Chapter Four – How does a Conveyor System Work?

Conveyor systems work as an integral part of a larger process. When explaining the function of a system, it is important to examine all aspects of the overall production process and how the various pieces fit together. Much of the determination of the workings of the system is set during the design phase. Once the system is in place, its inner workings become a complex moving process that is critical to the efficiency and success of an operation.

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How a Conveyor System Works

To limit the discussion of conveying systems, the information below focuses on belt conveying systems since they are the most common.

Belt:

Belt conveyors use a system of motorized pulleys that have a belt made of thick durable material looped over the pulleys. When the motor is activated, the belt is pulled between the pulleys.

Support System:

The support system allows the belt to move smoothly. It is specifically designed to hold the moving material without sagging. In the design phase, the weight capacity of the frame is determined and the frame is constructed to meet the needs of the operation.

Pulleys:

Conveyor belt systems have at least two pulleys to control belt movement, a drive pulley and tail or return pulley. In between them are idler or dummy pulleys that are moved by the belt. The drive pulley pushes or pulls the load, while the tail pulley returns the belt. As can be seen in the diagram, idler pulleys serve a variety of functions in guiding the belt, which include controlling its tension.

Belt Cleaner:

The purpose of a belt cleaner is to remove any carryback that may remain on the belt after the load is discharged from the belt. Carryback is common in all belt systems and is one of the major issues that causes belt malfunctions.

Drive:

The drive for the belt can be located in various positions in the conveying system. For most belt conveyors, the drive is located at the discharge or head of the belt. Other locations can be anywhere along the belt depending on the design. AC motors are generally used to power the pulley that moves the belt.

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This video will explain how a Rulmeca Motorized Pulley, three phase, squirrel cage, AC electric induction motor works, and how to troubleshoot it. These hermetically-sealed internally-powered conveyor drives are ideal in harsh operating conditions, especially when space is limited, and personnel safety is a concern.

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In this six-part video tutorial we will review drive power vs. belt pull, basic motor components, current flow in a stator, current flow vs. drive power, overcurrent and thermal protection, common causes of motor damage, how to check motors, and examples of damaged motors.

As presented in a previous Rulmeca video tutorial, we explained that it is essential to calculate effective tension (Te) or &#;belt pull&#; required to move a bulk handling conveyor, because knowing the belt pull will enable the designer to calculate the required power.

We know that once we have calculated Te in pounds (lbs) for a particular set of conditions and we know the belt speed in feet per minute (fpm), we can calculate required drive power using the equations below.

Required Power (in ft-lbs/min) = Te (in lbs) x V (in fpm)

1 HP = 33,000 ft-lbs/min

The basic components of an AC electric motor are a stator and a rotor. Notice that in a Rulmeca Motorized Pulley the rotor is directly coupled to the pulley shell through the gearbox.

This cross-sectional diagram illustrates the stator and rotor within a Rulmeca Motorized Pulley.

This cross-sectional diagram shows the motor directly coupled to either a two stage or a three-stage gearbox. The motor stator is &#;stationary&#; and the motor rotor &#;rotates&#; on two internal bearings, which are mounted in each of the two sides of the motor frame.

All Rulmeca Motorized Pulleys contain a certain quantity of oil. The oil serves to lubricate all of the mechanical parts and continuously cool the motor by pulling the heat away from the stator and transferring that heat into the conveyor belt through the pulley shell.

As the conveyor belt wraps around the face of the pulley, it continuously pulls heat from the face of the pulley and takes it away, dissipating the heat into the atmosphere.

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