Belt Conveyor-Pulleys & Idlers

Belt conveyor
INTRODUCTION
 A belt conveyor is a bulk material handling equipment.
 It transports bulk materials over long distances and over terrains requiring a wide range
of paths of travel.
 MAIN ELEMENTS OF BELT CONVEYOR
- BELT
- IDLERS
- PULLEYS
- DRIVE UNIT
- SUPPORTING STRUCTURE
 ASPECTS OF BELT CONVEYOR DESIGN

-CHECKING/DETERMINING CAPACITY OF A BELT CONVEYOR,
- CALCULATING MAX. BELT TENSION REQUIRED TO CONVEY THE LOAD,
- BELT SELECTION,
- SELECTION OF DRIVING PULLEY,
- DETERMINATION OF MOTOR POWER,  SELECTION OF IDLERS AND ITS
SPACING.
 BELT SELECTION CRITERIA
- All belt conveyors for bulk materials use rubber-covered conveyor belts made of a
woven carcass having strength enough to pull and support the load.
- Rubber cover protects it from being damaged.
- Types of belts according to application - Conventional belting - Steel cable belts - Heat
service belts
 FACTORS INFLUENCING BELT SELECTION
- Required belt tension requirements
- Length and speed of conveyor
- Abrasiveness of material handled
- Size of lumps and their tendency to cut or tear the cover
- Method of loading conveyor
Idlers and pulleys arrangement
 IDLERS

 - Idlers are used to protect and support the belt and load to be carried.
 - The spacing of idlers on the loaded run depends on bulk weight of material and width
of the belt.
 TYPES OF IDLERS
Carrying Idlers
Impact idlers
Return idlers
Impact Idler
Return Idler
Idlers inspection
Testing and Inspection is carried out at each and every stage of the manufacturing process and is a
continuous activity
All the idlers are 100% checked for their dimensional accuracy as per specification and relevant
standards during the manufacturing process as well as after assembly
The rollers, once manufactured are subjected to following tests.
1. Free Rotation Test:

This is required to check :
i. Free rotation of idlers.
ii. Proper setting of internal components.
iii. To know any rise in temperature in the bearing seating area.
2. Out of Run Test:
The maximum allowable run-out for NEC idlers is 0.8 mm, which is much lesser than the limit provided
by IS: 8598. The run out test is carried out on a special fixture with a run out dial indicator.
3. Dust Ingress Test:
This is one of the most important tests required to check any ingress of dust in the rollers
bearings. Most of the idler rollers are used in an atmosphere with high contamination of dust particles.
All the rollers are to be used perfectly sealed at bearing assembly to avoid any dust ingress while in use.
This is achieved by performing dust ingress test, where a roller is rotated at a specific RPM in a closed
chamber having a continuous cloud of dust which is maintained for a particular time period. At the end of
the test, the bearing assembly is removed to check any ingress of dust inside the bearing assembly.
4. Water Ingress Test:
This is similar to dust ingress test where the efficiency of sealing arrangement is tested against the
ingress of water. The roller is rotated in a special fixture having water showers impinging water on to the
roller housings at a particular pressure. At the end of the test, the bearing assembly is removed to check
any ingress of water droplets inside the bearing assembly.
5. Friction Factor Test: As per IS-8598
The friction factor is an important parameter of a roller design and directly affects the efficiency and
power requirement of a conveyor system. It also indirectly affects the life of the bearings.
The friction factor test is carried out dynamically under load on a special designed machine with a digital
tachometer, which gives digital output of the dynamic friction factor.
6. Weld Quality Check:
This is done to ensure a good quality of weld at the end discs. This in either done visually or by Die
Penetration Test as per QAP.
7. Paint visual &Thickness Check:
To ensure holiday free and defect free painting & minimum thickness of paint l over the roller shell.
Pulleys
pulleys incorporate several design features
Shells made of rolled steel plate or pipe with full penetration welding to the end-disc
Pulley shell surfaces may be in plain steel, hot vulcanised rubber, rubber, ceramic and
direct bond ceramic lagging
Keyless connection of shaft to end-disc using locking assemblies
Static and/or dynamic balancing
Drive/Head Pulley – A conveyor pulley used for the purpose of driving a conveyor belt.
Typically mounted in external bearings and driven by an external drive source.
Return/Tail Pulley – A conveyor pulley used for the purpose of redirecting a conveyor belt
back to the drive pulley. Tail pulleys can utilize internal bearings or can be mounted in
external bearings and are typically located at the end of the conveyor bed. Tail pulleys
commonly serve the purpose of a Take-Up pulley on conveyors of shorter lengths.
Snub Pulley – A conveyor pulley used to increase belt wrap around a drive pulley, typically
for the purpose of improving traction.
Take-Up Pulley – A conveyor pulley used to remove slack and provide tension to a conveyor
belt. Take-Up pulleys are more common to conveyors of longer lengths.
Bend Pulley – A conveyor pulley used to redirect the belt and provide belt tension where
bends occur in the conveyor system.

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Belt conveyor

 ASPECTS OF BELT CONVEYOR DESIGN

The rollers, once manufactured are subjected to following tests.

1. Free Rotation Test:

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