The document provides a comprehensive overview of conveyor belts, including their definition, types (troughed, flat, and pipe belts), and components. It explores various belt types like steel cord and textile belts, their typical failures, troubleshooting tips, and maintenance procedures to prevent issues. Additionally, it outlines safety measures and best practices for operating and maintaining conveyor systems efficiently.

1. Conveyor Belts

2. Definition
A mechanical
apparatus
consisting moving
belt that transports
material from one
place to another.

3. Types of conveyor belt system
1) Troughed belt conveyor
2) Flat belt conveyor
3) Pipe belt conveyor

4. Troughed belt conveyor
• Belt forms a trough
on the carrying side
while running over
idler rollers
• in set of 5 rolls, 3
rolls or 2 rolls.
• The troughing angle
adopted are: 15°, 20°
, 25° , 30° , 35° ,
40° , 45°.

6. Flat belt conveyor
• Belt runs flat on
the carrying side
over straight roller
type idler or a set
of idlers.
• Suitable for lower
capacity, low
speed
requirement .

7. Pipe belts
• Used where bulk materials
must be conveyed along
horizontal and vertical
curves in confined spaces
• Used where spillage must be
avoided.
• The belt can negotiate tight
horizontal and vertical
curves.

8. Belts
Conveyor belts
consists of 3 elements:
1)Top cover
2)Carcass
3)Bottom cover

9. Types of conveyor belts
1)Steel cord belt
2)Textile belts

10. Steel cord belt
1)Consists of top cover
layer
2)Adhesive component
3)carcass(steel cord
mesh)
4)bottom cover layer

11. Steel cord belt
1)They ensure maximum
conveying performance
under grueling stress
conditions.
2)High tensile strength.
3)Excellent impact
resistance.

12. Textile belts
1)Various cover stock
properties according
to applications.
2)Low price .
3)Easy maintenance.

13. Types of textile belts
1)Temperature resistance belts
2)Oil & grease resistance belts
3)Slit protection belts
4)Dirt repellent cover belts

14. Belt designation
1. Driving pulley
2. Tail roller at end of installation
3. Slider bed
4. Carrying rollers on the carrying side
5. Snub roller
6. Tail roller
7. Tension roller
8. Carrying roller on the return side

15. Belt nomenclature

16. Steel cord belt conveyor
2000 m DIN 22131 AB 1200 St 1600 7T/5 X
2000 m Length
DIN 22131 Applicable standard/norm
AB Manufacturer's acronym
1200 Belt width in mm
St Carcass material (steel cords)
1600 Belt's minimum breaking strength in N/mm *)
7 Top cover thickness in mm
T Textile reinforcement (in top cover) **)
5 Bottom cover thickness in mm
X Rubber Cover grade

17. Textile belt conveyor
E.G 1000 m DIN 22102 AB 1000 EP 630/4 6/2 Y
1000 m Length
DIN 22102 Applicable standard/norm
AB Manufacturer's acronym
1000 Belt width in mm
EP Carcass material (polyester warp / polyamide weft)
630 Belt's minimum breaking strength in N/mm
4 Number of plies
6 Top cover thickness in mm
2 Bottom cover thickness in mm
Y Rubber cover grade

18. Failures in belt conveyor system
• Drive unit failure
• Pulley failure
• Idlers and belts failure

19. Drive unit failure
• Drive unit consist of
electric motor, damping
coupling, two or three
stage gear-box and
coupling that connect
output shaft with pulley
• Failures occurs mainly
in Pulleys and gear box

20. Actual Pulley
Failed pulley
Pulley
failure

21. Idler & belt failure
• Due to over load Side
idler may fail.
• Due to foreign Pointed
bodies belt may cut
along its length.
• Bearings in the idlers
may fail

22. Belt conveyor troubleshooting

23. Problem Cause solution
1) Conveyor belt runs
to one side at a
particular point on the
conveyor.
One or more idlers not
at
right angles to
longitudinal
centerline of belt.
Build up of material on
idlers.
Sticking idlers.
Advance the end of
idler
to which the belt has
shifted in the direction
of
belt travel.
Improve maintenance.
Install scrapers.
Replace or free idler

24. Problem Cause Solution
2) Excessive wear on
bottom side of belt.
Slippage between belt
and drive pulley or
pulleys. (Cont.)
Sticking troughing
idlers.
Material ground
between
pulley and belt.
Lag drive pulleys,
renew
worn-out lagging.
Increase arc of contact
drive pulley with snub
pulley or use tandem
drive.
Replace or free stuck
idlers.
Install scrapers in front
of tail pulley or return
belt.

25. Problem Cause Solution
3) Excessive wear on
carrying side of belt.
Dirt, frozen or
misaligned return
idlers.
Excessive sag between
troughing idlers
causing load to move
and shift on
belt as it passes over
idlers.
Install belt-cleaning
plows at head end and
tail end.
Clean, repair and align
return idlers.
Increase belt tension if
too low.
Reduce idler spacing.
Use rubber skirt
material.
Avoid use of old
belting.

26. Problem Cause Solution
4) Short breaks in
carcass
of belt parallel to edge
and star breaks in
carcass.
Impact of lumps falling
on belt at loading
station.
Material trapped
between
belt and pulley.
Use impact idlers.
Install plows or
scrapers
ahead of pulley.

27. Problem Cause Solution
5) Belt running off at
tail pulley.
Build up of material on
return idlers.
Return rollers out of
line.
Unequal loading.
Remove material
provide better
housekeeping.
Adjust at right angle to
frame.
Adjust loading chute to
properly center the
load.

28. Preventive maintenance of belt
conveyor system

29. Daily preventive maintenance
1) Check operation of conveyor controls. Ensure
that all "STOP" pushbuttons operate properly.
Also ensure that all limit switches function
properly
2) Clean any accumulation of dust
3) Never touch a moving belt or rotating part.
4) Keep large lumps of material off belts
5)Note and mark “frozen” or damaged idlers for
repair or replacement.

30. Daily preventive maintenance
6) Check scrapers and plows for proper
operation.
7)Watch for material to build up on decking or
floor under idlers or pulleys. This is especially
important at training idlers.
8)Prevent large lumps from dropping onto
unprotected belt.

31. Weekly preventive maintenance
1)(Conveyor Drive) Check reducer (gearbox) oil
level, Check reducer for oil leaks, Inspect
drive coupling , Check oil level in backstop
and inspect for leaks , Ensure all safety guards
for drive are in place and in good condition.
never touch a moving belt or rotating part.
2)(Safety Switches) Inspect cables for correct
tension, Ensure flags are free from material
build up. do not touch loose wires.

32. Weekly preventive maintenance
3)Head pulley) Inspect belt cleaners for worn or
missing blades, Inspect belt cleaners for
cleanliness of frames and blades , Check belt
cleaner tension according to manufacturers
recommendation , Ensure belt is cantered on
pulley.
4)(Tail pulley) Ensure belt is centered on pulley,
check V-plow blade for wear, Check V-plow
mounting , Check V-plow tension

33. How to avoid spillage over
conveyor?

34. Spillage over the conveyor occurs mainly at
three different areas:
1)Loading point containment
2)Preventing the escape of material from the run
of conveyor
3)Managing the discharge of the materials being
conveyed.

35. Use of pipe conveyor belt

36. Scrapper
1)Scrapper cleans belt after
belt discharges material
from it.
2)Material carry back and
reduce spillage.
3)Avoid material built up on
snub pulley and return idler.

37. Skirt rubber
1)Prevents material
falling down.
2)Avoids spreading
dust in atmosphere.
3)It also serves
purpose of guarding.

38. Methods of conveyor belt joining

39. Belt splicing
Definition:
Conveyer belt
splicing is the
process of joining
together two pieces
of conveyer belt.

40. Mechanical splicing
 It involves use
of several types of
metal fasteners
 It is a quick and
versatile method
used in dirty and
confined
environments
 Relatively
inexpensive

41. Vulcanization
1)Vulcanization creates a splice by using
heat and/or chemicals.
2)Requires special tools, expertise, and a
clean, temperature- and moisture-controlled
environment.
3)Splice is smoother and typically more
durable than a mechanical splice

42. Types of vulcanization
Hot vulcanization Cold vulcanization
1)splices by using heat and
pressure through use of a
vulcanizing press.
1)Use of chemicals that bond two
pieces of belt.

43. Safety

44. How to avoid accidents in belt
conveyor?

45. Guarding
1) Each workplace must be examined at least once in each
shift for conditions which may adversely affect safety.
2) Prompt action must be initiated to correct hazardous
conditions.
3) Moving machine parts must be guarded to protect persons
from contacting them.
4) Guards must be securely in place while machinery is being
operated .
5) New employees must be indoctrinated in safety rules and
safe work procedures

46. Best practice
1)Maintenance should not
be performed unless the
power is off and
machinery components
are blocked against
hazardous motion.
2) Moving machine parts
should be guarded to
protect persons from
contact that could cause
injury.

47. 3)Maintenance should not be performed unless
the power is off and machinery components are
blocked against motion.
4)Visible or audible warnings should be
provided before conveyor start-up when the
entire length of the conveyor is not visible from
the starting switch.
5)Machine operators should take measures to
assure all personnel are trained in safe work
procedures.

48. Guard comparison
Bad guard Better guard

49. Bad guard Better guard

50. Thank you