Understanding Belt Pulley Size: Impact on Belt Longevity and Operational Efficiency
Belting is designed with a specified minimum pulley size by the manufacturer. Bending a belt over a radius that is too small can cause damage, such as separation of plies, ply failure, or cracking of the belt’s top cover. Insufficient pulley size can also result in mechanical splices pulling out. The minimum pulley diameter is determined by factors including the number of material plies (steel or fabric-reinforced), the rated tension of the belt, and the thickness of the top and bottom covers.
When designing a conveyor system, opting for a thicker belt (to increase belt life, especially in high-impact loading zones) may necessitate larger-diameter pulleys. However, a common mistake occurs when operators notice surface damage on the carrying side of the belt. The immediate response is often to install an even thicker belt with the expectation of extending its service life. Yet, if this thicker belt requires larger pulleys than those currently installed, it could shorten the belt's lifespan, exacerbating the initial problem the thicker cover was intended to address.