English 
简体中文 Three belt lines in the corner of the factory squeezed into a twist? You have to pay tens of thousands of dollars more every month just to clean and spread the material? Don't worry! Today we will useReal-life remodeling casesThe company teaches you three tricks of “cost-cutting and space-grabbing”. Dried for fifteen yearsConveyor line designI dare say--The 90%'s are a waste of money for the factory to spend, but you can actually save money by changing the turnout sink!
I. Why do traditional programs burn money and take up space?
Splash cold water first.The first thing most plants do when they encounter a turnaround convergence is to “add equipment”! Two wire splices are not enough? Then make it three! And what happens?
- Double your electricity bill.: Each additional motor consumes 3,000 kWh of electricity per month.
- Maintenance kills.: Spreading and jamming of materials at the lapping point, workers carry shovels to clear the dust every day.
- lit. occupy an area like swallowing gold: A ceramics factory hard by the machine head machine tail ate 200 square meters of workshop
Case of blood loss: A coal mine in Shandong originally used two belt machine lap, total length of 655 meters with three motors. Later, it was changed to a single line of turning convergence.Equipment footprint cut by 401 TP3T, electricity bill dropped by 331 TP3T--Save enough money for a six-month bonus!
Second, the transformation of the first move: modular “Lego assembly techniques”
Ask.What about three lines crammed in a dead end?A: Split the whole system into three modules: “steering+reversing+receiving”., like putting together a Lego free-for-all!
Practical manual(Just copy it and it will work):
- steering module::
- coreShaped Planetary Roller CylindersWhen the steering wheel
- Inside rollers than outsideRaise 100-150mmCreate a natural curve
- Receiving Module::
- plusCushion roller set + polymer liner retaining edge(wet material does not stick to the wall)
- The guide chute is extended to 2/3 of the belt to prevent material from “jumping”.”
- Reorientation module::
- Universal bracket to adjust the angleThe whole thing can be broken at any time from 30° to 180°.
- Transition section roller spacing is increased to0.75-1 mAnti-collapse waist
Teacher stepping on the pit warning: Module connectionsBelt transition plate must be added! Last year a plant skipped this step and ended up with a mountain of mineral dust leaking out of the seams, and the cleanup was ten times more expensive than the parts!
Third, the transformation of the second move: mechanics of “four two pounds”
Ask.Forcing a turn breaks the belt and spreads the material?A: Don't fight the centrifugal force, learn to use it!
| local method | Scientific Labor Saving Program | How much do you save? |
|---|---|---|
| Anti runout vertical roller hard breaking | Inner curve elevation 3°-5° | Turning radius from 5m → 1.8m |
| Flat rollers | Side rollers inclined 12° forwardchafing | Spreading reduction 80% |
| It's all in the motor. | Natural direction change + pressure pulley | Motor power drop 25% |
Focus on the inner curve elevated - like a highway curve outside padding to prevent rollover. Jiangsu a feed mill in 8 square meters of dead space to play a god operation:
- Inside RollerSneak up 4°.(Never exceed 5°!)
- Encrypted rollers to0.8 m spacing
- Turning point plusVertical roller + belt pulley double insurance
Hardly three lines tucked into corners that were thought to be only for trash cans!
Fourth, the transformation of the third move: dynamic tuning “three axes”
Equipment loaded and still spreading?Remember the 24-word mantra.
No-load adjustment of internal bias, loading to see the floating belt, plugging to check the paddles
Zhejiang electronic factory actual combat record.
- feel the pulse on an empty stomach::
- Starting with the drive rollers.Single-point micro-adjustment of the angle of the rollers(Don't tune more than one at a time!)
- Let the belt run slightly against the inside to create a natural centripetal force
- Heavy Duty Anti-Spill::
- feed point plusspoiler (automotive)(Angled to flare)
- Full material sensorMust be installed! A factory to save this 3,000 dollars, midnight blockage burn motor lost 80,000 yuan
- emergency measures to protect one's life::
- Side stand rollers + laser guidingDual system (10 times faster than manual inspection)
- doTensioning Physical Examination: No-load sag <2% bandwidth, current fluctuation <15%
V. Dust control and reduction of hidden technology
A must see for dusty plants!After the renovation of the River North Cement Plant, the number of complaints from neighboring residents dropped by 901 TP3T:
- dust coverBuckles on the side panels, curved to fit the belt perfectly
- Bottom Air Seal: Blowing compressed air in the baffle sandwich, dust wants to escape? No way!
- The Ultimate Solution: Lower Dust Cover ConnectionFilter bag extraction system(Expensive but worth it, one year payback)
A final word of truth.
Seen too many factories over the yearsSpending money on new equipment but looking down on minor remodeling. Actually, yeah.Every penny saved by turning and converging is earned by dealing with the laws of physics.Next time you plan a production line, take a tape measure and measure the corners. Next time when planning the production line, might as well take a tape measure to measure the corners - to those “waste space” turn up, may be more cost-effective than buying a new plant! After all, good equipment is tuned out, not bought out, don't you think?
