this system is also not possible. For this reason these devices are used only in case of short conveyors of up 60 m length and light duty.

Automatic Take Up arrangements

In automatic take up arrangement the take up pulley is mounted on slides or on a trolley which is pulled backwards by means of a steel rope and deflecting pulleys. The carriage travels on guide ways mounted parallel to the longitudinal axis of the conveyor, i.e., horizontally in horizontal conveyors and at an incline in inclined conveyors. Hydraulic, pneumatic and electrical take up devices are also used.

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Automatic take-up has the following features:

• It is self adjusting and automatic
• Greater take-up movement is possible