Belt conveyors, as vital equipment for modern material handling, are widely used in various fields such as coal mining, quarries, ports, and factories. Their assembly process not only ensures the normal and efficient operation of the equipment but also guarantees the safety of operators. Therefore, during the assembly of belt conveyors, it is essential to strictly adhere to relevant specifications and pay attention to every detail. This article will delve into the precautions during the assembly process of belt conveyors.
I. Preparation Work
Before assembling a belt conveyor, thorough preparation is required. This includes familiarizing oneself with the technical documentation, installation drawings, and relevant operation manuals of the equipment, as well as understanding the specific conditions of the construction site. Installation personnel need to be clear about the maximum dimensions and weight of the equipment and determine an appropriate installation plan based on transportation conditions. Additionally, necessary installation tools and auxiliary equipment, such as lifting equipment, measuring tools, and bolts, should be prepared.
II. Determining Installation Benchmarks
The assembly of belt conveyors begins with determining the installation centerline and the installation positions of the head and tail ends. These benchmark points should be marked on the corresponding positions of the tunnel roof and floor to facilitate subsequent installation work. Meanwhile, based on the equipment drawings, the tunnel floor should be cleared to ensure that the installation area is flat, allowing for the installation of the fixed parts of the belt conveyor. Besides the drive unit at the head, a lightweight track should be laid on one side of the body of the fixed part of the tunnel for transporting the conveyor belt and other materials.
III. Installing Drive Units and Intermediate Frames
The drive unit is one of the core components of a belt conveyor, and its installation quality directly affects the operating performance of the equipment. The base of the drive unit and the support of the transition section should be installed on the foundation and kept level to ensure the stability of the machine. During installation, all components should be transported to the installation point in sequence and assembled according to the drawings. The installation of intermediate frame assemblies is equally important, and the installation accuracy will directly affect the smooth operation of the belt. During installation, attention should be paid to the spacing and height of the idlers to ensure that the belt does not experience unnecessary friction and resistance during operation.
IV. Belt Installation and Debugging
Belt installation is one of the most critical steps in the assembly process of belt conveyors. Firstly, the appropriate installation method should be selected based on the width and length of the belt. For horizontally operating belt conveyors, the old belt can be cut at any position, while for inclined belt conveyors, an appropriate cutting point should be chosen to prevent uncontrolled movement due to self-weight. When installing a new belt, it should be ensured that the belt joint is firm, flat, and perpendicular to the belt centerline. The joint length should not be less than 90% of the belt width to ensure the belt’s strength and stability.
After belt installation, debugging is required. During debugging, the belt tension should be checked to ensure that the belt does not become too loose or too tight during operation. Tension adjustment can be achieved by adjusting the tensioning device. During debugging, it is also necessary to check for abnormal phenomena such as belt misalignment, slipping, or jumping. If any issues are found, adjustments should be made promptly.
V. Installation of Safety Protection Devices
During operation, belt conveyors may encounter various faults and dangerous situations. Therefore, corresponding safety protection devices must be installed to ensure the safety of the equipment and operators. These safety protection devices include low-speed protection devices, coal level protection devices, anti-misalignment protection devices, temperature protection devices, over-temperature sprinkler devices, and smoke alarm devices. The installation locations and quantities of these devices should be specifically determined based on the equipment type and operating environment.
For example, the temperature protection device should be installed on the main motor to monitor its temperature changes; the smoke alarm device should be installed within 1-5 meters of the return air side of the drive pulley, 600-800 mm away from the belt, to monitor smoke between the belt and the pulley. Anti-misalignment protection devices should be installed every 25 meters along the belt to monitor the belt’s operating state and prevent misalignment.
VI. Trial Run and Acceptance
After the belt conveyor is installed, a trial run is required. Before the trial run, a comprehensive inspection of the equipment should be conducted to ensure that all components are installed correctly and securely fastened. During the trial run, the operation of the belt should be observed, and checks should be made for abnormal sounds, vibrations, or friction phenomena. At the same time, the temperature and lubrication of bearings, gears, and transmission devices should also be inspected.
Safety should be particularly noted during the trial run. Operators should be familiar with the operating procedures of the equipment and strictly follow the procedures. If any issues are found during the trial run, the equipment should be immediately stopped for inspection and adjustment. After the trial run is successful, the equipment can be accepted. During acceptance, the equipment’s performance indicators should be checked to ensure they meet the design requirements, and an acceptance report should be filled out.
VII. Operation and Maintenance
Belt conveyors require regular maintenance during operation. This includes checking the wear of the belt, replacing severely worn components, cleaning debris from the belt and pulleys, and inspecting the lubrication of bearings and gears. Additionally, the equipment should be regularly inspected and debugged to ensure its normal operation.
Operators should be familiar with the operating procedures and safety precautions of the equipment and strictly follow the procedures during operation. If any abnormalities are found during operation, the equipment should be immediately stopped for inspection and adjustment. Furthermore, operators should receive regular training and education to improve their safety awareness and operating skills.
