Belt Conveyor Systems

Training Workshop Outline Choices

How a Belt Conveyor Works

• Major Components (Introduction)  
  • Belting
    • Function
    • Components
      • Carcass Constructions
      • Rubber Covers
  • Troughed Idlers
    • Function
    • Components
    • Types
  • Pulleys
    • Function
    • Components
      • Shaft
      • End Disk
      • Rim
      • Locking Device
      • Bearings
      • Lagging
    • Types
  • Take-up
    • Function
    • Types
  • Drive
    • Function
    • Components
      • Motor
      • Reducer
      • Couplings
      • Brakes
      • Holdback
      • Starter
      • Controller
• The System – Putting it all together
  • Volume (Capacity)
    • Belt Width, Idler Configuration and Velocity = Throughput
  • Belt Tension Diagram (Tension Cycle)
  • Power Requirementsc. Starting and Stopping
    • Torque vs. Time
    • Dynamic affects of Belt Elasticity
      • Tension Fluctuations- High and Low
      • Take-up Travel

System Design

• Calculations
  • Belt Tensions
    • Friction (CEMA 5th and 6th Comparison)
      • Idler Drag
      • Alignment
      • Rubber Indentation
      • Material and Belt Flexure
    • Lift
    • Secondary Losses
  • Power
  • Take-up Weight
    • Slip
    • Sag
• Conveying Profile (Route)
• Load Variations
  • Constant vs. Sporadic Loading
  • Normal vs. Peak Overloads
• Drive, Brake and Take-up Locations
• Selecting Components
  • Belting
    • Tension
    • Load Support
    • Troughability
    • Flex (Pulleys)
    • Impact
  • Idlers
    • Load Rating
    • L10 Life
  • Pulleys
    • Shaft Deflection
    • Stress
    • Bearing Life
  • Take-up
    • Location
    • Weight
    • Travel
    • Type, Gravity/Winch/et cetera
  • Drives
    • Horsepower
    • Types of Starting Devices
      • Fluid Couplings
      • VFD
      • Wound Rotor
      • Et cetera
    • Types of Stopping Devices
• Loading and Unloading
  • Chutes
  • Cleaners
  • Plows
  • Impact Idlers / Beds

Installation, Operation and Maintenance

• Belt Tensions affect…
  • Belt Life
    • Belt Tension Cycle
      • Transitions
      • Turnovers
      • Concave Curves
      • Convex Curves
      • Pulleys
    • Cycle Time
    • Splice Life
    • Cover Wear (Life)
    • Tracking
  • Pulley Life
    • The T1/T2 Ratio
    • Lagging Wear
    • Crowning
    • Alignment
  • Idler Life
    • Installation Tolerance
    • Transitions
    • Convex Curves
  • Take-up Requirements
    • How fast it moves…
    • How far it moves…
    • Component Installation
      • Idlers
      • Pulleys
      • Belting
      • Drives
• Maintenance Concepts
  • Unplanned
  • Preventive
  • Predictive
  • Proactive- Route Cause Failure Analysis
    • Belt Tracking
    • Belt Damage
    • Belt Splices
    • Transfers
    • Motor Overload
    • Idlers
    • Pulleys
    • Take-ups
    • Fluid Couplings
    • Wound Rotor
    • Reducers- Drive Components

Advanced Design Considerations

• Energy Efficiency
  • Low Rolling Resistance Rubber
  • Low Resistance Idlers
  • Alignment
  • Material and Belt Flexure
• Dynamic Analysis
  • Basics of time based transient analysis
  • Stopping a high incline conveyor- Location of take-up important
  • Stopping a long conveyor- Take-up Performance important
  • Starting a long conveyor
    • Time vs. Torque
    • Breakaway vs. acceleration
  • Starting with Fluid Couplings, et cetera
  • Starting with VFD, et ceterac. Fast Conveyors (How Fast?)
• Distributed Power
  • Head Tail Drives
  • Intermediate Drives
• Horizontal Curves
• Specialty Conveyors
  • High Angle Conveying
    • Pocket Belts
    • Sandwich belts
  • Pipe
  • Cable Belt
  • Others
• Transfer Chute Design using Discrete Element Simulation
  • Virtual Prototyping

Project Management

• Conceptual Design
  • Definition of Need and System Requirements
  • Development of Design Criteria
  • Functional Requirements
  • General Specification
• Preliminary Design
  • System Considerations
  • Evaluation of Alternatives
  • Trade-off Studies
  • Preliminary Design
  • Component QA/Testing Requirements
  • System Specification and Component Requirements/Performance Specifications
• Detail Design
  • Select Component Suppliers and supplier activities
  • Collect component characteristics and performance data from manufacturers
  • Evaluate manufacturer alternatives
  • Verification of Component Design
  • Verification of System Design
  • Final Design Review by Team including manufacturers, integrators, etc
  • Detailing
• Manufacturing
  • Confirmation of Component Quality
  • Confirmation of Component Performance
  • Review Manufacturing Discrepancies to determine system design sensitivity
• Installation
  • Structural Alignment
  • Horizontal Curve Alignment
  • Belt Splicing
  • Drive Alignment
  • Control Software
• Operation
  • System Performance Verification
• Maintenance