BELT CONVEYORS

Belt conveyors are a type of material handling equipment commonly used in various industries to transport goods from one point to another. They consist of a belt that moves continuously over a series of rollers, allowing for the efficient transfer of materials over long distances. Belt conveyors are popular due to their versatility, reliability, and ease of maintenance.

Design of Belt Conveyors:

The design of a belt conveyor depends on several factors such as the type of material being transported, the distance to be covered, the speed at which it needs to move, and the physical characteristics of the conveyor system. The primary components of a belt conveyor system include the belt, pulleys, idlers, and motor.

Belt:

The belt is the primary component of the conveyor system and is responsible for carrying the material. It is usually made of rubber, PVC, or other synthetic materials and is available in various thicknesses and grades depending on the application. The belt’s width is determined by the size and weight of the material being transported, with wider belts used for larger loads.

Pulleys:

Pulleys are used to change the direction of the belt and maintain tension. The pulleys are mounted on shafts and are designed to rotate freely, with the drive pulley powered by a motor. The pulleys are usually made of steel or aluminum and are available in various sizes depending on the application.

Idlers:

Idlers are used to support the belt and maintain its alignment. They are typically placed at regular intervals along the conveyor and are designed to rotate freely, allowing the belt to move smoothly. Idlers are available in various sizes and configurations depending on the application.

Motor:

The motor is responsible for driving the conveyor and is typically located at the end of the system. The motor is connected to the drive pulley via a gearbox or coupling, allowing it to rotate the pulley and move the belt.

Advantages of Belt Conveyors:

Belt conveyors offer several advantages over other types of material handling equipment, including:

1. Versatility: Belt conveyors can transport a wide variety of materials, including bulk materials, packaged goods, and heavy loads.
2. Reliability: Belt conveyors are known for their reliability and can operate continuously for long periods with minimal maintenance.
3. Efficiency: Belt conveyors can transport materials over long distances quickly and efficiently, reducing the need for manual labor and improving productivity.
4. Safety: Belt conveyors are designed with safety in mind, with guards and other safety features included to prevent accidents.
5. Cost-effective: Belt conveyors are typically less expensive than other types of material handling equipment, making them a cost-effective solution for many applications.

Applications of Belt Conveyors:

Belt conveyors are used in a wide range of industries, including manufacturing, mining, food processing, and logistics. Some common applications of belt conveyors include:

1. Mining: Belt conveyors are used in the mining industry to transport bulk materials such as coal, ore, and minerals.
2. Manufacturing: Belt conveyors are used in the manufacturing industry to transport goods between production processes and to package and ship finished products.
3. Food Processing: Belt conveyors are used in the food processing industry to transport raw materials, ingredients, and finished products.
4. Logistics: Belt conveyors are used in logistics and warehousing to transport goods within a facility and between facilities.

General Safety Procedures for Belt Conveyors:

Belt conveyors are designed with safety in mind, with guards and other safety features included to prevent accidents. However, it is important for operators to follow safety procedures to ensure their own safety and the safety of others working around the conveyor system.

1. Train Employees:

All employees who work around or operate the conveyor system should be trained on the proper procedures for safe operation. This training should include proper use of personal protective equipment (PPE), such as safety glasses, gloves, and hard hats. Ask ACT about our Core Training on material handling safety.

1. Lockout/Tagout Procedures:

Lockout/tagout procedures should be implemented to ensure that the conveyor system is properly shut down and de-energized before any maintenance or repair work is carried out. This procedure involves isolating the conveyor system from its power source and locking or tagging out the power source to prevent accidental startup.

1. Warning Signs and Labels:

Warning signs and labels should be posted at all entry points to the conveyor system to alert workers of potential hazards. These signs should include warnings to stay clear of the conveyor, not to climb on the conveyor, and to avoid loose clothing or jewelry that could become entangled in the conveyor.

1. Guarding:

The conveyor system should be properly guarded to prevent access to moving parts that could cause injury. Guards should be securely fastened to prevent them from becoming dislodged during operation.

1. Emergency Stop Button/ Pull-Cord:

An emergency stop button should be installed at a location that is easily accessible to operators in case of an emergency. This button should be tested regularly to ensure that it is functioning properly. This also applies to e-stop cables and cords positioned along the length of conveyor. These are typically placed on long, unguarded conveyors.

1. Regular Inspections:

Regular inspections should be carried out to identify any potential safety hazards, such as loose or missing guards, damaged components, or material buildup on the conveyor. Any issues identified during the inspection should be addressed promptly.

Preventative Maintenance

Preventative maintenance is critical to ensure the reliable operation of belt conveyors and to maximize their service life. It involves routine inspections, cleaning, lubrication, and replacement of worn or damaged components. A preventative maintenance program can help identify potential issues before they cause downtime, reduce maintenance costs, and extend the life of the conveyor system.

Inspection:

Regular inspections are necessary to identify any signs of wear or damage to the conveyor system. Inspections should be carried out by trained personnel and should include a visual inspection of the belt, pulleys, idlers, motor, and any other components of the conveyor. Any issues identified during the inspection should be addressed promptly to prevent further damage.

Cleaning:

Cleaning the conveyor system is essential to prevent material buildup, which can cause the belt to slip or become damaged. The conveyor should be cleaned regularly using a brush or scraper to remove any debris or buildup from the belt and other components.

Lubrication:

Lubrication is necessary to ensure the smooth operation of the conveyor system. Bearings and other moving parts should be lubricated regularly according to the manufacturer’s recommendations to prevent wear and reduce friction. Over-lubrication should be avoided, as it can lead to a buildup of grease or oil that can attract dirt and debris.

Replacement of Worn or Damaged Components:

Worn or damaged components should be replaced promptly to prevent further damage and ensure the reliable operation of the conveyor system. Components that are commonly replaced include the belt, pulleys, idlers, and bearings. It is important to use high-quality replacement components that meet the manufacturer’s specifications to ensure proper fit and function.

Belt conveyors are an essential piece of equipment in many industries, providing a reliable, efficient, and cost-effective solution for transporting materials. The design of a belt conveyor system depends on several factors, including the type of material being transported, the distance to be covered, and the physical characteristics of the conveyor system. Belt conveyors offer several advantages over other types of material handling equipment, including versatility, reliability, efficiency, safety. Preventative maintenance is crucial to the reliable operation and long service life of belt conveyors. A comprehensive preventative maintenance program should include regular inspections, cleaning, lubrication, and replacement of worn or damaged components. By implementing a preventative maintenance program, companies can reduce downtime, extend the life of their conveyor systems, and improve productivity.