How to design high efficiency belt assembly line? Selection Guide and Case Studies

First, first understand: your material is what temperament?

Selection of the first step is not to look at the equipment, but to find out what your "goods" character!

• ​particle sizeSmall particles (such as grain, sand and gravel) are recommended to use high-speed belts (2-4m/s), while large materials have to be slowed down to prevent splashing.
• ​Wet or not, sticky or notWhat's the best way to do this? Sticky materials (e.g. chemical raw materials) have to be selected with anti-stick belts + additional scraper cleaner.
• ​Weight and shapeHeavy goods (such as car parts) have to be thicker belts (≥6mm), light and small parts (such as electronic components) with thin models (1-3mm) more energy-saving!

​Case overturning scene: A factory used ordinary belt to transport ore, and the result was that it wore out in half a year! Later, it was replaced by steel rope core belt + buffer rollers, and the life span was directly doubled.

Second, three parameters determine life and death: speed, width, layout

1. How do I adjust the speed so that I don't roll over?

2. Wrong choice of width all white!

Take a chestnut 🌰:

• Shipping 20mm screws?300mm wide belt is enough​
• Shipping 1 metre of steel plate?At least 800mm wideWe'll have to add a baffle to prevent it from falling off.
  ​lazy formula: Bandwidth = Maximum material size x 1.5 + 100mm (safety margin)

3. Money-saving tips on layout

• ​Don't be stingy with the turning radiusThe radius of a 90° turn is ≥ 8 times the bandwidth (e.g. R4000mm for a 500mm bandwidth), otherwise the edge of the belt wears out quickly.
• ​Don't climb more than 15°.! Slope > 12° must be added non-slip belt
• ​Space saver: Use ofZ-stacked layoutThe upper and lower lines share the same bracket, the height of the plant saves 30%.

Third, how do you build a core component? Remember these 5 rules

​Question and answer time​
Q: What should I do if the belt runs out of alignment?
A: Three steps to save your life -
①Adjustment of rollers: Calibration with laser level, height difference ≤1mm
②Installation of deflection wheels: Pneumatic automatic deflector response speed <0.5 sec.
(iii)adaptor: Vulcanised joints have lower eccentricity than mechanical joints 80%

Q: What should I do if the motor keeps burning?
A.Tension was miscalculated!Remember the golden formula.Tension = belt length x 0.5%(50kg force is needed for 10m line). Add another wireless tension sensor and mobile phone APP alarm doesn't smell good?

​List of mandatory parts::

1. ​driving wheel: Measure the thickness of the rubber layer every week (replace it immediately if it is less than 3mm).
2. ​rolls: listen for noise twice a month (lubricate if it jams)
3. ​sweeper: Scrape the residual material before the end of each day (the sticky material is more than 5mm, hurry to clear it).

Fourth, anti-blocking and anti-collapse practical skills

New to the industry brother most afraid of plugging downtime? Try these tricks:

1. ​Anti-blocking three-piece set::
   • Vibrators (anti-clumping of materials)
   • Ramp guides (anti-stacking)
   • Infrared blockage sensor (automatic shutdown for offsets >5mm)
2. ​Tear prevention is a must::
   • fringe plusAnti-tear wire rope​
   • headerladdered lap(Higher strength than direct bond 60%)
3. ​Money Saving Maintenance Method::
   

   A food factory lays underneath the beltTeflon coated palletsThe coefficient of friction was reduced by 70%, saving $120,000 in annual electricity costs!

V. Case review: car factory to save millions of tawdry operation

The belt line was designed for a new energy plant last year and their original proposal was:

• Linear layout covers an area of 500m2
• Normal motor + mechanical tensioning
• Manual fault patrol

Let's optimise it:
✅Change to a U-shaped loop layout→ Provincial 40%
✅Hydraulic tensioning + inverter motor→ Energy consumption down 35%
✅Retrofitting of vibration sensors→ 3 hours advance warning of failures
And what happened? First year of productionSaved $800,000 on repairsDowntime has dried up from an average of 8 hours per month to less than 1 hour!

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And finally, a little bit of truth.

Designing a beltline is like fitting a computer -Don't just look at how good the CPU (motor) is, the memory (belt) and cooling (lubrication) have to keep up as well!Three things for newbies to remember:

1. ​Take a sample of material for testing first(Don't believe the manufacturer's promises.)
2. ​Leave 10% power margin(Prevention of production increases during peak seasons)
3. ​Monthly tension calibration(10 times cheaper than repairing it after the fact)
   Remember that brothers.Good design is not about piling up parameters, it's about dumbing down the production line - there's no way to tell!(meaning so few faults that there's no chance to complain 😉 )

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The data in this article comes from industrial field measurements and public technical white papers, individual parameters may fluctuate due to differences in working conditions.