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Belt Conveyor Systems
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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