Exploring the Essential Components and Functionality of Belt Conveyors in Material Handling Systems
Although each belt conveyor varies slightly, they share many common components. A typical conveyor comprises a continuous rubber belt stretched between terminal pulleys. One end, known as the tail, is where cargo loading primarily occurs, though loading can happen anywhere along the conveyor's length. Conveyors with multiple loading zones are quite common. The opposite end, called the head, is where cargo is usually discharged. However, with plows or trippers, cargo discharge can occur at various points along the conveyor.
The belt is supported on its upper (carrying) side by flat or troughing rollers called idlers. Troughing rollers shape the belt into a U-shape, increasing the conveyor's cargo capacity. On the lower (return) side, where the belt loops back to the loading point, return idlers provide support. These rolling components are housed in frames and supported by a steel structure called stringers. In certain applications, such as underground or overland conveyors, the rolling components may be mounted on suspended wire ropes.
Typically electrically powered, conveyor drive motors are usually positioned to rotate the conveyor's head pulley, although they can be located at various points along its length, especially on long or heavily-loaded conveyors.
A tensioning device, known as a take-up, ensures the belt remains taut against the drive pulley, maintaining necessary tension for belt movement and cargo transport. A common type is the gravity take-up, which employs a counterweight to create belt tension and is often situated near the drive pulley on the belt's return side. Bend pulleys guide the belt into the take-up pulley, which is connected to the gravity take-up's counterweight.
Another type of pulley, the snub pulley, is typically positioned immediately after the head pulley on the return side of the belt to enhance belt contact. This allows a smaller drive pulley to transmit the required tension to the belt.
Cargo loading usually occurs near the tail end in a section referred to as the loading zone. Components of the loading zone typically include a loading chute, tail pulley, idlers, belt-support systems, skirtboards, wear liners, dust seals, entry seals, and exit seals.
The head or discharge end of a conveyor typically includes the head pulley, a discharge chute, a belt-cleaning system, a dribble chute, and other equipment to monitor and maintain material flow.
A transfer point is where bulk material moves from one piece of equipment to another. This can be a loading or discharge zone, or in cases where one conveyor feeds another, a transfer point can encompass both loading and discharge functions. It can also involve feeding or receiving material from other handling or processing systems, such as storage vessels, trucks, railcars, barges, ships, or other processing equipment.
Depending on the material being conveyed, various ancillary equipment may be installed along the conveyor or at transfer points.