English (UK) 
简体中文 Friends, do you have any of those big things in your workshop - heavy, heavy blocks of lead that take a lot of effort to move? Every day just to move them have to be specially equipped with two or three people, but also move the conveyor belt to the pressure on the nest? Hey, to put it bluntly, this is to the high load conveyor does not understand! Today we will chatter, against this lead "giant", how to rely on thetailor-madeof the conveyance programme in one move!
What's so difficult about high-load conveying? Why do we have to customise?
I know you've got a big head. Lead, it's heavy, it's soft, it's probably corrosive. Normal conveyor belts are fine for lightweight cardboard boxes, but this stuff? Gee, you'll be on strike in no time! Let's take a look at some of the most annoying potholes:
- Collapsed waist (structural fatigue)Ordinary steel plates and bearings can't take lead banging down on them all day long. Over time? Deformation and fracture are not a problem!Maintenance costs are going up.The production schedule owes it all!
- Foot slip (drive failure): Not enough friction? The motor roars through the belt is not moving! Or barely move, stop and go, slower than an old ox pulling a broken cart.Efficiency? Don't mention it!
- One wrong step at a time (runaway): A guy that heavy, with a slightly off centre of gravity, or a belt running out of control? Finished! Directly give you a sideways derailment, blocking the mother do not know.
- Gnashing of teeth (excessive wear and tear): The surface of the lead block may be rough? Or with a bit of acidic oil? Ordinary conveyor belts don't have a surface that can withstand abrasion, and in no time at all they'll be torn and tattered like a beggar's garment.Change it twice in three days? The cost is prohibitive!
See? All these problems are intertwined because of it.Too heavy and too specialUp! Common, standardised equipment? Not a chance. I can't do this job!Why do we have to customise? It's because "standard parts" can't stand up to the "unconventional pressures"!
How does a customised solution strike? The core three axes!
The reasoning is clear, then what? Customisation, the focus has to take care of these three keys! Let's step by step to break apart and crumble to see:
The first axe: hardening the "skeleton" (strengthening the infrastructure)
Imagine you want to build a house that can withstand a magnitude 8 earthquake, wouldn't the foundation and columns have to be thicker and thickened? The same goes for delivering lead blocks!
- "Bones" (frame) are strong enough: Absolutely no fooling around with that thin-skinned tin! It's got to be.Welded frames of thick-walled square steel or heavy-duty I-beams. The welding process also has to be excellent to ensureRigid enough, no deformationThis is like the beam of a house. It's like the beams of a house; if it's not strong, it's useless to be fancy on top.
- "Joints" (bearings, rollers) are ultra-durable: The one time the lead comes down, it's all about the rollers and bearings taking it hard. Don't save on that! You have to.Heavy-duty special roller (wall thickness 7-8mm or more) with oversized, high-precision roller bearings.The bearing sealing grade should also be high. Bearing sealing grade should also be high, don't let the dust in "sabotage".
- "Thighs" (drive systems) are powerful: It's right to go up in motor power!Inverter motors are preferredThe speed reducer can provide a strong starting torque, but it can also regulate the speed to save electricity. For gearboxes, go for the "big boys".Shock-resistant hardened gearheadsIt's only reliable.
Knockout focus.You really can't save money on this part! Structural strength is the lifeblood of the entire conveyor line.Save a dollar up front and you may have to spend ten to fix it later on! It doesn't pay!
Axe 2: Buffing the "conveyor belt" (optimising conveyor components)
Lead is not a brick, its surface can be sticky and uneven, and it can "chew" on the belt. Therefore, the "contact surface" needs to be carefully considered:
- "Skin" (conveyor belt) must be resistant to manufacturing: Ordinary rubber bands? It won't work! It's got to be.Wear-resistant tear-resistant belt made of thickened, steel mesh layer and high-density material. The exact thickness and material (e.g., patterned rubber, special PU, etc.) depends on the shape of your lead, the weight, whether it's corrosive or whatever.The wear layer must be thick enough!
- Friction should be "wild".: Worried about slipping? A few tricks of the trade:
- banded with a patterned face: diamond pattern, herringbone pattern, the coefficient of friction immediately goes up a few steps.
- Oversized wrap-around corner design: Let the conveyor belt wrap around the drive pulley a few more times for a tighter "hug"!
- Dual or multi-point drive: One motor not enough power? Just install a few more! Spread the power and be steady!
- "Shock-absorbing airbags" (cushioning design) have to have: The lead smash down point should be protected with focus! Add onHeavy duty buffer roller sets or polyurethane buffer bedsIt is like a spring pad for the conveyor belt, absorbing shock and protecting the equipment and the belt.Get the cushioning wrong and the life of the equipment is fractured straight away!
Third Axe: Installation of a "Super Brain" (Intelligent Control and Protection)
Want to make this big man obedient? You can't rely on brute force alone, you need to be a little "smart":
- Never go off course (Intelligent deflection correction system): Top priority! The lead weight is there, and runs are the norm.Powerful automatic hydraulic or mechanical guiding devices are standard.The sensors find the slightest hint of this and correct it immediately.Stability is guarded by it!
- Foolproof and error-proof (protective devices): what if it does fall off the chain (e.g., clogging, overloading)?
- Emergency Pull Cord Switch: Arranged along the conveyor line, with an immediate stop at the drop of a hat.
- Run-off switch, plugging switch: Automatic alarm shutdown when problems are found to avoid secondary damage to the equipment.
- "Armour" (protective sealing) overlay: Dusty and corrosive?Fully sealed enclosures for critical parts (drives, drums, motors).The material for the sealing and anti-corrosion coating (e.g. 316 stainless steel parts, sprayed anti-corrosion paint) must also be selected.
- Visible status (intelligent monitoring): Advanced points can be retrofitted with sensors for real-time monitoringMotor current, belt speed, bearing temperatureThe data is transmitted to the control room to anticipate risks and prevent equipment from "dying".
| crux of the matter | Standard equipment shortcomings | Customised hardcore programmes | Visible results of the solution |
|---|---|---|---|
| The structure can't take the strain. | Thin steel frames, lightweight roller bearings | Thickened frame + forged rollers + heavy duty bearings | Rock-solid equipment and longevityDouble Extension |
| Not enough power to tow it. | General motor reducer | High-power inverter motor + heavy-duty reducer | Might makes right.Runs like a thief without a break |
| The belt is afraid of abrasion and slippage. | Plain rubber band, small wrap-around corner design | Thickened abrasion-resistant belt + strong pattern + large wrapped corners / multi-driver | The belts are built to last.Friction pulls full without slipping |
| Fall in line and love to run off the rails | No/simple deflection correction | Powerful automatic guiding device | The lead is going in a straight line.No fear of overturning and clogging |
| look after one's health | Open design, no monitoring | Sealed protection + condition monitoring and warning | Protection in place saves worry and effort, early detection and treatment |
Personal opinion: is customisation worth the money? So worth it alright!
I've seen too many factories trying to save a little money, bought the so-called "high-strength standard conveyor line" to deal with lead. The result? Three days to repair! Losses caused by production stoppages, maintenance of labour and material costs, replacement of equipment scrap ... ... add up to the original step to engage in customization is definitely much more expensive! It's also a serious delay in production, delaying the delivery date, so the loss is incalculable!
Customised lead conveying solutions are, quite frankly, tailor-made to suit your workshop's "jack of all trades".Look at the initial investment may be higher, but calculate the long-term account - equipment with a long time, fault repair less, production smooth, worker safety is guaranteed, save the maintenance fee, production losses and labour costs, the money back is a matter of time, but also to pull up the productivity by a large margin! This cost-effective, simply!Don't wait until your equipment is on the ground and you're looking at piles of lead and stalled production lines before you regret it!Customise early for peace of mind and benefit!
