What Factors Lead to Inflexible Rotation of Conveyor Roller

In our daily use of conveyor roller, inflexible rotation phenomenon may occur during the operation, what factors lead to inflexible rotation of conveyor roller? Let’s see the following two parts:
The manufacturing quality of belt conveyor idlers
The manufacturing problems of belt conveyor mainly are bearing lacks of rigidity, difficult to ensure the roller assembly accuracy , which restricts the operation flexibility.
Sealing, lubrication and maintenance
Because of belt conveyor working environment is relatively poor, generally, operation site is full of dust, and the bearing sealing form has big influence on roller operation flexibility. If sealing poor, dirt can easily enter into the bearing inner which causes inflexible rotation; in addition, if bearing grease adopts common calcium base grease ,it is easy to change color and become dry, can't reach a very good lubrication effect.

 

How to choose the suitable vibration motor for the vibration machine?

Vibration motor has many types and models with a wide application,it is usually applied with the feeder, vibrating screen combination. The vibration motor is very important in the vibration machine. It directly determines the working efficiency of the vibration machine.The vibration mechanical vibration motor selection steps are as follows:
A.According to the operating requirements, confirm the required vibration of the frequency (r/min) and the amplitude Ym (mm).
Such as the six vibration motor (n=960r /min) can drive the vibration chute, vibration feeder, vibration mill, vibrating screen etc.
B.According to the structure of the vibration machine itself, get the vibration weight G (kg) and calculate the required vibration force Fm (N) .
C.According to the vibration of the operation to get Fm, you can get the model of the vibration motor, please pay attention to the exciting force FH is larger than Fm.
D.Design the overall structure, and calculate the actual vibration parameters, after the calculation, if the vibration motor is too large or too small, motor model should be re-selected.
E.Design of vibration isolation system. 

Deliver Conveyor Rainproof Cover to Madagascar

Last week, more than 600 pieces conveyor rainproof cover used for belt conveyor was delivered from Shanghai Port. These goods were ordered by our Madagascar customer, and they will be transported to the Toamasina port as anticipated one month.

 

According to the information offered by our customer, we provided three kinds of conveyor rainproof cover to them. One is matched with 800mm belt width conveyor, another is matched with 1000mm belt width, and the last one is matched with 1400mm belt width. Meanwhile, the quantities of conveyor rainproof conveyor are 490 pieces, 110 pieces, 40 pieces respectively. Also, they have the same thickness that is 0.8mm.

 

Conveyor rainproof cover is the important component in belt conveyor. It can not only protect materials, but also protect the belt conveyor. PK Machinery can provide conveyor rainproof cover with high quality. Welcome to your enquiry at any time! 

Type and Function of Fixed Belt Conveyor Roller

Roller is used to support the conveyor belt and carry of the material, to ensure the stability of theconveyor belt.
In general, the fixed belt conveyor roller is the following:
1.Trough roller: it is also known as carrying roller which is used for carrying bulk material;
2.Parallel roller: parallel upper roller is used for carrying materials, parallel lower roller is to support the return branch of the conveyor belt;
3.Self-aligning roller: it includes taper aligning supporting roller and friction aligning roller which are mainly used for adjusting the belt deviation to avoid S-shaped, so as to ensure the stable operation of conveyor belt;
4.Impact roller: it is installed in the lower part of the conveyor belt, which can reduce the impact of the conveyor belt to extend the service life of the conveyor belt;
5.Return roller: it supports the conveyor belt of lower branch,including parallel type, V type, inverse V type,etc. V and inverse V type roller can reduce the conveying belt deviation possibilities;
6.Transition roller: it is installed between the drum and the first set of roller, which makes the conveying belt gradually turns from through shape into or flat shape and reduce additional stress of the conveying band edge turns to trough shape due to the expansion, at the same time,it can prevent the material spreading phenomenon of conveyor belt.
In addition, the comb type roller and screw roller, which can remove the sticky material on conveyor belt to keep the conveyor belt clean. 

Difference between Tapered self-aligning roller and Friction self-aligning roller

Tapered self-aligning roller is similar with Friction self-aligning roller in structure which are mentioned when introduce the belt conveyor, their purpose is protecting belt and preventing belt deviation. However, in the process of actual use, there is a big difference between them.
The main difference:

1.Stability performance: these two kinds of roller have their own advantages and disadvantages. Tapered self-aligning roller provides a more stable transport environment for belt and material, but since the tapered roller with a certain angle, if carries the material for a long time, it will increase the radial offset of roller. While friction self-aligning roller has a stable structure so that it can carry material for a long time and won’t be influenced. but there is a certain angle between belt and roller due to design of friction pulley, the joint degree of friction self-aligning roller is lower than tapered self-aligning roller, which will reduce the stability performance of belt conveyor.
2.Friction coefficient: concerning this aspect, tapered self-aligning roller has advantage over the friction self-aligning roller, tapered self-aligning roller has a special body design of roller, it could extremely increase joint degree of belt and roller to make the belt adapt to tapered roller, it also greatly reduce the force of friction.

3.Sealing Performance: the sealing performance of friction self-aligning roller is better than tapered self-aligning roller, the friction one adopts the design with independent installation of the friction pulley to promise a good sealing performance, however, because tapered self-aligning roller has a different diameter of pipe, it increase the difficulty of seal, meanwhile, performance of seal is also reduced.
4.Production cost: the structure and technology of tapered self-aligning roller are much simpler, so the cost is low, but if in the long run of using, the friction self-aligning roller is more stable and durable.

Features and functions of the special conveyor belt

With the rapid development of the financial, conveyor belt becomes more and more diversified, according to the technical comparison and different customer's requirements, please see the following opinions:

Acid and alkali resistant belt selects the cotton canvas, nylon canvas or polyester canvas as its core, belt body has a good elasticity and small elongation, it is easy to form a groove type. use. Selection of acid and alkali resistant materials polishing cover made of rubber, with good function of resistance to chemical erosion and good physical function. Used in contact with acid and alkali environment,such as phosphate fertilizer manufacturing, baysalt seawater. Acid and alkali resistant belt (acid and alkali resistant belt) rubber covering reference rubber plastic blending is adding alkaline material, excellent personality than neoprene acid-base belt resistance to acid and alkali resistant function better. Drum material referenced polyester canvas, more reliable than cotton canvas with acid core functions, easily made into a ring. And the ring-shaped belt is produced the ring belts process belts without joints, its core strength can reach the belt body of the joint office 90%, no significant joint belt surface faults, so belt moving flat with small elongation. Core references made of high quality cotton or cotton canvas.

Do you know the function of scraper on the belt conveyor?

Most belt conveyors has scraper on it,that is a very important part for belt conveyor, without it, the conveyor can not work smoothly.

Conveyor belt is the most commonly used material handling equipment, which is widely used in chemical, coal, iron & steel, metallurgy, mining industries, port, thermal power plant, etc. However, for conveyor belt which runs in the open air without cover hood, water scraper is a necessary accessory which is used to get rid of the stagnant water on the belt. 

Water scraper mainly consists of support & frame, idler sets, axle, bearing block, connecting rod, crank, electric-hydraulic pusher, etc. The operation precondition of water scraper is conveyor belt non-loading running. In the operation, press roller, trough carrier idler, flat carrier idler, connecting rod and crank are workings as a rotary body, the electric-hydraulic pusher drives the press roller and trough carrier idlers in clockwise rotation, then the top of trough carrier idlers and flat carrier idlers are on the same tangent plane. Under the clamping pressure of press roller and carrier idlers, the belt is lifted up, and the water is discharged from both sides of the conveyor belt. Thus the shift between normal operation and water removal can be achieved through the rotation of rotary body. When the conveyor belt is in normal operation, the trough carrier idlers of water scraper are used as the part of conveyor belt, so the belt can passes through the water scraper smoothly.This kind of water scraper has simple and reliable structure, which can avoid the belt damage. And it has the features such as safe and reliable operation, long service life, easy installation and convenient maintenance. 

From now on, you may have a good learn about the water scraper, and many more knowledge in www.pkmachinery.com, please check.

Introduction of Motor IP Grade :The Meaning of First Number

Motor IP (INGRESS PROTECTION) grade system is drafted by IEC (INTERNATIONAL ELECTROTECHNICAL COMMISSION ).IP grade is composed of two numbers, the first number represents for anti-invasion grade of external objects and dust, the second the number shows that the sealing degree of anti- invasion of moisture and water, if the number is greater, the degree of protection will be higher.
0: no special protection
1: it can prevent external objects with solid diameter larger than 50 mm entering into the casing.
2: it can prevent external objects with solid diameter larger than12 mm entering into the casing.
3: it can prevent external objects with solid diameter larger than 2.5 mm entering into the casing.
4: it can prevent external objects with solid diameter larger than 1 mm entering into the casing.
5: protection against dust, it can prevent dust from entering to affect the normal operation of the product, and prevent dust contacting the inner casing or parts.
6: sealing against dust, it can completely prevent dust from entering into the casing and prevent the dust contacting the inner casing or parts.

Common Troubleshooting Methods of Vibration Motor

1. after connect the power supply, motor is unable to start, please check:
(1) if power supply is lack of phase;
(2) if motor is loss of phase;
(3) if protective cover is damaged or rub eccentric block.
2. after start-up, there is big motor noise or motor heats, please check:
(1) if the contact surface roughness of vibration machine and motor foundation is in line with the installation requirements;
(2)if the anchor bolts are not tighten up ;
(3) if the vibration acceleration is in line with the requirements;

3. after the adjustment of eccentric block, amplitude changes abnormally please check:
If eccentric block on both ends of the rotor axis is symmetrical;
4. when two vibrating motors of vibration machine vibrate at the same time, if its phase does not conform to the requirements, please adjust the phase sequence of the single unit, don't adjust the total phase sequence of two vibrating motors.

How to Identify Counterfeit and Genuine Bearings of Vibration Motor

Due to the special structure principle of vibration motor, the quality and lifespan of vibration motordirectly affected by bearings, of course will be embodied in the price level of vibration motor. So it is really necessary to choose a good bearing manufacturer, the following methods will help us identify counterfeit bearings:
1. Packaging
Formal original packing of genuine bearing is comparatively normative which includes inner and outer packaging with unified standard and clear writing. However, the counterfeit bearing packaging material is inferior, printing is rough.
2. Color
Specific parts of genuine bearing present a certain color, for example: chamfer is black, if there is any other colors, it may be counterfeit bearings.

 

3. Appearance 
The writing letters of genuine bearing outer packing adopt special carving or spraying technology design, however, the counterfeit bearing printing is blurry.
4. Material 
Material selection of the genuine bearing is standard steel material, however counterfeit bearing adopts cheap ,fake inferior and unqualified material in order to reduce the manufacturing cost, the weight is light.
5. Processing technology
Genuine bearing manufacturing process is fine which can rotate smoothly However counterfeit bearing manufacturing process is poor with coarse surface ,it can not rotate smoothly.

The Risks of Conveyor Belt Running Deviation

The belt running deviation is rather harmful during the operation. According to the actual operation of belt conveyor, the deviation effects on the operation and production of belt conveyors are mainly in the following aspects:
1. Failure breakdown emergency stop device
The failure breakdown emergency stop device with protective purposes is installed on the belt conveyor. When the belt deviation occur and near the failure breakdown emergency stop device, it will causes the device to stop the machine immediately, and hence causes the conveying process to stop. This will affect the efficiency of production line, and hence increase the cost of production. Some serious cases might lead the project unable to finish on time, or even causes the undesirable contract disputes.

2. Reduce the life-span of main components
Firstly, the breakdown of roller, bearings and other mechanical components, such as belt running deviates frompulley will cause the increasing of the force of roller, and hence it will increase the probability of failure. Secondly, it leads the belt to be worn out in a shorter period. The belt running deviation cause the materials spread onto the return belt. It will cause the belt and roller encapsulate to wear and tear abnormally as the materials can’t be fully removed from the return belt. Thus, the life-span of belt and roller will be shorten. Thirdly, it leads the tear and wear from the edge of belt, if the edge of belt collides with frame for a long time during the operation, it will cause the severe wear of belt edge and thus affects the life-span of belt which will leads to the increase of maintenance cost and also the operation cost. When the serious belt deviation occurs, it causes belt tearing directly. Belt deviation might lead to serious overturning of belt, causing the increasing of unilateral force ,hence it will lead to belt transverse fracture. 

Eight Factors will Affect the Quality of Conveyor Roller

Conveyor roller is widely used in various types of industries, however, most customers lack of the knowledge for choosing the suitable conveyor roller. Let’s show you what are the factors that affecting the quality of roller.

 

1. Roller radial runout (the index directly affects the stability of the conveying materials)
2. Flexibility (the index affects the life-span of the roller and belt, as well as the driving power of the machine)
3. Dust resistance performance(the index affects the life-span of roller)
4. Shock resistance performance (the index affects the life-span of roller)
5. Rotational resistance (the index affects the life-span of tape)
6. Axial carrying capacity (the index affects the life-span of roller)
7. Water resistance performance(the index affects the life-span of roller)
8. Axial string momentum (the index affects the life-span of roller directly)

Do You Know What are the Main Technical Requirements of Conveyor Roller

1.Conveyor roller cylindrical radial circular runout
In order to guarantee the belt conveyor run smoothly, it is necessary to make strict specifications on roller radial circular runout, otherwise it will cause conveyor belt vibration, increase conveyor belt running resistance and consume more power due to its higher value. Therefore, this is an important technology index for roller.

 

2.Rotational resistance after installation of conveyor roller
Excessive roller rotational resistance will cause conveyor roller damage in advance and conveyor belt wears rapidly, it will also cause the increasing of the driving power, so this is another important technical index for roller.
3.Waterproof, dustproof, sealing performance of conveyor roller
The service life of roller depends on its sealing performance to a great extent, good seal performance can prevent dirt and moisture entering into roller bearing roller way effectively. In order to improve its service life, we must develop better way of waterproof, dustproof, sealing performance.

 

4.Roller axial carrying capacity
Generally, roller bears the roll force for only one direction, therefore, we must ensure normal operation under axial load of roller.
5. Service life of conveyor roller
This is a comprehensive index which involving the scientific rationality of structure design, the manufacturing quality of roller, bearing selection, the choice of grease and grease filling and sealing effect etc.

 

Why will Belt Conveyor Motorized Pulley Get Rusty

During the operation process of belt conveyor, it will occur some problems due to incorrect method of using or wear and tear, therefore, we need to know some knowledge in order to ensure the normal operation. Here PK Machinery will list some reasons why motorized pulley of belt conveyor will rust:
1. Electroplating time is not enough, it dues to the problem of process flow;
2. Air liquidity of the location where motorized pulley stores is not good, or the location is wet, it is may due to the large difference in temperature;
3. If the package sealing breaks, the motorized pulley may oxidate and get rusty;
4. The most important point is that before electroplating, the dirt on motorized pulley surface is not being cleaned well, it is also one of the reasons why the motorized pulley will get rusty.

 

 

Installation and Notes of Belt Conveyor Anti-rain Cover

1) Open cover and fixed cover are manufactured with the galvanized steel plate or the colorized coating steel plate. Generally ,there will be 1 piece of open cover and 7 pieces of fixed covers installed every 8 pieces covers, the 2 kinds covers also can be installed side by side alternately ( it also can be matched according to customer’s requirement). At first, fasten the fixed conveyor with drilling rivets and based on the line which is upward 30mm from the top of Z type steel, fix a mounting hole every 450mm, every piece of cover overlaps 2 wave crests. Open cover overlaps above the fixed covers in order to open conveniently.

 

2) The Z type steel or the connection angle iron which is the main support frame of the conveyor cover, the length is equal to the length of the installed conveyor cover
The Z type steel or the connection angle iron is welded on the channel steel or the little stiffening angle iron on both sides of the conveyor

3) Install the covers (fixed covers) from one side to another side along the conveyor, during installation, people are not allowed to stand on the covers and no hard beating and hitting is allowed.
4) Mount the fixed covers on the Z type steel with the drilling rivet. The mounting points are not less than 4 on every piece.

5) 1 piece of observation window cover could be installed every 10 pieces for convenient checking and inspecting. It is decided by users.

6) Salient point cover is only used for the salient points of the convex-concave of the conveyor. Deviation switch cover is only used for covering the deviation switch. These 2 kinds covers also can overlap the fixed covers.

 

4. Note

1) During the installation, please handle the anti-rain cover carefully and avoid scratching.

2) After installing the accessories, please clean the surface and paint the scratched points again.

Installation Drawing of Deviation Switch Cover

 According to the location of deviation switch, please install and center the drilled cover, then put the sealing strip on the cover open point flatly according to the height of the switch box cover , then install the switch box cover with 12－Φ5 rivet.

Installation drawing of deviation switch cover .

 

 

Installation of Open Belt Conveyor Cover

View 1: Installation drawing of whole open –close type 

 

View 2: Installation drawing of half open –close type (double chip open- close type) 

 

1) installation of handle 
After overlapping the open cover and fixed cover, based on the center line of the cover, the location upward 250mm is the center line used for installing the handle (it can be adjustable according to height of the conveyor support frame). Put the handle straightly and drilling a 4－Φ5 hole, then fasten with the rivets.

2) installation of hinge 
Adjust one side of the cover up higher from the top of the Z type steel (angle iron) 5mm, inward 140mm from the front and back sides of the cover, and upward 27mm is the location of the hinge, then drill holes Φ5 and fasten with the rivet. Others holes are also fastened with the rivets. 

3) installation of the lock catch
After installing the hinge, on the other side of the cover, inward 185mm from front and back sides of the cover, then based on the bottom, upward 36mm and 77mm , drill holes Φ5 and fasten the lock with the rivet, next keeping the lock locking( clamp status), and then putting the lock nose on the Z type steel straightly and drilling hole to fasten.

4) installation of the open cover
Overlap the open cover on the bilateral fixed covers. The overlapped length should be the length of 2 pitches of waves, then put the other side of the hinge appressed on the angle iron and drill hole 4－Φ5 with the rivet fastened.

Installation of Belt Conveyor Cover Support Frame

 Belt conveyor cover is applicable to power plant, cement plant, mines and other major factories which is waterproof, dustproof and windproof, it plays a great role in reducing the loss during the process of conveying goods ,making the conveyor belt more safe and reliable in operation and purifying the environment .

As the main support frame of the conveyor cover, the length of Z type steel or the connection angle iron is equal to the length of the installed conveyor cover. Please weld the Z type steel or the connection angle iron on the channel steel or the little stiffening angle iron on both sides of the belt conveyor. If need the stiffening angle iron, at first, weld the stiffening angle iron on both sides of the conveyor, then weld the Z type steel or the connection angle iron on the stiffening angle iron, detailed steps are as following:
 1) first weld the little stiffening angle iron ∟40*40*100*4(just for reference, it also can be indicated by users) every 1.5m or 2 m on both sides of the belt conveyor ( eudipleural ). The height from the intermediate frame to the top of little stiffening angle iron should ≥50mm ( it also can be decided by users).
2) Then weld the Z type steel 30*50*30*(2.0~3.0),( just for reference, it also can be replace by angle iron) and fix it on both sides of the intermediate frame top, the inner size should be 10-20mm bigger than outside size of intermediate frame.
3) After being welded please remove welding slag then paint.
 

How to Prolong the Lifespan of Vibration Motor

1. Make sure the wiring and insulation work of vibration motor is well done in order to prevent the lack of phase and short circuit .
2. Anchor bolt reinforcement work should be done frequently, take necessary prevention measures, such as using a double nut fastening to ensure vibration motor base and the floor contact well.
3. Attach great importance to the cover sealing of vibration motor, the dust inside the protection cover should be cleaned up frequently.
4. Strengthen the daily maintenance of vibration motor, remove the dust on the motor surface frequently, and reduce the impact on the vibrating motor due to the poor heat dissipation in order to make it work in a good condition.

 

5. Please pay attention to the symmetry when adjusting the vibration block, the gravity connection centerline of vibration block on both sides should be parallel to axis.
6. Check whether there is crack on motor appearance, all fastening screws and parts are complete and the fixed situation of the motor are in good condition or not.
7. Check whether the ventilation and bearing lubrication condition of vibration motor is normal or not.
8. Pull out the motor axis and check if rotor can rotate freely and whether there is noise during rotation.
9. Check whether the grounding device is reliable or not.