Installation Procedure for Balanced Spiral Woven Conveyor Belts

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Installation Procedure for Balanced Spiral Woven Conveyor Belts

Here’s a detailed and improved guide for installing Balanced Spiral Woven Conveyor Belts, tailored to include both Friction Drive and Position Drive modes. 

Preparation Before Installation

A successful installation begins with thorough preparation and inspection of the conveyor system. Follow these steps to ensure readiness:

1. Conveyor Structure Inspection:

   • ○ Shaft Alignment: Verify that all shafts are at 90° to the direction of travel and are perfectly horizontal.

   • ○ Roller Functionality: Ensure all rollers rotate freely without noise or resistance.

   • ○ Sprocket Positioning (for position-driven belts): Check that sprockets are aligned with the conveyor’s axis and correspond to the belt specifications.

   • ○ Supporting Surfaces: Confirm that belt supporting surfaces are smooth, level, and provide adequate clearance at the belt edges. Eliminate any protrusions or obstructions that could catch the belt.

   • ○ Take-Up Mechanism: Inspect the tensioning mechanism to ensure it functions smoothly and has sufficient adjustment range.

2. Belt Inspection:

   • ○ Examine the belt for twisted coils or deformed mesh due to packing or transit.

   • ○ Shake out or flatten any twisted coils manually before installation. Failure to do so can result in locked coils, leading to damage under tension.

3. Safety Precautions:

   • ○ Turn off the power supply and lock it out to prevent accidental startup.

   • ○ Ensure all personnel involved in the installation wear appropriate personal protective equipment (PPE), including gloves and safety glasses.

Required Tools and Equipment

To facilitate installation, ensure you have the following:

1. Safety glasses and work gloves

2. Flat-end pliers, side-cutting pliers, and needle-nose pliers

3. Cable ties, soft wire, or rope (optional, for securing components temporarily)

4. Pulling rope (optional, for long conveyor installations)

5. Tools for adjusting the conveyor belt take-up mechanism

6. Welding set for securing the belt edges at joints

7. Measuring tape and straight edge for alignment checks

8. Lubricant for moving parts (if applicable)

Detailed Installation Procedure

        1. Preparation and Preliminary Steps

        1.1. Ensure the electrical supply to the conveyor is turned off and locked out.

        1.2. Release the conveyor’s tensioning mechanism to its lowest tension setting to allow for maximum adjustment during installation.

        1.3. Confirm that the belt’s orientation is correct. Note that there is no specific top or bottom side, but the direction of travel should lead with the spiral welded to the crimp connector.

        2. Feeding the Belt Through the Conveyor

            Option A: Replacing an Existing Belt

1. Cut the old belt at the idle (non-drive) end.

2. Attach the new belt’s leading edge to the trailing edge of the old belt using cable ties or a similar method.

3. Slowly operate the conveyor at low speed to drive the new belt into place while simultaneously removing the old belt. Maintain slight tension to prevent slipping.

4. Once the new belt is fully in place, proceed to section 3.

            Option B: New Installation

1. Attach a steel bar to the leading edge of the new belt using cable ties or rope.

2. Secure a pulling rope to the steel bar and feed it through the conveyor to the discharge end.

3. Pull the belt manually or with mechanical assistance through the conveyor’s carryway section to the discharge end.

4. Feed the pulling rope back through the returnway section and pull the belt to the infeed end. Use slow-speed drive assistance if needed.

5. Once the belt is in place, proceed to section 3.

        3. Joining the Belt Ends

        3.1. Trim excess mesh while ensuring the correct right-hand and left-hand coil pattern. The left-hand coil on one end must align with the right-hand coil on the other.

        3.2. Temporarily tie the ends together using cable ties to facilitate joining.

        3.3. Insert a crimp wire through the intermeshing coils to join the belt ends. Ensure the wire passes through all coils evenly and maintains alignment.

        3.4. Cut the crimp wire to length and weld it securely to the edge coils, preserving the continuous pattern of the belt.

        Note: If the belt includes side guards or cross flights, ensure their pattern and construction align correctly before finalizing the joint.

        4. Final Adjustments and Testing

        4.1. Re-tension the belt gradually using the tensioning mechanism. Apply enough tension to ensure smooth operation without over-stressing the belt.

        4.2. Inspect the conveyor thoroughly to ensure no tools or debris remain on or inside the system.

        4.3. Remove the lockout tag and power on the conveyor. Perform a test run at low speed to check for smooth operation and correct alignment.

        4.4. Gradually increase the conveyor speed to its normal operating level, observing for any irregularities such as noise, vibration, or misalignment.

Additional Considerations

1. Long Belts: Some belts may be supplied in sections. Ensure proper alignment and joining of all sections during installation.

2. Positive Drive Systems: For sprocket-driven belts, disengage the motor or operate at slow speed to allow proper engagement of the belt with sprockets.

3. Side Chain-Driven Belts: Use the provided chain connecting links to maintain the side chain pattern when joining the belt.

Troubleshooting Common Issues

        1. Surging or Jerking (Slip-Stick Effect)

• Cause: This occurs when belt tension fluctuates due to low speed, high friction, or improper tensioning.

• Solution: Adjust belt speed, reduce tension, or modify belt support surfaces to reduce friction.

        2. Twisted Coils

• Cause: Twisted coils locked during tensioning or installation.

• Solution: Ensure coils are flattened or shaken out before tensioning.

        3. Misalignment

• Cause: Incorrect sprocket alignment or uneven tensioning.

• Solution: Realign sprockets and ensure even tension on both sides of the belt.

By following these comprehensive guidelines, you can ensure a smooth installation and optimal performance of the balanced spiral woven conveyor belt. For persistent issues, consult the manufacturer or a qualified conveyor technician.