A brief discussion on how to improve the load capacity of belt conveyors

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The load-carrying capacity of a belt conveyor depends on many factors, such as the friction of the belt, the size and surface roughness of the drums, and the power of the motor, among others. Today, I would like to share with you the factors that affect the load capacity of belt conveyors. Through calculations and analyses regarding the load-carrying capacity of belt conveyors, the following conclusions can be drawn, which are useful for guiding the design of such conveyors: (1) Given a constant belt width and belt speed, the load-carrying capacity of the drive wheel of a belt conveyor is determined by the following factors: ① The tension T0 of the belt on the output side of the drive wheel; ② The friction coefficient μ0 between the drive wheel and the inner surface of the belt; ③ The wrap angle α between the belt and the drive wheel. (2) Effective ways to enhance the load-carrying capacity of a belt conveyor include: ① Increasing the tension T0 of the belt on the output side of the drive wheel. Raising this tension can improve the power transmission capability of the conveyor, but it also increases the working stress on the belt. As a result, the strength of the belt must be enhanced, which in turn raises the manufacturing cost of the belt. Therefore, this is not the best approach, and it is generally not used in practical engineering applications. ②Increasing the friction coefficient μ0 between the drive wheel of the belt conveyor and the inner surface of the belt is effective, as there is an exponentially increasing relationship between the maximum pulling force generated by the belt at the drive wheel and this friction coefficient μ0. Therefore, raising the friction coefficient between the drive wheel and the belt’s inner surface can significantly enhance the load-carrying capacity of the belt conveyor, and this is the method preferred in engineering applications. ③Increasing the wrap angle α between the belt of the belt conveyor and the drive pulley results in an exponentially increasing relationship between the maximum traction force exerted by the drive pulley on the belt and this wrap angle α. Therefore, increasing the wrap angle between the belt and the drive pulley can very effectively enhance the load-carrying capacity of the belt conveyor system, which is why this approach is preferred in engineering practice. By using a tensioning pulley and designing an appropriate tensioning position and adjustment direction for it, the belt wrap angle can be effectively increased, thereby enhancing the driving friction between the drive pulley and the belt. Increasing the belt angle means increasing the contact area between the belt and the drive pulley. Typically, in the design, the gradually increasing wrap angle between the drive pulley and the belt should be no less than 120°; this angle can be increased to 210°–230° after adjusting the tension pulley. ④Increasing the width of the belt conveyor belt essentially means increasing the contact area between the belt and the drive pulley, which in turn allows for an increase in the driving friction between the drive pulley and the belt. However, increasing the belt width not only raises costs but also takes up unnecessary extra space, so this method is generally not used. In summary, the most effective way to improve the load-carrying capacity of a belt conveyor is to ensure that there is a sufficiently large wrap angle between the belt and the drive pulley ； Increase the friction coefficient between the driving pulley and the inner surface of the belt as much as possible. Therefore, when designing belt conveyors, special attention should be paid to ensuring the wrap angle between the belt and the drive pulley; at the same time, the friction coefficient between the drive pulley and the inner surface of the belt should be increased as much as possible. The following measures can generally be taken to increase the friction coefficient between the drive pulley and the belt surface: (1) Designing and processing the surface of the drive pulley of the belt conveyor to have a textured surface, along with applying hardening treatments. (2) Change the material pairing between the drive wheel of the belt conveyor and the belt. For example, embedding a layer of rubber on the outer surface of the driving wheel is also a commonly used treatment method.