Conveyor Design Special Topic

Comprehensive conveyor design guide from basic theory to engineering practice

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Basic Theory

Conveyor Classification & Structure

Understand the working principles, structural characteristics and application scenarios of different types of conveyors.

Conveyor Classification and Structure

The most commonly used continuous conveying equipment, suitable for horizontal or inclined conveying of various bulk materials. It mainly consists of conveyor belt, idler rollers, drums, drive unit, tensioning device, etc.

Uses chains as traction and bearing components, suitable for conveying heavy bulk materials or finished products. Features simple structure, reliable operation and easy maintenance.

Pushes materials forward through rotating screw blades, suitable for conveying powdery and granular materials. Compact structure, good sealing performance, can achieve vertical, inclined or horizontal conveying.

Common Conveyor Type Comparison

Compare the advantages and disadvantages of different conveying forms to help you select the right type.

Type Advantages Disadvantages Application Scenarios
Belt High efficiency, low energy consumption, low noise Not suitable for high-temperature, high-viscosity materials Mining, ports, chemical industry, food processing
Chain High load capacity, strong adaptability Low speed, high wear rate Heavy industry, foundry, heat treatment
Screw Compact structure, good sealing Short conveying distance, material易破碎 (easy to break) Grain processing, chemical industry, building materials powder
Roller Simple structure, easy maintenance Only horizontal or small-angle conveying Logistics sorting, packaging lines

Calculation Tools

Conveyor Power Calculation

Calculate the required drive power for conveyors.

Conveyor Power Calculation
P = (Q × v × 9.8 × k) / (3600 × η)
Where k=1.2 (Comprehensive Resistance Coefficient)

Drum Diameter Calculation

Calculate the recommended drum diameter based on conveyor belt type.

D ≥ K × Z
Rubber belt: K=125, PVC: K=100, Steel cord: K=150×d (mm)

Conveyor Belt Tension Estimation

Estimate the minimum tension of conveyor belt (for tensioning device selection reference).

Fmin ≈ 1.5 × (q + qb) × g × L × μ'
Simplified estimation, qb=10kg/m, μ'=0.03

Motor Starting Torque

Calculate the required starting torque of motor shaft.

T = 9550 × P / n × K

Motor Selection Steps

  1. 1. Determine Load Characteristics
    Analyze load type, working environment (temperature, dust), determine duty cycle (S1-S10) and protection class (IP54/IP55).
  2. 2. Calculate Required Power
    Calculate shaft power P using the calculation tools.
  3. 3. Consider Safety Margin
    Select safety factor 1.2 ~ 1.5. P_motor ≥ P × safety margin.
  4. 4. Determine Pole Number/Speed
    Determine motor speed based on belt speed and reduction ratio (usually 4-pole 1450rpm or 6-pole 960rpm).

Structural Design

Drum Structural Design

Drum Composition
  • Shell (Q235/Stainless Steel)
  • Web/Hub
  • Shaft (45#/40Cr)
  • Bearing Housing
  • Sealing Components
Design Key Points
  • Shell thickness is usually 8-14mm
  • Shaft needs torsion and bending strength check
  • Expansion sleeve connection is recommended
  • Drive drum is recommended to be lagged (diamond/herringbone pattern)

Bearing Selection Key Points

Common Types
  • Spherical Roller Bearing (222/223 series): High load capacity, allows certain misalignment, suitable for fixed/redirect drums.
  • Deep Groove Ball Bearing (63 series): Suitable for high-speed, light-load idlers or small drums.
Life Formula
Lh = (10^6 / 60n) × (C/P)^p

p=3 (ball bearing) or 10/3 (roller bearing)

Tensioning Device Design

Common Forms
  • Screw Tensioning: Simple structure, small stroke (≤0.5m), suitable for short conveyors (<30m).
  • Counterweight Tensioning: Automatic constant tension, suitable for medium and long distance conveyors.
  • Hydraulic/Winch Tensioning: Large stroke, high automation, suitable for large conveyors.
Tensioning Stroke Estimation

Usually 1% ~ 1.5% of conveyor length, and not less than 0.5m. Need to consider belt elongation.

Troubleshooting

Belt Misalignment

Main Causes
  • Improper parallel installation of drums and idlers
  • Improper material feeding point
  • Uneven belt splice
  • Frame distortion
Solutions
  • Install self-aligning idlers
  • Adjust head/tail drums
  • Optimize guide chute and add baffles

Belt Slippage

Main Causes
  • Insufficient tension
  • Worn drum lagging or presence of water/oil
  • Severe overloading
Preventive Measures
  • Check and adjust tension stroke
  • Clean or re-lag drums
  • Install slip protection device

Belt Tearing

Main Causes
  • Sharp materials (steel bars, drill rods) getting stuck
  • Severe belt misalignment scraping against frame
  • Idler falling off and getting caught
Protective Measures
  • Install magnetic separators/grilles at feeding points
  • Install anti-tear switches
  • Use anti-tear mesh core belts