High Performance Pulley for Belt Conveyors
Our company has adopted proprietary technology and equipment imported from German PWH company for the design and manufacturing of various pulleys . As a key component of the conveyor, the pulley should have high reliability. Our company’s R&D center has improved the pulley structure, reduced structural stress, and increased the lifespan and reliability of the pulley group through finite element analysis and optimization calculations. Our company’s pulley is manufactured from specialized high-end manufacturing equipment and has achieved serialized and large-scale production.
We have produced conveyor pulleys for belt width up to 2.4 m, pulley diameter up to 1.8 m, and maximum tension up to 300 tons.
|smooth, ordinary rubber, wear-resistant rubber, UHMW-PE, rubber ceramic, etc..
|glued or casted
|light, medium and heavy type
|Shafts and wheels of the medium and heavy-duty pulley are connected by expansion sleeves.
|made of Q235B carbon steel, with high roundness and straightness ensuring rotation balance
|45 # round steel or according to your requirements;
ultrasonic inspection, quenching and tempering treatment, strict control of key fit size tolerances, greatly extending service life.
|Havalo, SKF, FAG, SNK or according to your requirements
|Integral bearing seat, partial bearing seat
|bright red paint or according to your requirements
VARIOUS TYPES OF PULLEY ADHESIVE SURFACE
BEARING SEAT MODE
TECHNICAL SPECIFICATIONS & PARAMETERS
|Technical Parameters for Belt Conveyor Pulley
|Belt Width (mm)
|Pulley Standard Diameter without Adhesive Layer(mm)
|Outer Circle Diameter D Deviation
| 200 ≤ 1.5
400 ≤ 2.0
1000 ≤ 2.5
|Radial Runout of Outer Circle
| D ≤ 200 ; without adhesive 0.3 ;with adhesive 0.5
200 < D ≤ 800 ; without adhesive 0.6; with adhesive 1.1
800 < D ≤ 1600 ; without adhesive 1.0; with adhesive 1.5
1600 < D ≤ 1800 ; without adhesive 1.5; with adhesive 2.0
|Static Balance Accuracy
PROCESS FLOW OF PULLEY
Our company is equipped with necessary equipment for processing pulleys, such as large oil pressure machines, rolling machines, specialized pulley automatic explosive welding operators, large diameter lathes, boring machines, ultrasonic flaw detectors, static balancing devices, pressure casting machines, etc. Due to the special correction process adopted by the company, the pulley pipe skin is rounded before processing, and the pulley pipe wall is uniform after processing, thereby ensuring that the pulley has high static balance performance and high mechanical performance.
For pulleys with complex forces, large loads and used in heavy working conditions, they all adopt a cast welded structure and expansion sleeve connection. Compared with traditional drums in China, this type of drum mainly has the following characteristics :
(1) The structural parameters of the pulley are advanced and reasonable, and there is a dedicated computer calculation program to determine the shaft diameter, cylinder skin thickness, wheel amplitude plate shape and spacing, as well as the position of the circumferential weld seam set at the position where the stress is minimum and the number of cycles is minimum.
(2) The key technology of using single sided welding and double sided forming ensures the quality of the weld seam.
(3) The expansion sleeve connection is used between the drum hub and shaft, which not only solves the problem of key connection stress concentration that has been existing for many years and the technical difficulties of manufacturing and installing axial double keyways, but also achieves overall quenching and eliminates welding internal stress.
(4) The circumferential and longitudinal welds of the pulley have undergone non-destructive testing, and the casting quality of the wheel hub has undergone magnetic particle or ultrasonic testing.
(5) The total radial runout of the outer circle after roller casting is less than 1mm.
(6) All drums undergo static balance tests before leaving the factory to achieve G40 accuracy.
(7) All driving pulley and directional pulley with high stress have undergone finite element analysis to ensure that the stress and strain of the rollers meet the requirements.
Due to a series of measures taken, the pulley group produced by SK has a reasonable structure, large bearing capacity, and reliable performance. And it overcomes the problem of fatigue fracture at the welding seam of the existing pulley plate in China. The pullley (including the welding part) is guaranteed to have a rotational fatigue strength of over 108°.
WORKSHOP OF FINISHED PULLEIES
PACKAGE AND DELIVEYR
CONVEYORS EPC/BOT CONTRACTING CAPABILITY
VARIOUS CONVEYOR SPARE PARTS SUPPLY
AERIAL VIEW OF OUR FACTORY
INTELLIGENT PRODUCTION & TESTING
CERTIFICATES & HORNORS
BRANCHES & OFFICES
LONG-TERM STRATEGIC COOPEATORS
DOMESTIC & OVERSEAS EXHIBITIONS
GLOBAL BUSINESS NETWORK
|Smooth, Rubber or Ceramics
|Chemical Industry, Grain Transport, Mining Transport, Power Plant, Port, Dock, Energy, Cement, Metallurgy, Steel
Can drive pulleys withstand extreme environmental conditions?
Drive pulleys are mechanical components used in various systems to transmit power and motion. They are commonly found in industries such as manufacturing, mining, and agriculture. The ability of drive pulleys to withstand extreme environmental conditions depends on several factors, including the materials used, the design and construction of the pulley, and the specific conditions it is exposed to.
In general, drive pulleys are designed to be durable and capable of operating under a wide range of environmental conditions. They are typically made from materials such as steel, cast iron, or aluminum, which offer good strength and resistance to wear and corrosion. These materials can withstand moderate to high temperatures, as well as exposure to moisture, dust, and other contaminants.
However, there are limits to the environmental conditions that drive pulleys can withstand. Extreme temperatures, such as those found in extremely hot or cold environments, can affect the performance and lifespan of the pulleys. High temperatures can cause thermal expansion, which may lead to misalignment or excessive wear. Cold temperatures can make materials more brittle and prone to cracking or breaking under stress.
In addition to temperature, other environmental factors such as humidity, corrosive substances, and abrasive particles can also impact the performance of drive pulleys. High humidity levels can promote corrosion, especially if the pulleys are not properly protected or coated with suitable protective finishes. Corrosion can weaken the pulley’s structural integrity and lead to premature failure.
Abrasive particles, such as dust or grit, can cause wear and tear on the pulley’s surface and the belt that runs on it. This can result in reduced traction and slipping, affecting the efficiency and reliability of the system. Proper maintenance and regular cleaning can help mitigate the effects of abrasive particles.
It’s worth noting that some applications may require special types of drive pulleys specifically designed to withstand extreme environmental conditions. For example, in industries where pulleys are exposed to chemicals or highly corrosive substances, pulleys made from stainless steel or other corrosion-resistant materials may be used.
In conclusion, while drive pulleys are designed to be robust and capable of withstanding a wide range of environmental conditions, there are limits to what they can endure. Extreme temperatures, humidity, corrosive substances, and abrasive particles can all impact the performance and lifespan of drive pulleys. It’s important to consider the specific environmental conditions and select pulleys that are suitable for the intended application.
What safety considerations should be kept in mind when using drive pulleys?
When using drive pulleys, it is essential to prioritize safety to prevent accidents, injuries, and equipment damage. Here are important safety considerations to keep in mind:
1. Guarding and Enclosure:
Drive pulleys should be properly guarded and enclosed to prevent accidental contact with moving parts. Guards and enclosures should be designed and installed in accordance with applicable safety regulations and standards. They should effectively restrict access to the pulley and associated belts or chains, reducing the risk of entanglement or entrapment. Regular inspection and maintenance of guards and enclosures are necessary to ensure their effectiveness and integrity.
2. Lockout/Tagout Procedures:
When performing maintenance, repair, or servicing tasks involving drive pulleys, proper lockout/tagout procedures must be followed. Lockout/tagout procedures involve isolating the power source, locking out the energy supply, and using tags to communicate the equipment’s inoperable status. This ensures that the drive pulley and associated machinery cannot be accidentally started or operated while maintenance work is being conducted, protecting personnel from unexpected hazards.
3. Training and Education:
Personnel involved in operating, maintaining, or working near drive pulleys should receive proper training and education on safe practices. They should be familiar with the potential hazards associated with drive pulleys and understand the safe operating procedures, including the use of personal protective equipment (PPE), lockout/tagout protocols, and emergency response measures. Ongoing training programs should be implemented to keep personnel updated on safety best practices.
4. Risk Assessment and Hazard Identification:
A comprehensive risk assessment should be conducted to identify potential hazards and risks associated with the operation and maintenance of drive pulleys. This assessment should consider factors such as pinch points, entanglement hazards, electrical hazards, and potential for material spillage or falling objects. By identifying these risks, appropriate control measures can be implemented to mitigate the hazards and ensure a safe working environment.
5. Maintenance and Inspection:
Regular maintenance and inspection of drive pulleys are crucial for safety. Routine inspections should be performed to check for signs of wear, damage, or misalignment. Any issues identified should be promptly addressed, and damaged or worn components should be replaced. Lubrication requirements should be followed to maintain smooth operation and prevent overheating. Adequate records of maintenance and inspections should be maintained for reference and compliance purposes.
6. Ergonomics and Body Mechanics:
When working with drive pulleys, proper ergonomics and body mechanics should be observed to minimize the risk of strain or musculoskeletal injuries. Personnel should be trained in proper lifting techniques, avoiding excessive bending, lifting heavy loads, and maintaining good posture. Mechanical aids, such as hoists or lifting equipment, should be used when handling heavy pulleys or components to reduce the risk of injuries.
7. Warning Signs and Labels:
Appropriate warning signs and labels should be placed near drive pulleys to communicate potential hazards and provide safety instructions. These signs should be clearly visible and easy to understand. They may include warnings about rotating parts, entanglement hazards, pinch points, and required PPE. Warning signs and labels serve as visual reminders to personnel and visitors to exercise caution and follow safety protocols.
8. Emergency Stop and Emergency Response:
Drive pulley systems should be equipped with emergency stop controls that can quickly shut down the equipment in case of emergencies or hazardous situations. Personnel should be trained on the location and operation of emergency stop buttons. Additionally, an emergency response plan should be in place, outlining procedures for addressing accidents, injuries, or equipment malfunctions. This plan should include protocols for providing first aid, reporting incidents, and evacuating the area if necessary.
In summary, ensuring safety when using drive pulleys is of paramount importance. This involves proper guarding, lockout/tagout procedures, training personnel, conducting risk assessments, performing regular maintenance and inspections, observing ergonomics, using warning signs, and having emergency stop controls and response plans in place. By following these safety considerations, the risks associated with drive pulleys can be minimized, promoting a safe working environment.
How does the size and design of a drive pulley affect its performance?
The size and design of a drive pulley have a significant impact on its performance and the overall operation of a power transmission system. The size and design of a drive pulley influence various aspects such as speed, torque, power transfer efficiency, belt or chain life, and system reliability. Here are the key ways in which the size and design of a drive pulley affect its performance:
1. Speed and Torque:
The size of a drive pulley directly affects the speed and torque of the power transmission system. A larger pulley diameter results in higher belt or chain speed and lower torque output. Conversely, a smaller pulley diameter increases torque output but reduces belt or chain speed. By selecting the appropriate pulley size, the system can be optimized to achieve the desired speed and torque requirements for the driven components.
2. Mechanical Advantage:
The design and size ratio between the driving and driven pulleys determine the mechanical advantage of the power transmission system. By using different-sized pulleys or multiple pulley arrangements, the mechanical advantage can be increased or decreased. This affects the force or torque that can be transmitted from the driving source to the driven components. The mechanical advantage provided by the pulley design influences the system’s ability to handle loads or resistance efficiently.
3. Power Transfer Efficiency:
The design and size of a drive pulley impact the power transfer efficiency of the system. An appropriately sized pulley with the right groove profile facilitates proper belt or chain engagement, reducing slippage and power losses. A well-designed pulley minimizes friction and improves the grip between the pulley and the belt or chain, enhancing power transmission efficiency. Proper pulley design, such as V-grooves or toothed profiles, ensures efficient power transfer and reduces energy losses.
4. Belt or Chain Life:
The size and design of a drive pulley can significantly affect the life and durability of the belt or chain used in the power transmission system. Improper pulley design, such as sharp edges or inadequate groove profiles, can cause premature wear and damage to the belt or chain. Additionally, excessive belt tension resulting from an undersized pulley can lead to accelerated belt wear. Choosing the correct pulley size and design helps optimize belt or chain life, reducing maintenance costs and downtime.
5. Vibration and Noise:
The size and design of a drive pulley can influence the level of vibration and noise in the power transmission system. Improperly designed or unbalanced pulleys can introduce vibration, leading to increased wear and reduced system performance. The design of the pulley, such as the groove profile and the use of vibration-damping materials, can help minimize vibration and noise, ensuring smoother operation and improved system reliability.
6. Belt or Chain Tension and Alignment:
The size and design of a drive pulley affect belt or chain tension and alignment in the power transmission system. An undersized pulley can result in excessive belt or chain tension, leading to increased wear and reduced efficiency. Proper pulley design, including adequate groove width and profile, ensures optimal belt or chain engagement, minimizing tension and alignment issues. This promotes longer belt or chain life and reduces the risk of premature failure.
7. System Compactness and Space Constraints:
The size and design of a drive pulley also play a role in system compactness and space constraints. In applications where space is limited, smaller pulleys may be preferred to achieve the desired speed and torque. Conversely, larger pulleys may be required to accommodate higher power requirements or to optimize the mechanical advantage. The compactness and size of the pulley design should be considered to ensure proper installation and efficient use of available space.
In summary, the size and design of a drive pulley have a significant impact on its performance. They influence speed, torque, power transfer efficiency, belt or chain life, vibration, noise, tension, alignment, and system compactness. Careful consideration of these factors is essential in selecting the appropriate pulley size and design to optimize the performance, reliability, and efficiency of the power transmission system.
editor by CX