FEATURES

Selecting the Right Conveyor Pulley

ulleys used in bulk material handling applications come in a variety of types and styles. A glance in the conveyor components section of the DODGE catalog reveals pulley types that include the Heavy Duty Drum, Mine Duty Extra (MDX), Engineered Class, T-Section, and Wing. With so many options its sometimes difficult to know where to begin the selection process. Perhaps the best place to start might be a review of the advantages of each pulley and how it might perform in a given application. The most popular and most basic pulley is the Heavy Duty Drum pulley. This

pulley is designed to meet the load limits set by the Conveyor Equipment Manufacturers Association (CEMA). These pulleys are used throughout the aggregate industry and in some light mining applications. CEMA pulleys are welded-steel construction and typically utilize flexible end discs. But how do you know if you need more than a CEMA pulley? The end disc design is the most common differentiator between a heavy duty or extra heavy duty construction. The limiting factor that prevents additional load capacity in the pulley is the heat-affected zone (HAZ) at the end disc to hub weld. The heat-affected zone is an area within the base metal that has

D/R 28

FEATURES

its mechanical properties or microstructure altered by the heat of the weld itself (see head affected zone drawing on page 30). These zones become the weak link within the pulley and therefore are the subject area for fatigue failure. Cracks in this area are the most common type of failure mode for CEMA pulleys. Another factor to consider before choosing between a heavy duty or extra heavy duty pulley is the shaft size of the application. The stress increases in the end disc are a function of shaft size, so for a given load, the smaller the shaft, the greater the shaft deflection at the hub. Higher shaft deflection at the hub will result in more distortion within the end disc. This distortion influences the stress in the end disc welds. As end disc stress increases, so does the probability for premature pulley failure, which can be

verified through finite element analysis (FEA). This type of failure will generally occur when pulley shafting is undersized for the tensions applied to the pulley. Basically the bending stress in the end disc reaches such elevated levels that the material experiences fatigue failure in the area similar to a paper clip bending several times in your hand. Larger shafts with less deflection will minimize the amount of stress in the end disc. One way to eliminate this end disc failure is to increase the shaft size. The larger shaft will prevent excess deflection. This in turn will minimize the end disc stress and prolong pulley life. Another option is to choose a different style of pulley

D/R 29

FEATURES

altogether. The DODGE Mine Duty Extra (MDX) pulley has integral hubs within the end discs. The integral hub of the MDX eliminates the fatigue point in the heat affected zone and provides much greater service factor to the pulley. DODGE Engineered Class pulleys are usually stronger than MDX pulleys. Engineered pulleys are just that; they are custom designed to the tensions, bearing centers, and wrap angles of the application. CEMA or MDX pulleys may qualify for the Engineered Class rating, provided they can meet the design requirements for the application. It never hurts to have Engineered Class pulleys quoted when tensions are known and pulley specifications are provided.

T-Section pulleys, which include Super Pulleys, are larger pulleys that are generally much more expensive. The need for these types of pulleys is generally based upon enhanced reliability and/or elevated tension levels. T-Section pulleys are rare and will generally include Super Pulleys on large mining conveyors. Wing pulleys are another offering available for belt conveyors. Wing pulleys are essentially combination belt cleaners and belt supporters. Separate contacting surfaces on the pulley beat the conveyor belt through chordal action to remove dirt and debris. As this debris falls off the belt it is directed outward away from the pulley through angled spacer plates existing within the wing pulley itself. If the debris were not removed the belt and drum pulleys would wear, resulting in decreased product life. Wing pulleys are available up to 350 PIW (pounds of tension per inch of belt width) and are typically used as bend, snub or take-up pulleys.

The heat affected zone (MA 2) caused from welding is normally the limiting factor to a conveyor pulleys load transmitting capability. As a result of the welding process, this areas mechanical properties and microstructure are altered, weakening the parent material. Stress reduction in this area will prolong a conveyor pulleys operating life; a design concept that is used by the engineers who design DODGE pulleys.

HEAT AFFECTED ZONE WELD ZONE

End disc design is the primary differentiator between conveyor drum pulleys. The welded design end disc is the most common, with the integral hub and T-section designs offering greater service factor within the application.

D/R 30

FEATURES

Other Considerations before Making Final Selection

Most pulleys discussed in this article can also be either a crown or straight-faced pulley. Crown faced pulleys are tapered to the center of the pulley and aid with belt tracking in applications where there is a long unsupported span of belt. Crown faced pulleys may also be a good choice for applications where there are end pulleys on the return side of the belt, tail pulleys witnessing long unsupported spans, and even short conveyors with wide belts. However, crown pulleys are not recommended for tensions exceeding 750 PIW or high-modulus belts. Lagging, sometimes required for efficient long-term pulley operation, is another option to consider when ordering a pulley. Particularly harsh environments, typically found in the aggregate and mining industries, may demand additional protection provided by lagging. Lagging reduces the wear caused by abrasive materials and can be used to increase the traction or griping capacity of drive pulleys to the conveyor belt. This additional traction helps prevent slip and increases the life of the pulleys and belts. Any pulley that will transmit torque works best if lagged. A layer of rubber lagging will also protect the rim from wear and prevent catastrophic rim failure as the rim thickness decreases from the wear. If the rubber wears, it can be relagged at a much lower cost than complete replacement of the pulley. Many customers will specify lagging on all pulleys encountering the dirty side

of the belt. This would include snub pulleys and bend pulleys. With so many types, styles, and different options available today, choosing the right pulley for your application can be confusing. The bottom line is to choose a pulley that has been designed for your particular application. If you have any doubts, or need any help in making that decision, please contact the application engineering department at 864.284.5700.
Finite element analysis (FEA) is often utilized to control stress distribution in the pulley, along with shaft and rim deflection. The result is a reliable DODGE pulley that offers many years of dependable service.

Tension Range (PIW*) CEMA MDX Engineered Class 0 750 0 750 0 2,500+

Available Bushings HE, TL, QD HE HE, TL, QD, Keyless Keyless

Available as Wing? Yes Yes Yes No

End Disc Welded Hub Integral Hub Welded Hub or Integral Hub Integral and Profiled

T-Section / Super Pulley 2,500 10,000+ *PIW = Pounds per inch of belt width

D/R 31