English (UK) 
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 remodelling casesThe design of the conveyor line is a very important part of the design of the conveyor line, hand in hand to teach you three strokes "cost cutting, space grabbing" hard work. Dried fifteen years of conveyor line design, I dare to 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 programmes 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 points, and workers carrying shovels to clear the dust every day.
- lit. occupy an area like swallowing gold: A ceramics factory hard by the machine head machine tail to eat 200 square metres of workshop
Case of blood loss: A coal mine in Shandong originally used two belt conveyors with a total length of 655 metres with three motors. Later, it was changed to a single-line turnaround convergence.Equipment footprint cut by 401 TP3T, electricity costs down 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 the 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 metreAnti-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: the mechanics of the "four two catapults"
Ask.Forcing a turn breaks the belt and spreads the material?A: Don't fight the centrifugal force, learn to borrow from it!
| local method | Scientific labour-saving programmes | How much do you save? |
|---|---|---|
| Anti-runaway 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 steering + pressure pulley | Motor power drop 25% |
Focus on the inner curve elevated - like a motorway curve outside padding to prevent rollover. A feed mill in Jiangsu played a god operation in the 8m2 dead end:
- Inside rollersSneak up 4°.(Never exceed 5°!)
- Encrypted rollers to0.8 metre spacing
- Turning Points PlusVertical roller + belt pulley double insurance
Hardly three lines tucked into corners that were thought to be only for bins!
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 the same 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 yuan, midnight blockage burn motor lost 80,000 yuan
- emergency survival::
- 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 factories!After the renovation of the Hebei Cement Plant, the number of complaints from neighbouring residents dropped by 90%:
- dust coverBuckles on side panels, curved to fit belt perfectly
- Bottom Air Seal: Blowing compressed air in the baffle sandwich, the 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 modifications. 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, it may be worthwhile to take a tape measure to measure the corners - 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?
