Main parts

Pulleys
There is quite a broad variety of pulleys in terms of items, aim and design specifications. Either a removable rubber lining is installed on the working surface of the shell of the pulleys, or a ceramic lining with a longer service life is glued in case of increased requirements. A distinctive feature of the design of the pulleys are various options for connecting the shaft to the hub:

  • by means of a wedge expanding element (KTV and others), which simplifies disassembly during repair;
  • landing of the hub on the key.

The bearings (produced by MPZ, SKF, FAG) are chosen with a sufficient reserve under the designed load. Various effective methods of protecting bearing assemblies from external contamination are used - labyrinth and lip seals.

Drive pulley with ceramic lining.
The shell size is 1,250x1,600 mm.
The shell on the shaft is fixed by the KTR release elements.
The bearing size is 3003264.
Split bearing housings.
Installation of semicouplings with release element.

Discharge pulley with ceramic lining.
The shell size is 1,000 x 1,600 mm.
The shell size is 1,250 x 1,600 mm.
The shell on the shaft is fixed by the KTR release elements.
The bearing size is 3652.
Split bearing housings.

Rigid reliable pulley design - welded shell (sheet up to 40 mm), cast hubs, a stiffening rib is installed.
Bearings 3644, 3652, 3664, roller double-row self-aligning.
It is allowed to tilt / rotate the housings up to 3 degrees when installed on the conveyor (complete set of installation inaccuracies).
The bearing housings are split, which simplifies disassembly when replacing bearings.
Bearing units have a combined reliable protection against external contamination, a cup and labyrinth seal with an independent system for supplying grease to the bearing cavity and the labyrinth.

The service life of the pulley, subject to the lubrication schedule, is up to 15 years.

Drive stations

The drive station of the conveyor belt consists of a frame of drive pulleys connected by a low-speed coupling with a drive unit, which is equipped with a gearbox, motor, high-speed coupling.

Drive stations of various modifications are manufactured depending on the types of equipment included (installation of up to 4 drive pulleys).

At the request of the customer, the drive stations of the conveyor belt can be equipped with imported units. Unloading and driving sections, intermediate sections with loading (wrench fault).
A centralized lubrication system for pulley bearings is installed.

The drive station of a belt conveyor with a belt width of 1,000 mm.
Number of drive pulleys 2 pcs
Diameter of drive pulleys 630 mm
lining of pulleys ceramics
The speed of the belt movement 2,5 m/s
The drive station of a belt conveyor with a belt width of 1,600 mm.
Installed drive power 4x500 kw
Number of drive pulleys 4 pcs
Diameter of drive pulleys 1000 mm
Lining of pulleys ceramics
The speed of the belt movement 3,15 m/s
The drive station of a belt conveyor with a belt width of 1,600 mm.
Installed drive power 1x500 kw
Number of drive pulleys 1 pc
Diameter of drive pulleys 1000 mm
Lining of pulleys ceramics
The speed of the belt movement 4 m/s
The drive station of a belt conveyor with a belt width of 1,400 mm.
Installed drive power 400 kw
Number of drive pulleys 1 pc
Diameter of drive pulleys 1000 mm
Lining of pulleys ceramics
The speed of the belt movement 3,15 m/s

Unloading and unloading-drive sections

designed to secure the unloading pulley through which the transported rock mass is unloaded. Belt cleaners are fixed on the frame. There are two options for the manufacturing of the unloading section:

  • rigid with a thrust into the roof and soil;
  • unloading retractable boom, adjustable in length and height.
    It is possible to combine the unloading section with the drive section.
Unloading and driving section of the conveyor with a belt width of 1,200 mm.
Shell diameter 800 mm
The bearing size 3632
Frame mounting into the roof and soil
Lining of pulleys ceramics
Unloading and driving section of the conveyor with a belt width of 1,000 mm and an adjustable boom height
Shell diameter 500 mm
The bearing size 3526
Drive pulley
Shell diameter 630 mm
The bearing size 3632

Drive units

One of the main units of the conveyor is a drive unit, which consists of a gearbox, electric motor, brake device and connecting elements. The reliability of the operation of the units largely defines the reliability of the conveyor as a whole.

PBU 1000 drive unit
Gearbox Flender B3SH 15 i = 20
Electric motor MORLEY, GM60 E400/800,
400 kw, 1500 1,500 rpm.
Turbo coupling CKRBW 21
Disc-type brake USB 3-I
3-FVB drive unit
Gearbox Flender B3SA 14 i = 20
Electric motor MORLEY, GM66 E400/800,
500 kw, 1500 rpm.
Low-speed coupling RFK 250
Disc-type brake USB 3-I
3-FVB drive unit
Gearbox MOVENTAS, D3 RST 82X0 i = 20
Electric motor MORLEY, GM66 E400/800,
500 kw, 1500 rpm.
Low-speed coupling RFK 210
Disc-type brake USB 3-I

The manufactured drive units are equipped with gearboxes David Brown (England), Flender (Germany), Moventas (Finland), electric motors of both domestic and foreign production – Morley (UK), Ruselprom (Russia), ABB (Germany), EMIT (Poland), Damel (Poland), WEG (Brazil), Orlan (China), PEMZ (Lugansk), Electromash (Moldova) with a power of 160 – 1000 kW and voltage of 660/1140 V, 6000 V, with independent air and liquid cooling. Using this equipment increases the reliability of the belt conveyors.

Active hoists

The use of active (automatically controlling the tension of the conveyor belt) winches ensures the tension of the belt at a given level. This is achieved through the use of a strain gauge and a frequency converter.

Conveyor hoist with a belt width of 1,600 mm

  • The use of an active hoist allows you to achieve the following results:
  • reduction of the dynamic load on the belt (the joints of the belt last longer);
  • reduction of the dynamic load on the belt (the joints of the belt last longer);
  • due to tension control, the possibility of slipping of the drive pulleys is eliminated, as a consequence the service life of the lining increases;
  • rapid damping of the stretching wave in the belt:
  • no popping of the belt on the telescope.

The greatest effect from the use of an active winch is manifested on long high-loaded conveyors.

Linear support

Designed to support the conveyor belt.

  • The main advantages:
  • provides fast rewiring due to the use of bolt-free connections;
  • provides maximum protection of the belt from longitudinal gust;
  • provides maximum receiving capacity due to the angle of inclination of the side rollers of 35 degrees;
  • reliability and durability in operation.

Several standard sizes of supports for the width of the belt 800, 1,000, 1,200, 1,400, 1,600 mm have been developed and produced.

Conveyor linear support structure with a belt width of 1,000 mm.

Conveyor linear support structure with a belt width of 1,600 mm.

Manufactured conveyors

  • The manufactured conveyors could be equipped with:
  • platforms for stepping on and off while transporting people;
  • automation and control system;
  • efficient belt cleaning systems;
  • centralized automatic lubrication system.

Feeder

  • The feeder is aimed at working with bulk materials with the following specifications:
  • Volumetric mass, t/ m3 from 0.5 to 2.0;
  • Grain size of the material from 0.1 to 10*;
  • Water content, % not higher than 15;
  • Temperature of the material, degrees, not higher than +150 (200)**

*It is possible to manufacture a feeder with a deviation from the stated sizes, if required.

**At short-time feeding.

The feeder is aimed at transporting and batch-loading of bulk materials in the process lines of metallurgic, cement, mining, enrichment, construction and other industries.

The feeder can be used within the dosage systems.

Lining

The enterprise has its own production line for lining surfaces of varying complexity, including surface and underground pulleys of belt conveyors. The personnel of the enterprise was trained under the guidance of German specialists.
The material used for the lining is ceramics supplied by Germany, the leading ceramics manufacturer.