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Heavy-duty, end-drum conveyor discharging pulleys are used in mineral processing plants, steel manufacturers, coal mines, and bulk industries requiring massive material transportation. Various pulleys are employed on a conveyor system's discharge side to consider application-specific elements such as the type and temperature of the conveyed material, dweller intensity, and available space.
Conveyor pulleys made of steel
Steel pulleys are extremely strong and difficult. They can tolerate heavy loads and tough conditions, such as abrasives materials, and are therefore appropriate for mining and heavy industry. Steel pulleys are manufactured by welding a steel plate shell around a bull, with the bull supported by bearings on both ends. They can be machined into a crown shape to help the belt's tracking, which reduces belt misalignment by providing a slight curve that helps the belt's tracking. This design helps to keep the belt centered and reduce wear on both the belt and the conveyor system.
Rubber Lagged Conveyor Pulleys
The steel pulleys' surface can be lagged with rubber to avoid belt slippage and provide a stronger surface for gripping the conveyor belt. Rubber lagging also absorbs shocks, reducing the system's wear and allowing it to be used in wet, oily, or extremely slippery conditions. The lagging is carried out by bonding the rubber to the pulley and the shell surface with a steel wire to enhance traction. Rubber lagged pulleys provide effective belt grip, tensioning the belt to prevent slippage in wet, oily, or extremely slippery environments. Because they also absorb shocks, they reduce wear and tear on the system and increase its lifespan.
Conveyor Discharge Pulley
Discharge pulleys are used at the end of a conveyor system to easily shed materials off the belt. These pulleys provide a rough, non-slip surface for better material release on their respective belting surfaces, which typically features rubber with deep grooves to help powerfully grip the belt. Some feature ingenious self-cleaning designs that aid in banishing stubborn material residue caught on the belt. Conveyor discharge pulleys are made to augment discharging capacity while preventing belt slippage by quietly gripping the belt and fiercely resisting powerful material weight without fear of flipping it away.
Tail Pulleys for Conveyors
The tail pulley serves as the tensioning element, providing a fixed anchoring point for the conveyor belt. Positioned at the conveyor's entrance adjacent to the tail pulley, the belt is tensioned by winding it around the tail pulley with a belt take-up assembly. This enables fine tension adjustments critical to maintaining optimal belt performance. The lagging on tail pulleys aids tension distribution across the entire belt, minimizing stress concentrations that could lead to premature failure. Enhanced traction between the belt and pulley facilitates effective even tension delivery that aligns with the conveyor system's entire length.
When choosing conveyor pulleys, buyers should start by considering the type of material each pulley will handle daily. Heavy-duty gradual pulleys fabricated with lagging and abrasion-resistant material are ideal for the long term when used with bulk items like rocks, ores, or grain. Moderate-duty rubber lagged and crowned pulleys are better suited for lighter materials such as sand, gravel, or agricultural products. Additionally, the diameter of the pulley affects its functional use. Larger pulleys are suitable for carrying very massive consolidated items as they provide more surface area, while smaller pulleys are functional for light loads. Bearings are also crucial parts of the conveyor discharge pulley that are relevant to long-term efficiency. Washable bearings demand less care but can get easily degraded when exposed to food-processing or mill environments.
The environment in which each conveyor system operates will affect the choice of pulleys. Conveyors working under extreme temperatures require corrosion-resistant pulleys, such as those made of stainless steel. Conveyor discharge pulleys working in very humid conditions should be kept in either stainless lagging or galvanised steel pulley. Also, the system's power and energy efficiency should be employed by choosing pulleys with low friction bearings and a crown where necessary to support smoother operations that reduce energy wastage.
Subsequently, buyers should evaluate the supporting structure of the discharge pulley that coincides with the specified conveyor belt. The pulley shaft should also be in line with the belt to do away with frictions that can slow down operations. Finally, considering the future potential needs of the conveyor system can be beneficial. A pulley with more grooves can be used for variable speed applications, while larger pulleys provide more surface area in case a belt of a different size is required later on.
To optimize lifecycle value, a few key specifications and details involving the advance maintenance of pulleys must not be overlooked:
Rotation gauges
Lagging thicknesses, bearing downsizing, and crown angles used on the pulleys' rotation refinements should match the conveyor's motion. Higher ratios are used for intense differential usage, while proportionally smaller ratios serve mild utilizations. Regularly inspect the pulley for signs of wear, cracking, or detachment of the lagging material. Visible wear could lead to reduced performance or slippage. Replace lagged pulleys showing significant wear or damage.
Belt alignment issues can result in mis-tracking that leads to uneven pulley wear. Ensure the belt is properly centered on all pulleys. Various designs are available with crowns of differing angles, largely determined by the belt's width and its incline. When belts slide on pulleys, it indicates either insufficient tension or excessive pulley wear. Adjust belt tension so there is sufficient friction without slack. Regularly check pulley alignment to ensure it's parallel with other components. Misalignment causes uneven wear, slippage, and premature failure. In the course of maintenance, all pulleys should be aligned. Workers should employ a string line or laser alignment tool to do this. Misalignment damages the belt and leads to uneven pulley wear. Washable bearings replace grease within a conveyor system's bearings to reduce friction. Some pulleys contain sealed-for-life bearings that generally require no care. Bearings that are meant to be washed should be cleaned frequently and repossessed of lubrication, especially in debris or moist environments. Inspect bearings for signs of wear and replace them as necessary.
Iron pulleys like rubber can erode if they are used in external environments. Such designs should be painted or fitted with covers and inspected regularly for signs of rust. Water, chlorine, and corrosive chemicals such as acids and alkalis can corrode both the people and the pulley, leading to failure. The water content of the air and these substances can also penetrate and penetrate the body and the pulley and cause corrosion, leading to its impairment. Assess the pulley periodically for any corrosion signs, and treat or replace affected areas as required. Affected by environmental conditions, pulleys exposed to such conditions should be more protected from corrosion. Dust, dirt, and other types of material may accumulate within the conveyor system, including the pulleys, bearings, and belt. This could lead to inefficiency, increased heat production, or deterioration. The effort should be made to clean the interiors of the system continuously, particularly around the pulleys and the belt, to do away with such deposits. The lifespan of pulleys and overall operational efficiency can be lengthened by following these preventive measures. In case a severe case is contained, it is strongly advisable to fix the issue without delay, as this often reduces the pulley configuration's effectiveness and poses a danger of belt slippage. Consult the manufacturer for specific guidance and replacement timelines for pulleys.
A1: Common discharge pulley problems include loud noises, unusual vibrations, visible wear on the lagging, belt slippage, and overheating bearings. These are sufficient reasons incapable of being used and requiring complete change.
A2: Yes, as long as it is fabricated with the appropriate materials, the pulleys can operate outside. However, pulleys exposed to the sun, rain, or snow must have special care against corrosion and weathering, unlike pulleys used in enclosed spaces.Using pulleys also prevents some of the extreme heat that can cause cracking on pulleys.
A3: While flat pulleys have an even surface that is useful for nearly all conveyor systems, crowned pulleys slant slightly towards the edges. This helps in better belt alignment and tracking by naturally centering the belt as a feature of its rounded design.
A4: The tail pulley is located at the conveyor's entrance and serves as the tensioning point by evenly distributing the belt tension across the system. Proper pulley functioning ensures even tensioning, which has a positive influence on how long the belt lasts.
A5: Yes, depending on the degree of pulley wear or damage and its surface material, rubber lagging can be replaced sometimes. It must be replaced more frequently if exposed to tougher environments.
