English (UK) 
简体中文 Are you also in the headache: conveying line obviously full of horsepower, why the output is not on? The equipment is spinning loudly, but the material is like squeezing toothpaste like slowly moving? Don't be anxious! Today we will chatterFour hands-on optimisation solutionsMany factories use the direct efficiency improvement of 30% or more - the key is not burning money!
First, the equipment parameters tuning: speed & width is not just fill in!
Bandwidth (B) and band speed (v)This is a golden pair that directly determines the ceiling of the delivery volume. But a lot of people press on and don't get it:
- Double the bandwidth, triple the capacity.! For example, 500mm bandwidth carries about 200t/h of coal, replace it with 1000mm directly dry to 600t/h!
- Belt speed up 0.5m/s, efficiency up 30%! But don't speed up blindly - powder exceeding 1m/s raises dust, ore exceeding 2.5m/s increases wear and tear dramatically!
Ask yourself: Why isn't my speed up working?
Self-answer.Check the material cross-section! When the belt speed is mentioned from 1.5m/s to 2m/s:
- If section S = 0.3m² → Increment = 3.6 x 0.3 x (2 - 1.5) x 800 =432 tonnes/hour!
- If S is only 0.2m² → increment is only 288 tonnes
Not enough cross-section, speed for nothing!
The powertrain is a hidden test point.::
- 1 metre bandwidth for transporting ore.22kW motors are the bottom lineThe only way to handle peak loads is with 30kW.
- Screw machine speed over the critical value? The material "takes off" directly! Remember the formula:
n ≤ 30/(π√D)
Second, automation control: let the conveyor line itself "brain"
Add a PLC control systemIt's the equivalent of putting a brain on a conveyor line:
- Dynamic speed control: Sensors monitor the amount of material in real time, automatically speeding up when there is more and slowing down when there is less -Direct energy consumption reduction of 25%
- Clogging warning: Vibration sensor detects abnormal vibration and alarms 30 minutes in advance.Avoidance of production stoppage losses
Inverters are money savers::
- Automatic speed reduction when coal is low 50%.Save ￥3000+ on monthly electricity bill
- Conveyor line idling for more than 5 minutes? Automatic sleep standby
Ask yourself: it costs a lot of money to get on automation, doesn't it?
Self-answer.A small makeover with a big payoff! RetrofittingInfrared sensors + invertersI'll get it done in $10,000, and I'll get it done in $10,000.Less than half a year's payback.
III. Layout optimisation: bends and gradients are "efficiency killers"
Inclination over 15°? 15% discount on delivery!
- For each 1° increase in inclination, the efficiency decay is 0.5% -18° slopes carry 151 TP3T less grain than flat land yields
- Remediation programmes::
- Extra Long Distance PlusIntermediate drive motorPower loss is cut in half.
- Can't change the slope? changeDeep Grooved RollerElevated friction
Right angle bends = black hole of efficiency::
- 90° hard turns with 3 times the resistance.Conveyance Direct Drop 30%
- miraculous operation: Change the right angle bend toRound belt designThe efficiency of the seconds back to 90%!
IV. Maintenance: Avoidable failures of the 90%
Untimely dust removal = chronic suicide::
- Dust build-up increases resistance.Electricity bills rise by ￥2000+ per month
- Belt deflection due to jammed rollers.Deliveries Plunge 30%
Lubrication is the code for longevity::
- sprocketsMonthly greasingLife expectancy extended by 2 years
- For high temperature workshopHigh temperature resistant greaseReduces wear rate by 3 times
| Maintenance items | Consequences of laziness | correct handling |
|---|---|---|
| ash removal | Soaring electricity bills + overheated equipment | Weekly purging |
| Chain Lubrication | 3 months for a new chain | Monthly greasing + quarterly testing |
| bolt fastening | Parts fall off during operation | Tighten before start-up inspection |
Personal opinion: Don't be fooled by "experience"!
Do twelve years of production line transformation, seen too many people superstitious equipment parameters, but planted in theSudden change in material propertiesUp:
- Last month a cement factory complained about inefficiencies, and a check revealed that.Rainy day limestone moisture content soars from 5% to 15%, stack density up 12% - it's a wonder it doesn't clog up when run on dry material parameters!
- Another food factory carries starch in a screw machine.Sticky material gums up the bladesThe volume of conveyance was cut back...
Remember this golden formula::
Actual conveyance = Theoretical value × Humidity factor × Inclination factor × Maintenance factor
- Humidity > 10%? Factor times 0.9
- Inclination > 10°? Multiply coefficient by 0.95
- No maintenance for more than 3 months? Multiply by 0.8
Equipment is the skeleton, the material is blood, will breathe the conveyor line to run happy!
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