TERM PAPER

Dynamics of Machines (MEC-302)

Belt Conveyor System

SUMITTED BY : Vardhan Mahendru Roll No : B15 Section : M3R06 SUMITTED TO : Ms. Sumit Shoor DOS : 04/04/2012

Index

1. Acknowledgements 2. Conveyor System 3. Whats a Conveyor Belt? 4. Conveyor Belt Construction 5. Belt Conveyor Systems 6. Working of a Belt Conveyor System 7. Applications 8. References

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Acknowledgements
I avail this opportunity to convey my sincere thanks to Mr. Sumit Shoor our MEC-302 teacher who helped me to use my skill in the right way by giving me and by rendering all the possible help from all the sides. Without his kind co-operation and noble assistance this project would not have been concluded. Therefore, from the nucleus of my heart, I express gratitude to my worthy teacher for devoting his worthless time and helping me in this project.

I also feel acknowledged to my parents and my friends who encouraged me to work and complete the project .There have been others also who have motivated; corrected or customized my thoughts and I would be grateful to them from the interior of my heart.

Thanking You Vardhan Mahendru

Conveyor system
A conveyor system is a common piece of mechanical handling equipment that moves materials from one location to another. Conveyors are especially useful in applications involving the transportation of heavy or bulky materials. Conveyor systems allow quick and efficient transportation for a wide variety of materials, which make them very popular in the material handling and packaging industries. Many kinds of conveying systems are available, and are used according to the various needs of different industries. There are chain conveyors (floor and overhead)as well. Chain conveyors consist of enclosed tracks, I-Beam, towline, power & free, and hand pushed trolleys. Types of conveyor systems Gravity roller conveyor Gravity skate wheel conveyor Belt conveyor Wire mesh conveyors Plastic belt conveyors Bucket conveyors Flexible conveyors Vertical conveyors Spiral conveyors Vibrating conveyors Pneumatic conveyors Belt driven live roller conveyors Line shaft roller conveyor Chain conveyor Screw conveyor Chain driven live roller conveyor Overhead conveyors Dust proof conveyors Pharmaceutical conveyors Automotive conveyors

Well be focusing our study on Belt Conveyors only.

Whats a Conveyor Belt?

A conveyor belt (or belt conveyor) consists of two or more pulleys, with a continuous loop of material - 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 while the unpowered pulley is called the idler. There are two main industrial classes of belt conveyors; those in general material handling such as those moving boxes along inside a factory and bulk material handling such as those used to transport industrial and agricultural materials, such as grain, coal, ores, etc. generally in outdoor locations. Generally companies providing general material handling type belt conveyors do not provide the conveyors for bulk material handling. In addition there are a number of commercial applications of belt conveyors such as those in grocery stores. The belt consists of one or more layers of material. They can be made out of rubber. Many belts in general material handling have two layers. An under layer of material to provide linear strength and shape called a carcass and an over layer called the cover. The carcass is often a cotton or plastic web or mesh. The cover is often various rubber or plastic compounds specified by use of the belt. Covers can be made from more exotic materials for unusual applications such as

silicone for heat or gum rubber when traction is essential. Material flowing over the belt may be weighed in transit using a beltweigher. Belts with regularly spaced partitions, known as elevator belts, are used for transporting loose materials up steep inclines. Belt Conveyors are used in selfunloading bulk freighters and in live bottom trucks. Conveyor technology is also used in conveyor transport such as moving sidewalks or escalators, as well as on many manufacturing assembly lines. Stores often have conveyor belts at the check-out counter to move shopping items. Ski areas also use conveyor belts to transport skiers up the hill. A wide variety of related conveying machines are available, different as regards principle of operation, means and direction of conveyance, including screw conveyors, vibrating conveyors, pneumatic conveyors, the moving floor system, which uses reciprocating slats to move cargo, and roller conveyor system, which uses a series of powered rollers to convey boxes or pallets.

Carcass
The reinforcement usually found on the inside of a conveyor belt is normally referred to as the carcass. In a sense, the carcass is the conveyor belt since it must: Provide the tensile strength necessary to move the loaded belt. Absorb the impact of the impinging material being loaded onto the conveyor belt. Provide the bulk and lateral stiffness required for the load support. Provide adequate strength for proper bolt holding and/or fastener holding. The carcass is normally rated by the manufacturer in terms of maximum recommended operating tension permissible ( pounds per inch i.e., ppi). Similarly, the manufacturer rates the finished belt in terms of maximum recommended operating tension per inch of width (which is the total of the preceding, multiplied by the number of plies in the belt construction) i.e., 4 plies of 110# fabric = a 440 pound per inch of width (PIW) working tension belt. The manufacturer determines the maximum recommended operating tension per inch of width with considerations given to: Stretch characteristics of the belt. Fastener/bolt holding capability. Load characteristics. Stiffness. Impact resistance of the belt construction.

Conveyor Belt Construction

Conveyor belts generally are composed of three main components: 1. Carcass 2. Skims 3. Covers (carry cover and pulley cover)

There is a relationship between the recommended maximum operating tension per inch of width of the belt and the ultimate tensile strength (breaking strength) of the belt which will be explained later.

conventional plied belting design its broad customer acceptance. When cotton and similar materials were widely used as carcass components in plied belts, a breaker strip, an additional layer of open weave fabric was added between the carcass and the top cover for heavy abuse constructions, helping absorb the loading impact. The switch to modern synthetic carcass materials (like polyester and nylon) has essentially eliminated the need for the breaker strip. Today, breaker strips are seldom found in plied belt constructions except in extreme impact applications. Conventional plied belting constructions, employing all synthetic carcasses and elastomer covers appropriate to the end use, are particularly recommended for: 1) Hard Rock Mining a) Aggregate, sand and ore 2) General purpose applications 3) Forest products 4) Soft Minerals a) Coal b) Potash, Phosphates c) Grain 5) Unit Handling a) Parcels b) Baggage c) Mail

Carcass Design
Multi-Plies + Elastomer = Plylok Supreme Plylok, PHR and PRL The most common carcass design is made up of layers or plies of woven fabrics bonded together (see Illustration below). This conventional plied belt construction, generally employs a plain weave or twill weave carcass which is built up into as many layers as is required to provide the necessary belt strengthusually bound together with rubber. In the plain weave, the warp yarns (lengthwise yarns) and the fill yarns (crosswise yarns) pass over and under each other. This means that both members are crimped (Essentially, each assumes a sine-wave-like configuration). This fact, plus the basic characteristics of the fiber used give the belt its stretch characteristics. Conventional plied carcass belts have been used for decades. Consequently, they are the most common belt design used today. Most conveyor engineers and millwrights are familiar with conventional plied belting constructions and their characteristics. Virtually, all belting mechanics know how to splice conventional plied belts. This familiarity with the belts characteristics and the ease of endlessing gives the

Skims
The rubber, PVC or urethane between plies is called a skim. Skims are important contributors to internal belt adhesions, impact resistance, and play a significant role in determining belt load support and troughability.

Improper or marginal skims can adversely affect belt performance in general and can lead to ply separation and/or idler junction failure.

Straight Warp constructions are used for: 1) Hard Rock Mining a) Aggregate, sand and ore b) High impact applications 2) General purpose applications 3) Soft Minerals a) Coal b) Potash, Phosphate c) Grain 4) Unit Handling a) Parcels b) Baggage c) Mail The solid woven design can be considered an extension of the straight warp concept. Polyester filament yarns, as well as spun polyester staple yarns, are coupled in a highly complex fabric construction, which is somewhat similar to the straight warp. However, because of the high performance requirements of these constructions, more than one layer of basic, warp yarns are used. The whole is interlocked and tied into one single mass by means of a uniquely designed binder warp system. Spun polyester staple yarns protect the two faces of the carcass construction and combined with the high performance PVC, form the working surface of the belt itself. PolyVinylok, a single-ply conveyor and elevator belting construction, has found wide acceptance in: A broad range of industrial applications Agricultural equipment Food processing; Grain handling (conveyor and elevator);
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Straight Warp Wearlock, Kordlok, PVK, PHR.

The straight warp carcass design yields a carcass construction wherein the basic lengthwise (warp) yarns are essentially uncrimped. These are the main loadcarrying tension yarns. Fill yarns are then laid transversely and alternately, above and below the main tension yarns. This construction gives greater dimensional stability to the belt, and does employ a beam" effect for better load support and transverse rigidity. The yarns used are much thicker than yarns in conventional fabrics. Further, they are locked together by means of another series of lengthwise yarns, known as the binder warp system. The binder warp system locks the tension and fill cords tightly together, creating a belt which is unusually tough and which has exceptional tear and impact resistance, as well as good fastener and bolt holding ability. The straight warp configuration for the basic tension yarns essentially eliminates geometric stretch and results in a conveyor belt construction with a minimum stretch characteristic. . .a significant advantage in most conveyor belt applications.

Underground mining, such as coal, potash, and other soft minerals; Forest products.

Steel Cord + Rubber Steel Cord-type constructions utilize a single layer of uniformly tensioned steel cords as strength members; encased in rubber. Steel cord belts are generally found in high tension applications ranging from 600 PIW to 5,000 PIW and/or where extremely low stretch is a necessity. Typical elongation for steel cord conveyor belting is less than 1/3 of 1%. Steel cord belts must be manufactured to width. Strength Designations In the past, when cotton was the primary fabric for carcass construction, all fabrics were designated by the weight of a piece of fabric 42" X 36", i.e., in cotton 28 oz., 32 oz. Duck, etc. As new carcass materials were developed that varied in strengths and weights, new methods of designation were required. As a general rule, current fabrics in use are designated by the working tension or strength of the fabric, shown in pounds per inch of width (PIW), i.e.25, 45, 80, 110, 125,150, 200, 250 and 300 pound fabrics, etc. When dealing with carcass fabrics, we work with two separate strength measurements. The first is the Maximum Working Tension or strength of the belt. This is the highest tension occurring in any portion of the belt on the conveyor system, under normal operating

conditions. This is the strength measurement used to determine the proper belt for the system. The second measurement is the Ultimate Tensile Strength of the belt. The ultimate tensile strength of a belt is the point at which that belt will rupture and fail due to excessive tension. The difference between the maximum working tension and the ultimate tensile strength of the belt is often referred to as the service factor. On top quality domestic conveyor belting, this service factor is 8-10 to 1. Most Georgia Duck belting has a 10 to 1 service factor. This means that if the maximum working tension is 200 PIW, the ultimate tensile strength would be 2,000 PIW. Belting utilizing nylon constructions generally has a service factor of more than 10 to 1. This higher service factor is necessary to overcome some of the inherent properties of nylon, such as excessive elongation. Most conveyor belt fabrics are produced today with polyester warps (lengthwise yarns) and nylon fills (widthwise yarns). This combines the best properties of both textiles offering high strength, low stretch conveyor belt with excellent impact resistance, troughability, load support, and fastener and/or bolt-holding ability. Materials - Fibers Carcass materials used in belt manufacture in recent years are listed as follows. Given is the common name, the composition and some general comments about each material. (Please note their characteristics and current position in the market place)

Cotton

Natural Cellulose Composition Only natural fiber used to any great extent in belting manufacture. Increases in strength when wet. High moisture absorption - consequently, poor dimensional stability. Susceptible to mildew attack. At one time represented 80% of the raw fiber input into belt manufacture. Currently, something less than 5%. Regenerated Cellulose Composition Slightly stronger than cotton, but tensile strength is lowered by water. Chemical resistance similar to cotton. High moisture absorption consequently, poor dimensional stability. Susceptible to mildew attack. Almost nonexistent in conveyor belt today. Glass Very high strength compared to rayon. Low elongation. Mainly used in high temperature applications. Poor flex life. Limited use in belt manufacture currently. Polyamide High strength, high elongation, good resistance to abrasion, fatigue and impact. While moisture absorption not as high as cotton, it will absorb up to 10% of its own weight in moisture. Consequently, poor dimensional stability. High resistance to mildew. At one time, nylon represented 40% of the raw material input into belt manufacturing. Today, it is something less than 20%. Polyester High strength, exceptionally good abrasion and fatigue resistance. Extremely low moisture absorption. . .consequently good dimensional stability. Unaffected by mildew. Georgia Duck selected polyester as its fabric of choice in 1960. Polyester usage in the manufacture of belting has grown from 0% in 1960 to something in the range of 70-75% today. (See Georgia Duck technical data bulletin Polyester, The Fiber of Choice). Steel Used where high strength and extremely low stretch are a necessity. A small amount of woven steel carcass is found in todays market. However, more steel is used in steel cord-like belt constructions. Kevlar Aramid Aramid (the material used in flak jackets and bullet-proof vests) has twice the strength of steel, with stretch characteristics roughly halfway between steel and polyester. It is significantly lower in weight than steel and will not rust. Aramid Aramid (the material used in flak jackets and bullet-proof vests) has twice the strength of steel, with stretch characteristics roughly halfway between steel and polyester. It is significantly lower in weight than steel and will not rust.

Rayon

Glass

Nylon

Polyester

Steel

Kevlar

Covers
Covers are used in conveyor belt constructions in order to protect the base conveyor belt carcass and, if possible, to extend its service life. In addition, covers do provide the finished belt with a wide variety of desirable properties, including the following:

Textures o To increase friction o To increase inclination o To control product Cleanability A specific coefficient of friction A specific color Cut resistance Enhanced impact resistance, etc. Hardness Fire Resistance, Oil & Chemical Resistance

Modern day belt constructions, with their high adhesion levels and synthetic carcasses, are considerably less susceptible to moisture and chemical attack, and do not require edge protection. They make possible the slitedge belt distribution programs currently used in the Belting Industry. Costs are minimized since an 84" slitedge belt can be manufactured about as quickly (if not more so) as a 24" molded edge construction. Further, the labor involved is somewhat less. Georgia Duck uses an extremely wide variety of polymers for our cover needs, including: Polyvinylchloride, natural rubber, various synthetic rubbers and urethane - -to meet individual customer needs. Quality competitors offer covers made of similar polymers although their individual recipe may be somewhat different. Individual cover formulations are usually blends consisting of one principal polymer and assorted modifiers, such as other polymers, antioxidants, accelerators, curatives, pigments, extending and reinforcing fillers, plasticizers, etc. Specific conveyor belt applications seldom require the belt cover to satisfy one or two conditions. More usually, a broad variety of required and desired properties are encountered. The specific cover formulation is quite likely to be a compromise, which seeks to meet the customers criteria and still remain cost effective. For many applications, the blending of polymers adds properties that could not be obtained in a single polymer compound.

Cover type, quality and thickness are matched to the service life of the belt involved. A specific cover formulation used in an individual belt construction is determined by the material to be carried and the environment in which the belt will operate. Historic belt constructions were highly susceptible to moisture and chemical attack because of their cotton carcass components. Accordingly, it was common to extend the belt covers over the edges of the belt in what is known as the molded edge construction. This type of manufacturing can be expensive because of the additional labor and machine time involved.

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The Georgia Duck Chemical Resistance Chart lists characteristics of many belt covers offered by Georgia Duck. Specific compound properties are detailed as is chemical resistance. This list is an important assist in selecting proper cover compounds. In addition to selecting proper compounds for cover material, it is also necessary to determine the proper cover thickness. The thickness of a cover is influenced by the amount of abuse and wear the belt will receive. The cover is usually the lowest cost component of the belt. The severity of the wear depends on the nature of the material and on the size, weight, shape and trip rate of the material conveyed. Sharp edges, particularly on large pieces, can quickly cut a cover badly. On the other hand, if loading conditions are ideal, with the material being loaded in the direction of travel of the belt, and with only a slight impact onto the belt, even very sharp material may not seriously cut or wear the belt surface. Cover wear is also influenced by the loading area being on the horizontal compared to loading a conveyor belt on an incline which will result in the product bouncing around more before the load settles down. This increased product movement will adversely affect cover wear.

Wearability of rubberlike compounds can be characterized by PICO abrasion test. This test assigns wearability level or abrasion numbers to various elastomers. The higher the number, the more durable the elastomer. For example, Grade I rubber normally will test out at a PICO rating of 135, while a Grade II rubber will yield a PICO of 100, and PVC a PICO of 50. The Taber abrasion test more directly relates to sliding wear ( slider beds, side loading, etc.) and is therefore used more frequently in measuring belts used in unit handling systems. Fillers and additives added to a given recipe can affect the PICO adversely. It is not uncommon, for example, for an oil resistant, MSHA, rubber elastomer to yield a PICO in the 50s or 60s.

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Belt conveyor systems

Conveyor belts are basically very wide belts attached in a loop to two or more turning rotors driven by motors. The loop is the actual conveyor belt, and is generally made of two or more layers of rubber, one layer to give shape and structure to the belt and one to allow it to transport its load safely. This conveyor loop is generally attached to two wheels, called rotors, which are spun by motors. The conveyor belt has enough friction between it and the rotor that it sticks to this rotor. Conveyors are durable and reliable components used in automated distribution and warehousing. In combination with computer controlled pallet handling equipment this allows for more efficient retail, wholesale, and manufacturing distribution. It is considered a labor saving system that allows large volumes to move rapidly through a process, allowing companies to ship or receive higher volumes with smaller storage space and with less labor expense. Rubber conveyor belts are commonly used to convey items with irregular bottom surfaces, small items that would fall in between rollers (e.g. a sushi conveyor bar), or bags of product that would sag between rollers. Belt conveyors are generally fairly similar in construction consisting of a metal frame with rollers at either end of a flat metal bed. The belt is looped around each of the rollers and when one of the rollers is powered (by an electrical motor) the belting slides across the solid metal frame

bed, moving the product. In heavy use applications the beds which the belting is pulled over are replaced with rollers. The rollers allow weight to be conveyed as they reduce the amount of friction generated from the heavier loading on the belting. Belt conveyors can now be manufactured with curved sections which use tapered rollers and curved belting to convey products around a corner. These conveyor systems are commonly used in postal sorting offices and airport baggage handling systems. A sandwich belt conveyor uses two conveyor belts, faceto-face, to firmly contain the item being carried, making steep incline and even vertical-lift runs achievable. Belt conveyors are the most commonly used powered conveyors because they are the most versatile and the least expensive. Product is conveyed directly on the belt so both regular and irregular shaped objects, large or small, light and heavy, can be transported successfully. These conveyors should use only the highest quality premium belting products, which reduces belt stretch and results in less maintenance for tension adjustments. Belt conveyors can be used to transport product in a straight line or through changes in elevation or direction. In certain applications they can also be used for static accumulation or cartons.

On the Time Scale

Primitive conveyor belts were used since the 19th century. In 1892, Thomas Robins began a series of inventions which led to the development of a

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conveyor belt used for carrying coal, ores and other products. In 1901, Sandvik invented and started the production of steel conveyor belts. In 1905 Richard Sutcliffe invented the first conveyor belts for use in coal mines which revolutionized the mining industry. In 1913, Henry Ford introduced conveyorbelt assembly lines at Ford Motor Company's Highland Park, Michigan factory. In 1972, the French society REI created in New Caledonia the then longest straight-belt conveyor in the world, at a length of 13.8 km. Hyacynthe Marcel Bocchetti was the concept designer.[citation needed] In 1957, the B. F. Goodrich Company patented a conveyor belt that it went on to produce as the Turnover Conveyor Belt System. Incorporating a half-twist, it had the advantage over conventional belts of a longer life because it could expose all of its surface area to wear and tear. Mbius strip belts are no longer manufactured because untwisted modern belts can be made more durable by constructing them from several layers of different materials. In 1963-64, First Indian Small Scale Industrial Unit with Japanese Plant for Rubber Belts for Conveyor / Elevator / Transmission was installed near National Capital Territory of Delhi and its Mr. Belts Conveyor Belting has been widely used in Steel, Cement, Fertilizer, Thermal Power, Sponge Iron Plants and Coal / Mineral establishments / Mines, Port Trusts and similar material handling applications of Industry for the last over 4 decades.

Working of a Belt Conveyor System

The Movement of a Conveyor Belt As a rotor turns, the conveyor belt will turn as well due to the intense friction between the rotor wheel and the belt. This turning motion of the rotor causes one side of the belt to move in one direction, while the other moves in the opposite direction. This means that both wheels must always be moving in relatively the same direction, either clockwise or counter-clockwise. If the two rotor wheels moved in opposite directions, the conveyor belt would not travel at all.

The Transportation Along a Conveyor The word convey means to send or transmit; therefore, a conveyor is something that sends or transmits. Conveyor belts, mostly used in industry, convey products or raw materials through the use of either friction or mounts on the belt meant to hold the product in place as the belt moves. As the conveyor belt moves its product, the product stays around one place on the conveyor. Many times, twists or turns are put in conveyors; these are facilitated by cone shaped rotors or wheels, which allow the conveyor to turn.

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Applications
Manufactured with the best quality steel such as EN 9, EN 8 and EN 24, our Portable Belt Conveyor has found a number of applications in cement, agriculture and paper industries. Ideal to be used for medium and heavy weight, our Belt Conveyor System is found in a number of dimensions to meet the specific requisites of the clients. Today, we are counted among the leading Flat Belt Conveyor Manufacturers and Suppliers. Flat Belt Conveyor: This is normally used for light and medium weight loads between operations, departments, levels, and buildings. It is imperative in places where incline or decline is included in the conveyor path. The belt is generally of roller or slider bed supported for small and irregularly shaped material. Portable Belt Conveyor: The portable belt conveyors are suitable for light to medium loads and offer flexible conveying path such as inclination, curve, long term dependability and low operational cost. Our range is used for transport industrial and agricultural materials, such as grain, coal, ores and many more.

Features: Consists of rollers mounted on self aligning frames. Bearing are incorporated in the rollers to minimize the mechanical losses. Gantry are provided for stiffening available up to 2000mm width &infinite length Walkway is provided on one/ both sides of conveyor in order to maintain the conveyor Drive as given through rubberized rollers and tension is adjusted through gravity and screw.

Belt Conveyor Systems are Commercially used in:

Agriculture Construction - heavy building materials. Food and beverage processing. Forestry - logging, sawmill, paper pulp, etc. Mining and quarrying. Factory production line. Airports.

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References: Bulk Material Handling by Conveyor Belt by M. A. Alspaugh Automation, Production Systems, and Computer-Integrated Manufacturing by Mikell P. Grover Theory of Machines by S.S. Ratan R. S. Khurmi Theory of Machines

Websites: http://www.ehow.com/howdoes_4922797_conveyor-beltwork.html http://en.wikipedia.org/wiki/Convey or_systems http://garlockrubber.com/primary/pro ducts/heavy-duty-conveyorbelts/hdcb-resources/conveyor-beltcomponents/ http://en.wikipedia.org/wiki/Belt_co nveyor

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