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.
|Adhesive Material||smooth, ordinary rubber, wear-resistant rubber, UHMW-PE, rubber ceramic, etc..|
|Adehensive Treatment||glued or casted|
|Carrying Capacity||light, medium and heavy type|
|Connection Mode||Shafts and wheels of the medium and heavy-duty pulley are connected by expansion sleeves.|
|Pulley Pipe||made of Q235B carbon steel, with high roundness and straightness ensuring rotation balance|
|Shaft||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.
|Bearing Brands||Havalo, SKF, FAG, SNK or according to your requirements|
|Bear Seat||Integral bearing seat, partial bearing seat|
|Color||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)|
|1||Outer Circle Diameter D Deviation|| 200 ≤ 1.5
400 ≤ 2.0
1000 ≤ 2.5
|2||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
|3||Static Balance Accuracy||G40|
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
|Manufacturing Process:||Forging, Casting|
|Surface Treatment:||Smooth, Rubber or Ceramics|
|Application:||Chemical Industry, Grain Transport, Mining Transport, Power Plant, Port, Dock, Energy, Cement, Metallurgy, Steel|
Are there different types of drive pulleys, and how do they differ in their applications?
Yes, there are different types of drive pulleys available, each designed for specific applications based on factors such as power requirements, belt type, speed, and environmental conditions. These different types of drive pulleys offer variations in design, construction, and features to suit various industrial applications. Here’s an overview of some common types of drive pulleys and how they differ in their applications:
1. Flat Belt Pulleys:
Flat belt pulleys have a flat cylindrical surface and are typically used with flat belts. They are commonly found in applications where moderate power transmission is required, such as in light-duty machinery, conveyor systems, and agricultural equipment. Flat belt pulleys are known for their simplicity, cost-effectiveness, and ease of installation. They are available in various sizes and materials, including cast iron, steel, and aluminum.
2. V-Belt Pulleys:
V-belt pulleys have a V-shaped groove on their cylindrical surface and are designed to work with V-belts. The V-groove helps improve belt grip and prevents slippage, making them suitable for high-power transmission applications. V-belt pulleys are commonly used in automotive engines, industrial machinery, HVAC systems, and heavy-duty equipment. They are available in different configurations, including single-groove, multi-groove, and variable speed pulleys.
3. Timing Belt Pulleys:
Timing belt pulleys are designed to work with timing belts, also known as synchronous belts. These pulleys have teeth or grooves on their surface that mesh with corresponding teeth on the timing belt, providing precise and synchronous power transmission. Timing belt pulleys are commonly used in applications that require accurate positioning and synchronization of components, such as CNC machines, robotics, printing presses, and automotive engine systems.
4. Chain Drive Sprockets:
Chain drive sprockets are used in systems that utilize roller chains for power transmission. These pulleys have teeth or cogs that mesh with the links of the roller chain, enabling efficient power transfer. Chain drive sprockets are commonly used in heavy-duty applications, such as industrial machinery, conveyors, motorcycles, bicycles, and agricultural equipment. They are available in various configurations, including single-strand, double-strand, and multi-strand sprockets.
5. Cone Pulleys:
Cone pulleys have a tapered or conical shape and are used in applications that require variable speed drives. By adjusting the position of the belt on the conical surface, the effective pulley diameter changes, resulting in different speeds. Cone pulleys are commonly found in machine tools, drill presses, lathes, and other equipment where variable speed control is necessary.
6. Magnetic Pulleys:
Magnetic pulleys are designed with a magnetic surface to attract and hold ferrous materials. They are used in applications such as magnetic separators, material handling systems, recycling, and mining industries. Magnetic pulleys are effective in removing tramp iron or unwanted metal contaminants from conveyed materials.
These are just a few examples of the different types of drive pulleys available. Each type has its own specific design and features that make it suitable for particular applications based on factors like power transmission requirements, belt compatibility, speed control, and environmental conditions. It’s important to select the appropriate type of drive pulley based on the specific needs and operating conditions of the application to ensure optimal performance and longevity.
How are drive pulleys integrated into industrial machinery and conveyor systems?
Drive pulleys play a crucial role in industrial machinery and conveyor systems, providing the necessary power transmission and motion control. They are integrated into these systems in various ways to ensure efficient operation and reliable performance. Here are the key aspects of how drive pulleys are integrated into industrial machinery and conveyor systems:
1. Power Transmission:
Drive pulleys are the primary components responsible for power transmission in industrial machinery and conveyor systems. They are typically connected to the motor or engine shaft and transmit rotational motion to the driven components or conveyor belts. The pulleys are designed to match the power requirements of the system, offering high torque capacity and efficient power transfer. The integration of drive pulleys ensures the reliable transmission of power throughout the machinery or conveyor system.
2. Belt or Chain Drive:
In industrial machinery and conveyor systems, drive pulleys are commonly used in belt or chain drive configurations. They are paired with belts or chains that wrap around the pulley grooves, creating a positive engagement and transmitting power. The drive pulleys are designed with specific groove profiles to ensure proper belt or chain tracking and prevent slippage. Belt or chain drives allow for flexible power transmission and are suitable for various applications, including conveying materials, driving rotating components, or operating auxiliary systems.
3. Pulley Arrangements:
Industrial machinery and conveyor systems often utilize multiple drive pulleys arranged in specific configurations. These arrangements include single pulley setups, multiple pulleys in parallel, or pulleys arranged in a series. The selection and arrangement of drive pulleys depend on factors such as the desired speed ratio, torque requirements, and system layout. Multiple pulley arrangements enable the system to achieve the desired speed, torque, and power distribution for efficient operation.
4. Tensioning and Tracking:
Drive pulleys are integrated with tensioning and tracking mechanisms to maintain proper belt or chain tension and alignment. Tensioning devices, such as idler pulleys or tensioners, are used to apply the appropriate tension to the belt or chain, preventing slack and ensuring optimal power transmission. Tracking mechanisms, such as adjustable pulleys or guide rollers, help keep the belt or chain properly aligned on the pulleys, minimizing misalignment and reducing wear. The integration of tensioning and tracking systems with drive pulleys improves overall system reliability and performance.
5. Pulley Design and Materials:
The design and materials used in drive pulleys are carefully considered to suit the specific requirements of industrial machinery and conveyor systems. Pulleys are designed with appropriate groove profiles to match the belt or chain type, ensuring optimal engagement and minimizing slippage. They are constructed from durable materials such as steel, aluminum, or engineered plastics, depending on factors such as load capacity, environmental conditions, and system dynamics. The integration of well-designed and robust drive pulleys enhances the longevity and reliability of the machinery or conveyor system.
6. Maintenance and Serviceability:
Drive pulleys are integrated into industrial machinery and conveyor systems with ease of maintenance and serviceability in mind. They are often designed for simple installation, adjustment, and replacement, allowing for quick and efficient maintenance tasks. Accessible pulley locations, such as removable guards or covers, facilitate inspection and maintenance activities. The integration of service-friendly drive pulleys minimizes downtime and contributes to the overall reliability of the machinery or conveyor system.
7. System Optimization:
Drive pulleys are integral to optimizing the performance and efficiency of industrial machinery and conveyor systems. Proper selection and integration of drive pulleys, along with other system components, allow for achieving desired speed, torque, and power requirements. By carefully considering factors such as pulley size, groove design, belt tension, and system layout, the performance of the machinery or conveyor system can be optimized. Drive pulleys play a crucial role in system optimization, ensuring smooth operation, minimized energy losses, and enhanced productivity.
In summary, drive pulleys are essential components integrated into industrial machinery and conveyor systems. They enable power transmission, are used in belt or chain drive configurations, and can be arranged in various configurations. They incorporate tensioning and tracking mechanisms, are designed with specific groove profiles, and are constructed from durable materials. The integration of drive pulleys ensures efficient operation, reliability, and serviceability in industrial machinery and conveyor systems.
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