HGRS MASTER - Maintenance

Type of Skill: Specific Technical Skills

Category : Transport Equipment
Module: Belt conveyors
Unit: Pulleys and Drive 07 of 18
Version: 1.0 06-02-03
Reference: Belt conveyors MTC Training.ppt

Pulleys and Drive

Purpose:  To understand the principal functions of both pulleys and drive
 To understand the basic type and design criteria
 To understand the maintenance requirement

Description: Pulley design

Pulley Types (Flat and Crown)

The most commonly used conveyor pulleys are the standard steel pulley. They are
manufactured in a wide range of sizes and consist of a continuous rim and two end discs
fitted with compression hubs. For very wide-faced conveyor pulleys, intermediate stiffening
discs are welded inside the rim. Other pulleys available are self-cleaning wing and wrapped
wing types. These are used at the tail end, take-up or snub portions in cases where material
tends to build-up on the pulley face. In addition there are magnetic pulleys that are used to
remove tramp iron from the material being conveyed.

Standard Steel Pulley

There are basically two different groups of Pulleys:

Flat Face Pulley Crown Face Pulley

Crown Pulleys

Pulleys that have larger diameters at the center than at the edge are sometimes used to
provide a centralizing effect. These crowned pulleys operate on the basic principle that the
belt moves to the part of the component it touches first. Here, it first touches the higher
crown and is directed into the center (training effect).
Crown pulleys are most effective in conveyors with short, low-tension belts. With higher
tension, steel cable belts and troughed conveyors, little steering effect is obtained from the
crown of the pulley. Crowns are more effective where there is a long unsupported span - four
times the belt width or greater - approaching the pulley. As this is not often possible on the
carrying side of the conveyor, the use of crown head pulleys is relatively ineffective and may
not be worth the stress it produces in the belt. Crown pulleys are somewhat more effective
when used as a tail pulley.

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 There are currently two types of pulley crowns available, the tapered crown and the curved
crown.

Taper Crown:

On taper-crown pulleys, the face forms a “V”, with the rotating axis larger in diameter in the
center of the pulley, and a straight taper to the smaller diameter ends.

Curve Crown:
Curve-crown pulleys have a flat surface in the center of the pulley with the ends curved to a
smaller diameter. Length are 1/3 of the belt width. Slope generally 1%
This is the generally recommended design.

Curve Crown:
RECOMMENDED

Wing Pulleys
NOT RECOMMENDED

Winged pulleys are often installed as a method to reduce the damage of the entrapment of
lumps of material between the belt and the pulley.
These pulleys feature vanes resembling the paddle wheel on a steamboat that allow
material that would otherwise become trapped between a solid pulley and the belt to pass
through the pulley face and fall to the ground. Between the crossbars are inclined, valley-
shaped recesses that prevent fine or granular material from being caught between the tail
pulley and the return belt. These valleys provide a self-cleaning function–there is less
surface area on which material can accumulate, and the turning of the pulley is intended to
throw accumulations off the pulley’s face.
If a conveyor handling such fine or granular material is likely to spill some of it onto the
return belt, the wing pulley can act as an effective device for removing spillage without belt
damage. Wing-type pulleys are also used on vertical gravity take-up, offering the same
benefits in this application.

Unfortunately, the uneven action of the winged tail pulley introduces an oscillating action to
the belt that negatively affects the belt line and belt sealing. This vibration makes it difficult to
effectively seal the loading zone. It would be counter-productive to design a transfer point
with an emphasis on belt stability to minimize fugitive material and then
install a winged tail pulley that defeats all that effort.

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 This type of pulley stresses the belt by creating bend points. Bending a belt in too small a
radius will cause stress on the top cover. This stress on the top cover will cause the rubber
to crack exposing the reinforcing material of the belt carcass.
Despite the design intention, wing pulleys are still subject to buildup and entrapment, and
often do not provide the desired protection. They are most successful on slow-moving belts
where cleaning and sealing are not critical requirements and for use with granular, free-
flowing materials. Wing pulleys should be avoided when handling sticky or wet materials.

Wrapped wing Pulley

NOT RECOMMENDED

A better choice than the conventional winged tail pulley is a spiral-wrapped wing pulley.
These pulleys have an additional steel strap wrapped in a spiral around the pulley
circumference over the top of the wings. The steel band is wrapped in a spiral from the
center out to each end of the pulley. Wrapping this band of steel around the wing pulley
allows the pulley to provide the self-cleaning function, but the wrapping of steel prevents the
“bounce” imparted to the belt, and the stress of the bend points.

Pulley Lagging

Lagging is recommended for drive pulleys for the following reasons:

1.Improved coefficient of friction. This permits a belt to be driven by lower slack side tension
and sometimes results in lower total tension.
2.Reduction of slippage due to wet conditions if grooved lagging is used.
3.Increased life for pulley and lower cover of belt.

Other pulleys in the system, especially those contacting the carrying side of the belt, are
often lagged to prevent build-up of material, and damage to the belt and pulley. Grooving is
intended to improve cleaning action on lagging and the belt.

Types of Lagging

Bolted Lagging

Bolted Lagging is usually fabric reinforced, the fabric being necessary to give proper bolt-
holding. This type has no inner or pulley cover. Where no grooving is intended, 1/8” top
cover is the proper minimum, but if the lagging is to be grooved a minimum of ¼” top cover
must be used.
Attachment methods include slotted bolts with tapped holes or self tapping screws for use in
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 welded steel pulleys. It is necessary that the bolt heads be sunk below the level of the
surrounding lagging to prevent damage to the belt at it passes over the pulley. This may be
accomplished by counter-sinking the holes in the pulley or, where the lagging cover is
greater than about 1/8”, it is possible sink the heads merely by tightening the bolts. Ends of
the strip should be bolted in a dovetail joint as shown in the following figure.
In addition, bolts should be used in rows running across the face and around the
circumference of the pulley no further than 10” apart in either direction. Edges of all strips
should be bolted down and it is recommended that all exposed fabric edges be cemented to
keep out moisture.

Vulcanized lagging

Vulcanized lagging is a sheet of rubber, usually ½” thick, bonded directly to the metal. No
fabric is used because no bolt-holding reinforcement is needed. It is much longer wearing,
has a more uniform adhesion to the pulley and eliminates the hazard of serious belt damage
due to a loose bolt.
This type of lagging can be applied in two different ways, Spiral method and sheet wrap
method.
Standard hardness go from 45 to 65 shores, High tension drive can go up to 70 shores with
higher manufacturing quality (dimension) of the lagging
This type of lagging is used for friction in drive, for other pulleys it can be use to avoid wear
or build-up

Replaceable pulley lagging

Replaceable pulley lagging is also available which features replaceable rubber pads that slip
into metal guides bolted or welded to the pulley.

Grooved lagging

Grooved lagging should be used on drive pulleys as they are liable to get wet in many
applications. The grooves break the film of moisture between the belt and lagging thereby
eliminating slippage. Either bolted or vulcanized lagging can be supplied with grooves. Either
type can be grooved in the field with a tire-groover if there is sufficient rubber to prevent
cutting into the fabric carcass or metal pulley. Herringbone and Chevron are the most
common groove patterns. Some specific designs have been developed e.g diamond… (see
below).

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 Ceramic lagging

Ceramic lagging is used for the heavy duty drive, where a high friction coefficient is required.
The ceramic tiles of different shapes are molded into a rubber lagging whereby the friction
coefficient is almost doubled.

Pulley specifications

Pulley diameters are determined according to the belt and the specific load and application
of the pulley, see unit 4 design basics

Manufacturing criteria are mainly dependent on the load on the pulley. Run out should be
below 0.5% of the diameter and for high tension application always below 0.7 mm
This criteria applies during the lifetime of the pulley.
Worn lagging and drums should be replaced.

Shafts and shell are designed to not bend when loaded and be resistant to load cycles
(fatigue criteria)

Drive arrangements

For specific applications with high tension, more than one drive is needed. Some examples
of arrangements are shown below:

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Standards:  Crown pulleys with specific lagging
 Proper design and manufacturing criteria

Impact if not  Inefficient operation, increased number of slipping problems

correct:  Breakdowns

Actions:  Correct design and maintenance

Unit  Check available design on the plant belts

Completion:
See site specific unit for additional information, respective actions and applicable safety instructions

"Lagging
Materials.zip"

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