The document is an e-learning presentation on conveyor belt systems, detailing the types, components, and working principles of conveyors used for bulk material handling. It explains various conveyor types, essential parts like pulleys and idlers, and methods for maintaining and splicing conveyor belts. Additionally, the presentation covers safety devices and maintenance practices to ensure optimal performance and longevity of the conveyor systems.

1. E-LEARNING ON CONVEYOR BELT SYSTEM OR BULK
MATERIAL HANDING
NAME NITESH KUMAR
REGISTRATION NO 20290401709131
SUBJECT CONVEYOR BELT SYSTEM
SUBMITTED TO MR.NIKUNJ AGARWAL SIR
IMPROVEMENT IN GIVEN PRESENTATION

2. Improvement in slide 2
CONVEYOR
 machine or thing that transports material from one place to another.
CONVEYORS ARE USED:
 When material is to be moved frequently between specific points
 To move materials over a fixed path
 When there is a sufficient flow volume to justify the fixed conveyor
investment

3. Add in slide 3
CONVEYORS CAN BE CLASSIFIED IN DIFFERENT WAYS:
 Type of product being handled: unit load or bulk load
 Location of the conveyor: overhead, on-floor, or in-floor
 Whether or not loads can accumulate on the conveyor
TYPE OF CONVEYOR
1 Chute Conveyor
Unit/Bulk + On-Floor + Accumulate
2. Wheel Conveyor
Unit + On-Floor + Ac
3. Roller Conveyor
Unit + On-Floor +
4. Chain Conveyor
Unit + In-/On-Floor + No Accumulate

4. Add in slide 4
5. Slat Conveyor
Unit + In-/On-Floor + No Accumulate
, 6. Flat Belt Conveyor
Unit + On-Floor + No Accumulate
7. Magnetic Belt Conveyor
Bulk + On-Floor
8. Troughed Belt Conveyor
Bulk + On-Floor
9. Bucket Conveyor
Bulk + On-Floor
10. Screw Conveyor
Bulk + On-Floor
12. Pneumatic Conveyor
Bulk/Unit + Overhead

5. Add slide 4a
BELTS TYPE CONVEYOR
PART OF BELT CONVEYOR
 Head pulley Head/Drive Pulley
 Tail pulley
 Idle pully

6. Add in slide 5
WORKING PRINCIPLE OF CONVEYOR BELT
A conveyor belt is composed by two endpoint pulleys and a closed conveyor belt.
The pulley that drives conveyor belt rotating is called drive pulley or transmission
drum; the other one–only used to change its movement direction–is called bend
pulley.
Drive pulley is driven by the motor through reducer, and conveyor belt dragging
relies on the friction drag between the drive pulley and the belt.
Conveyor belts generally are composed of three main components:
1. Carcass
2. Skims
3. Covers
There are two types of belt available:
1. Rubber belt
2. Steel Cord

7. Add in slide 4a
Type Of Conveyor Belt
Troughed conveyor:
These are conventional belt conveyor where the belt is troughed of angles 30, 35 &
45 Degree

8. Pipe conveyor
The belt in this system flattens itself at the loading and discharge stages after it
takes a pipe shape during its forward / return runs.

9. Improvement in slide 6
Component of teough conveyor belt system

10. Improvement in slide 6
HEAD/DRIVE PULLEY
Head/Drive Pulley is located at the discharge terminus of the conveyor. It
provides the driving force for the conveyor. In order to increase pulley life
and traction, it often has a larger diameter than other pulleys.
TAIL PULLEY
Pulley which can be moved to keep belt tight is called take-up pulley.
Take-Up Pulley may be a drive pulley or an idler pulley.

11. Improvement in slide 7
SNUB PULLEY
Pulley, which is provided to increase/decrease, warp/contact angle of belt
on nearby pulley, is called Snub Pulley.
BEND PULLEY
The Bend Pulley is used for changing the direction of the belt.The Bend
Pulleyis usually installed at the tail part or

12. Improvement in slide 8
IDLERS.
Idlers Introduction
Idlers are an important component in any conveyor system as they are
used to support the conveyor belt and the load carried on the belt.
a) TROUGHING IDLER
b) TRAINING IDLER
c) IMPACT IDLER
d) RETURN IDLER

13. Improvement in slide 10
Conveyor chutes are used in bulk handling to perform a variety of
operations. In particular, the loading of a belt conveyor, and the transfer
of material from one moving belt conveyor to another, are important
tasks. Such operations are widely used for the transport of both coarse
grain material

14. Slide 11
TAKE UP: -Take up devices, the name from the fact that it takes up
changes in belt length. In taking up length they maintain tension. Often the
critical point lies immediately following the drive since it is necessary to
maintain tensions at the point to prevent slippage on the drive pulley

15. Improvement in slide 13
A conveyor belt is the carrying medium of a belt conveyor system A belt conveyor
system is one of many types of conveyor systems. A belt conveyor system consists
of two or more pulleys (sometimes referred to as drums), with an endless loop of
carrying medium the conveyor belt that rotates about them. One or both of the
pulleys are powered, moving the belt and the material on the belt forward. The
powered pulley is called the drive pulley

16. Improvement in slide 14
CONVEYOR BELT BASIC REQUIREMENT
 Flexibility
 Transverse rigidity
 Low mass per unit length
 High strength
 Simplicity and inexpensive
 Longer life
 Should not stretch under normal working
 stresses ,i.e., low relative elongation.
 Wear resistant
Fire resistant

17. Improvement in slide 15
CONVEYOR BELT CONSTRUCTION
The belt consists of one or more layers of material.
◦ An under layer-to provide linear strength and shape called a carcass(polyester,
nylon and cotton)
◦ An over layer called the cover. (rubber or plastic compounds)
Belts are typically made from cotton, canvas, Kevlar, nitrile, nylon, polyester,
polyurethane/urethane, PVC, rubber, silicone,
steel cord, Teflon, wire mesh or weave

19. Add slide 16
Type of belt
Textile Conveyor Belting
Width up to 2400 mm
Strength up to 3000 KN / m width
Steel Cord Conveyor Belting
Width up to 2400 mm
Strength up to 7500 KN / m width

20. Improvement in slide 31
BELT JOINTING
To make the belt endless, belts are joined. The methods of belt
jointing are:
Hot Vulcanizing
Mechanical Fastening
Cold Patching (Pasting

21. Improvement in slide 33
HOT VOLCANAISATION PROCESS

22. Improvement in slide 35
SPLICING PROCESS
 General preparation
 Preparation of the lower part of the belt
 Preparation of the upper part of the belt
 Joining of the splice
 Vulcanizing the splice
 Final measures
SPLICING TOOLS
 Safety Glasses
 Tape Measure - 16' x 3/4" Blade
 Angle square
 Plumb line
 White Mechanical Marking Pencil w/ Pocket Clip (Soft Crayon)
 Claw hammer
 Duplex belt nails
 Smooth Flat Face Roller #50D - 2" x 2"
 Smooth Flat Face Roller #50C - 1/2" x 2"
 Corrugated Face Stitcher #50B - 1/4" x 2"

23.  Corrugated Face Stitcher #50E - 1/8" x 2"
 Needle Face Roller - 2” x 2”
 Electric Stripping Cable Winch
 Drying hood (not for use with Flammable Solvents & Cements)
 Stainless Steel Stripping Frame or Grip tongs
 Whetstone #68
 Foxtail Hand Dust Brush
 Curved Hand Rasp - #51
 Drill Arbor for Wire Wheel
 3" Rotary Wire Brush
 Air buffer
 Pincers - 250mm
 Ply Lifter #78
 Offset Knife #77
 Rubber Knife - 6" Long #72
 Bevel Point Knife - 4" x 1"
 Curve V-Trim Knife - 2 1/4" X 3/4"
 Mill Knife Handle (Dull & Rounded Tip)
 Off Set Single Ply Knife - .065 Cutting Depth
 11.5" Heavy Duty Bent Handle Sicissors w / Grips
 18mm Break Off Tip Cutter with Rubber Grip
 Replacement Blades for 18mm Cutter - 50 Pack
 Splice Kit
 Rags
 Cement brush
 White Marking Rubber
 Belt Clamps
 Come-a-longs
 H.D. C-Clamps
 Screw clamps
 Vulcanizing press

24. Improvement in slide 36
GENERAL PREPARATION
 clean and dry conveyor belts
 .Remove oily or greasy substances
 Provide tools, equipment and splicing products.
 If a new belt is installed, place a working platform at the head or tail of
the conveyor.Otherwise install it in the conveyor construction (remove
carrying idlers, if necessary).
 Position it in such a way that the conveyor belt lies on it even and
straight without tension.
 The working platform (approx. 10 - 13 ft long) consists of three parts
aligned in the direction of the conveyor belt: the lower part of the
vulcanizing press,
 The belt ends have to be aligned in the direction of the conveyor belt in
such a way that they overlap each other on the lower part of the
vulcanizing press and that the belt center lines are exactly
superimposed.
 The length of the overlapping area has to be splice length plus bias cut

25. Improvement in slide 38
PREPARING THE BELT ENDS
 The establishment of the center line is easiest done with two rulers. The three
center markings on each belt end are then connected by means of a chalk line
which represents the belt center line.
 This center line ensures exact alignment of the belt ends, which indispensable
for straight belt running.
 Destroyed or missing belt edges must be considered. The width of the belt
edge is established by measuring the width of the belt at suitable areas of the
undamaged belt ends
 Establish a perpendicular square line across the upper belt end at the end of
the splice area.

26. Improvement in slide 39
C on the center line equidistant to point A (AB=AC).
Now describe a circle with the same radius around points B and C by means of a
plumb line and a pen. The points of intersection of both circles must still be on the
belt. These intersections are points D and E.
A line drawn between these two points will be perdendicular to the belt edges
and forms the square line, which should pass point A for additional control.
This square line will be the starting point from which the splice will be laid out.

27. Improvement in slide 40
PREPARATION OF THE LOWER PART OF THE BELT
1. Fold back the upper part of the belt. Make a bias cut on the lower belt
part .Splicing process With an off-set knife, cut the rubber edges flush with
the upper fabric ply.
2. Fold back the lower part of the belt and draw a line parallel to the bias cut
on the pulley side,at 1 inch from the belt end.
Cut the rubber cover along that 1inch line with a dull & rounded tip Mill Knife
held at an angle (of approx.45°), without damaging the top fabric ply.
Also cut the rubber cover along the marked rubber edges with the mill knife
held vertically, without damaging the top fabric ply.
3. Fold back the lower part of the belt again and mark the splice length (lv
according to the chart), step length (ls) and rubber edges.
Draw another line 1inch parallel to the splice length line.
Cut the rubber cover along this line with a dull tipped Mill Knife held at an
angle of approx. 45°. Also cut the rubber edges with a Mill knife held
vertically.

28. Improvement in slide 41,42
.
4. Cut the rubber cover in narrow strips (approx. 1 -1.5 inch wide) and strip
them using pincers or griptongs.
5. Cut the top fabric ply with the one ply knife 1 in.from the rubber
cover,detach this ply using a plylifter and strip it with pincers or grip tongs.
Mark the subsequent fabric plies according to thestep length (ls), cut them
and detach these plies.

29. Improvement in slide 40
JOINING OF THE SPLICE
Step1
 Carefully buff the cut edges of the rubber covers and the surface of the rubber
edges with a buffing tool (e.g. a rotating wire brush).
 Buff the intermediate rubber and buff even any un-even spots.
When buffing, do not scorch or smear the rubber nor leave shiny spots on it.
 Round the edges of the fabric steps, without damaging the fabric (e.g. protect it
with a thin tin plate).
 Carefully remove the buffing dust with a dry brush.
2.step
 Thoroughly stir the required quantity of splicing cement before use.
 The splicing cement should remain covered until use and then recovered to
min thicking.
 Apply two coats of the splicing cement to the whole splicing area and the joint
gaps of both belt ends.
 Use a brush with short bristles.
 Let the first coat dry completely (minimum: 30 min.)
 Let the second coat dry (for approx. 30 mins. at 68°F), until it is just a little sticky
(check with the back of your finger).

30. Step3
 Cover the fabric steps of the lower belt part with uncured tie gum
rubber.
Step4
 Cover the rubber edges and fabric steps with anapprox. 1 inch wide
strip of uncured tie gum rubber.
Step5
 For the joint gap on the pulley side cut to size an exactly fitting filler
strip consisting of a strip of uncured tie gum rubber, breaker fabric and
uncured cover rubber.
Step6
. Superimpose the upper and lower belt ends, aligning them exactly using
the center line of each belt and avoiding air entrapment.

31. Step7
apply one strip of uncured tie gum rubber to the joint gap on the carrying
side, then fill the gap with uncured cover rubber and stitch vigorously.Trim
excess filling flush with the belt surface .

32. Improvement in slide 45
TYPE OF MECHANICAL FASTENERS
Most commonly used Mechanical Fasteners are-
1. Solid Plate Bolt Type Fasteners
2. SR Rivet Hinged Type Fasteners
3. Lacing Type Fasteners

33. Add slide 45
BELT JOINT FAILURES
Symptoms Of Joint Failure
• Bubble development.
• Bulging
• Cracks
• Development of openings
from the line of joints
• The bonding property was lost
• The quality of tension member got deteriorated
The drive pulley belt slips and turns without moving forward after the starting of
the belt conveyor motor. The belt failing in rotating is due to the insufficient belt
tension, overlong of the belt, inappropriate adjustment of the tension equipment, too
frequent start-up and the coal piled up at the end of the belt conveyor.
This problem is mainly caused by the large belt joint, poor belt buckle quality, long
time use of the belt and the unprofessional belt maintenance. In this case, we
should tighten the tension equipment, change high quality belt in time and
improve the maintenance level.

34. Temperature of the reducer rises too fast
It is due to the over mount of lubricant, poor heat dispersion, speed reducer burying
in coal. The lubricant oil amount should be reduced and the coal should be removed
to solve this problem.

35. Improve slide 71
BELT CHANGING
Remove the return roller at the identified problem area.
The Sure Align Tracker replaces the existing return roller. In cases where more
tension is required, leave the return rollers in place and install the mounting
bracket between the existing return rollers

36. Improve slide 73
Bolt the mounting bracket to the conveyor frame. There are 4 predrilled holes
in the mounting bracket. The 2 inside holes are used to bolt the mounting
bracket to the conveyor frame. The two outside holes are used to install the
pivoting members

37. Improve slide 77
CONVEYOR SATETY DEVICES
List of protection system in a conveyor system-
a) Belt Sway Switches (BSS)
b) Zero Speed Switches (ZSS)
c) Trainer idlers
d) Electromagnet
e) Gratings
f) Chute level sensors
g) Motor Overload current protection
h) Fire Hydrants
Weight scale

38. Improve slide 79
BELT SWAY SWITCH
Belt Sway Switch is a protective switch for detecting the
meanderin(sway or deviation) of belt conveyors, and sends out an
alarm signal and an emergency stop signal.

39. Improve slide 81
ZERO SPEED SWITCHES (ZSS)
Zero speed switches (ZSS) also known as Speed Actuating Sensing
Switches are used to detect whether a rotating shaft is turning (even at very
slow speeds) in various machines, conveyors, power plants, and in
industries involving the production of cement, sugar, textiles, paper, etc

40. Improve slide 85
PULL CORD SWITCH
Pull cord switch is mounted on the walkway side of the conveyor belt,
preferably at about every 20 mtrs or it can vary as per standard procedure.
When the rope is pulled from any side. The switch is operated. Unless and
until the handle is reset to normal position manually, the switch remains in
operated condition

41. Improve slide 89a
To prevent unnecessary accidents, damage to machinery and
down time, all conveyor belts are equipped with the following
(1) Interlocking devices.
(2) Tripping devices.
(3) Warning bells or sirens.
(4) Lock-out system
For safety purposes conveyor belts are normally equipped with
sirens or warning bells situated so as to warn persons of the
subsequent starting-up. These sirens or warning bells ore
connected to operate for a set period immediately prior to the belt
start-up.

42. Improve slide 94
CONVEYOR MAINTENANCE
Basic Conveyor Maintenance
To obtain the optimum return on conveyor systems, the following components that
typically make up a conveyor system must be maintained:
 Drives
 Take-up systems
 Control equipment
 Belting
 Pulleys
 Troughing idlers
 Return idlers
 Tail sections
 Impact-loading equipment
 Chutes
 Skirting
 Belt scrapers
 Equipment guards
 Covers
 Walkways
 Structure
 Transfer stations
 Specialized components associated with site-specific activities

43. Improve slide 97
Conveyor Maintenance
Here is a quick list to help you stay on top of maintenance for your conveyor
system. While the system is in operation, check the following issues and refer to all
relevant safety warnings and information:
 Regularly walk around both sides of the system and note the condition, as well
as any unusual behavior of all the moving components.
 Note points of material buildup.
 Look for any signs of misalignment or improper belt tracking.
 Check drive amperage requirements and compare amperages to previous
levels for similar loads and conditions.

44. Add slide 99
TRACKING THE BELT
 Basic rule: the belt moves toward the end of the roller that it contacts
first
 Rollers must be square with the housing and parallel to each other
 Belt Tension must be great enough to prevent slippage. Tension
before running the conveyor
 Run the conveyor. Check to see that the belt runs centered on the
drive roller. Turn off the machine. Adjust drive roller if necessary.
 To adjust drive roller, loosen the four nuts on the bearing holder
plate, and the jam nut on the threaded adjuster.

45.  add slide 101
 adjusting is complete. Normally, once the drive roller is tracked at the
factory is rarely needs adjustment
Cleaning and Lubricating Checklists
These checklists are primarily concerned with cleaning, lubricating, and
tightening activities. These jobs do not require as high a level of technical
skill as those appearing on inspection checklists. Performance frequencies
for cleaning and lubricating checklist activities are also limited to monthly,
quarterly, semiannual, and annual interval1.

46. Improvement in slide 107
TROUBLE SHOOTING
It is a process of trace and correct faults in a mechanical or electronic
system.
if the excessive load carry by the conveyor it create problem.
It is due to loosing of scrub pad

47. add in slide 109

48. add slide 110

49. add in slide 115