Parts of a Conveyor Belt
Belts
Multi layered rubber or similar materials sheeting surrounding the “carcass”/ core of the belt. The carcass is tightly woven fabric within the top and bottom covers of the belt. Belts are wound around the head and tail pulleys on the conveyor bed, powered by the motor. Belts are created in a multitude of materials, sizes, and functions. Hoverdale predominantly deals with rubber belts however steel belts are used by other businesses’ benefits of using rubber are:
- Wear resistant & oil resistant
- High temperature resistant & acid & alkali resistant
- Can transport 300 tons of material per hour & transport up to 203 metres
Rollers
Conveyor rollers are used in roller conveyors and material transport stands to support and move bulky items such as boxes and totes. The rollers let loads roll from one place to another, reducing the effort it takes to move the loads. Roller conveyors save time and improve efficiency in repetitive load movements with pre-plotted circuits by reducing manual handling of the goods.
O – rings/ bands – O-rings or O-bands are rubber-based circular bands that are routed in channels on rollers. O-rings allow multiple rollers to spin, keeping constant and stable movement forward as the product passes the section. Without O-rings, a roller would only move as the product skates over it. With O-rings, rollers in front of the package spin with the previous section, ensuring the package does not stop or jam.
Pulleys
Conveyor belts are routed through a bed structure via a pulley system to drive movement forward. Pulleys provide stable motion by maintaining belt tension, tracking, traction, and direction. Each pulley in a conveyor bed provides a different function based on its location. Pulleys are mainly only used for belted conveyors, although some manufacturers do have chain-routed pulleys for live (continuously moving) roller applications. Tail end – Pulley positioned at the conveyor section infeed. Bend – Pulley that directs the belt down to the take-up. Take-up – Situated lower than in the conveyor than the other pulleys, the take-up manages tension for the entire belt route. Snub – Increases traction and stability by providing angled tension to the head pulley. Head – Main pulley that drives the motion forward at the conveyor discharge.
Motors
The engine of the conveyor, an electric motor (or gearmotor) generates energy for the gearbox, providing power to the moving components of the unit. Placed at the discharge end, or centre of the conveyor, motors can vary in size, shape, and horsepower. For a single unit, a 2hp or 3hp motor provides adequate power, while faster conveyor systems (like a sorter) require larger, more powerful motors. Conveyor motors come in various types and sizes, depending on the specific application and conveyor configuration. Motors can be AC (alternating current) or DC (direct current) and can have different power ratings, speed capabilities, and torque outputs. Conveyor motors are typically connected to the gearbox or the conveyor pulley or roller, and their speed and direction can be controlled through a variable frequency drive (VFD) or other speed control devices.
In addition to their power and durability, conveyor motors are also known for their low maintenance requirements and ease of use. They can be easily installed, repaired, or replaced, minimizing downtime and improving overall efficiency. Conveyor motors are also energy-efficient, reducing energy consumption and costs while maintaining high-performance levels.
Bearings
Bearings play a critical role in the smooth operation of conveyor systems. Serving as the mechanical interface between moving parts, bearings provide support, reduce friction, and facilitate the motion of the conveyor belt. They are typically mounted on conveyor rollers, pulleys, and other rotating components, allowing them to rotate freely while minimizing wear and tear. Bearings enable the efficient and reliable movement of the conveyor belt, helping to transport materials smoothly and consistently. Properly functioning bearings are essential for preventing belt misalignment, reducing downtime, and extending the overall lifespan of the conveyor system. With their crucial role in ensuring reliable and smooth conveyor operation, high-quality bearings are a key component in maintaining the performance and productivity of conveyor systems.
Brakes
Brakes are an important safety feature in conveyor systems, providing control and stability during operation. These mechanical devices are designed to halt or slow down the movement of the conveyor belt or specific conveyor components. Brakes can be applied in various ways, including drum brakes, disc brakes, and calliper brakes, depending on the specific conveyor system’s requirements. One of the key benefits of brakes in a conveyor system is enhanced safety. They can prevent conveyor belt slippage, which may occur during sudden stops or in emergency situations, reducing the risk of accidents or injuries. Brakes also allow for precise control over the conveyor’s speed, direction, and positioning, helping to avoid damage to materials, equipment, or personnel. In addition to safety, brakes also provide operational flexibility. They allow for smooth and controlled stops, starts, and changes in direction, which can optimize the conveyor system’s performance. Brakes enable the conveyor to handle varying loads, inclines, or declines, ensuring consistent and reliable operation.
Guardrails & support
Guardrails and supports are crucial components of a conveyor system, providing stability, safety, and structural integrity. Guardrails, typically installed along the sides of the conveyor, serve as a physical barrier to prevent materials from falling off the conveyor belt or interfering with surrounding equipment or personnel. They help to contain and guide the materials being transported, ensuring that they stay on the conveyor and do not pose a hazard to the surrounding environment. Supports, on the other hand, are used to provide structural stability and maintain proper alignment of the conveyor belt. They are usually positioned underneath the conveyor belt and provide support to the conveyor frame, rollers, and other components. Supports are designed to withstand the weight of the conveyor system, the materials being transported, and any additional loads or impacts that may occur during operation. Guardrails and supports are typically made of durable materials, such as steel or aluminium, to provide strength and durability to the conveyor system. They are often adjustable and customizable to accommodate different conveyor configurations, heights, and widths. Guardrails and supports may also be equipped with additional features, such as guide rails, brackets, or brackets, to ensure proper alignment, prevent material spillage, and optimize conveyor performance.
Gearbox
A gearbox is a critical component in a conveyor system, serving as a mechanical power transmission device that controls the speed and torque of the conveyor belt. It is typically connected to the motor and the conveyor pulley or roller, and its main function is to convert the rotational speed and torque from the motor to the desired speed and torque for the conveyor belt.
Gearboxes contain a set of gears with different sizes and arrangements, which determine the gear ratio and subsequently the output speed of the conveyor belt. The gear ratio can be adjusted to suit the specific requirements of the conveyor system, allowing for precise control over the belt speed, direction, and performance. Gearboxes can be configured with various gear types, including:
- Spur
- Helical
- Bevel
- Worm
Gearboxes also provide torque multiplication, allowing the motor to generate higher torque at the conveyor pulley or roller, which is essential for overcoming the resistance and friction of the conveyor belt and the materials being transported. This enables the conveyor system to handle heavy loads, inclines, or declines, while maintaining the desired belt speed and performance.
Gearboxes play a crucial role in protecting the motor and the conveyor system. They can absorb shocks and vibrations, smooth out the power transmission, and prevent excessive wear on the motor and other conveyor components. Gearboxes also provide safety features, such as overload protection, by using clutches, brakes, or other mechanisms to prevent damage to the motor or the conveyor system in case of excessive loads or sudden stops.
Why Choose Hoverdale?
Industry-leading expertise
Hoverdale are the founders of the bi-metallic plate industry in the UK. We were the first company in the UK to install the Hood & Spoon conveyor system, the benchmark in reliability for the 21st Century.
Reduced maintenance costs
Our products and services routinely reduce maintenance costs by 80% by providing a longer life and minimising downtime.
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Want to see if our recommendations work? Why not let us install a trial for you so that you can judge the results for yourself. We expect you to be delighted with the results.
The benchmark for quality in the industry
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