6 Reasons for Damage to Belt Conveyor Belts and 4 Ways to Repair Tapes

Issuing time:2019-03-27 09:42

With its characteristics of long distance, large capacity and continuous transportation, the belt conveyor has become more and more widely used and has become the main way of material transportation. From the perspective of the use of belt conveyors, the investment in tapes accounts for about 80% of the maintenance costs of belt conveyors. Therefore, the maintenance of conveyor belts has been strengthened, the investment of tapes has been reduced, and the service life of tapes has been increased Conveyor operation benefits, an important aspect of reducing maintenance costs.


Tape damage is an inevitable problem in the operation of the belt conveyor. It is very important to properly repair the damaged tape and reduce downtime. This article shares the six causes of belt conveyor belt damage and four methods of tape repair.


Analysis of Damage Causes of Belt Conveyor Tape


From the structure of the tape and the function of each part, the tape can be divided into two parts: core (tensile layer), upper and lower adhesive and side adhesive (protective layer). The core of the tape is a skeleton, and its function is mainly to withstand tension. The more layers there are, the greater the ability to withstand tension. The side glue and the face glue are protective layers. Its functions are mainly anti-wear, anti-corrosion, preventing direct impact of materials, and buffering and protecting the core skeleton.


From the actual use situation, the main reasons for the damage of the tape are as follows:


(1) Because of the drop in the belt conveyor or the transfer point in the system, the buffering rollers at the tail end lose elasticity. When a large piece of coal or vermiculite falls from the top, a large impact force is formed and the tape is broken. The upper cover layer of the fiber even breaks the belt core to form a cave. Especially when sharp objects such as anchors are trapped in the material, it is easy to cut the tape, causing the tape to tear longitudinally.


(2) Due to the defect of the idler during the operation of the conveyor, the idler frame is easy to scratch the tape.


(3) When the conveyor belt passes through the roller, foreign matter is caught and the tape is damaged.


(4) Edge wear. Mainly due to the deviation of the tape, causing friction between the tape and the rack, resulting in cracking of the edges. After the edge of the belt is worn, water immerses from the damaged place, and the belt core gradually rots, and the steel wire core gradually corrodes and breaks.


(5) The joints of the tape are poor, the joints are uneven or uneven, causing the tape to be unevenly stressed and broken.


(6) Excessive tension of the tape can easily cause the tape to age and damage in advance.


The importance of tape repair


Timely and effective repair of the tape can not only guarantee the normal operation of the system, but also increase the service life of each part of the belt conveyor.


1. Leakage of material at the damaged area will cause serious damage to the surface of the roller, and more serious damage to the adhesive tape. This will cause the belt conveyor to run away for a long time, which will seriously affect the equipment operation. 2. When the damage is not quickly maintained and managed, when the damaged area comes in contact with the cleaner, the cleaner will jam the breach, which will cause more serious damage to the tape or even the entire tape to be scrapped.


Method for repairing belt conveyor tape


There are many reasons for the damage of the tape, and corresponding measures should be taken to prevent the damage. In particular, when the tape is found to be damaged, it should be repaired in time to prevent the damage from expanding and causing the broken belt. According to the degree of damage to the tape, the following methods are commonly used to repair the tape:


Viscose cold patch


This method is suitable for cases where the protective layer of the tape is damaged, the area is not large, and the core layer is relatively lightly damaged. The specific steps are:


(1) Use a repair knife to cut and tear the cover layer according to the damage range.


(2) Use a wooden file to polish the bonding surface to a certain roughness.


(3) Mix the colloid evenly, apply it evenly to the sanding place of the tape with a brush, and air dry for about 20min.


(4) Cut the adhesive tape of the cover layer into the shape of the repair place, put it in the bonding position, and then hit it evenly with a wooden hammer until the bonding is tight and air-dry for two hours.


Panel tape buckle repair


The wire rope core tape is often smashed out of the wire rope by the material. When repairing, the tape buckle can be repaired along the length of the crack of the wire rope (as shown in the figure below). Although the plate type tape buckle component is small, it is very convenient in repairing the tape. It can well control the small damage of the tape and prevent the damage of the tape from expanding.


Holes in the tape can be excavated. First, dig out a square of the damage, then cut a piece of tape of the same size to fill the hole and snap it around with tape around it (as shown in the figure below). The patch can be cut on the old tape, but it must be the same size as the tape used, and the warp and weft directions of the tape core must be the same as the direction of the tape used.


Hot glue


If the tape is partially torn, it needs to be repaired with hot glue. That is, after the crack is treated, it is coated with raw rubber paste, and the raw tape is adhered. Then, under a certain pressure, temperature and time, the raw rubber becomes cured Vulcanized rubber to obtain the best adhesion strength at the cracks. The specific steps are:


(1) Foam. Use unleaded gasoline to evenly spread the raw green tape used for hot-adhesive tape to make a thin rice soup.


(2) Surface treatment at the crack of the tape. On the upper and lower surfaces of the tape, remove the 30 mm wide rubber layer on the left and right sides of the crack along the length direction, and use the abrasive wheel to shave the exposed canvas layer to completely remove the remaining rubber.


(3) Apply glue. Use a small brush to brush the soaked glue evenly inside the crack of the tape and the rough canvas layer, and put the rubber cut according to the site size in the crack and the area where the rubber is peeled off.


(4) Heating. Immediately after the glue application is completed, the heating operation is performed. When heating, make the upper and lower heating sleeves tightly clamp the cracks of the glued tape, put the heating plate in the upper and lower heating sleeves in order, and start heating after power on. When the temperature reaches about 148 ° C, stay for 2 to 3 minutes, disconnect the power supply, and allow the heater to cool slowly to normal temperature (about two hours), remove the heater, and complete the bonding of a crack.


Vulcanized joint


The final method of repairing the tape is to make a new tape joint. This method is suitable for the tape that is damaged badly and can no longer bear the tension during operation. If it is continued, the tape may break. There are many ways to redo the adhesive tape joint, including mechanical buckle connection method and vulcanization thermal connection method. When conditions permit, vulcanization and heat bonding should be preferred. Vulcanized tape joints have good quality and high tensile strength. However, vulcanization usually requires more complicated procedures and takes a longer time. The vulcanization of the whole core tape is usually as shown in the figure below. According to a certain size, the tape heads to be butted are cut into a zigzag shape. After the vulcanizate is coated on the serrated contact surface, the two tape heads are overlapped, and then The upper and lower sides of the joint are covered with core rubber and the surface rubber are heated and pressurized to form a whole.


If the adhesive surface of the tape and the core skeleton are not severely damaged, the tape can continue to be used; once the adhesive surface of the tape is evenly worn more than 1/3, the core is exposed, and the remaining rubber surface is foamed, wrinkled, or a section of tape Many serious injuries are difficult to repair, it can be considered that this (segment) tape has reached the ideal service life.


In addition, in the production process, it is necessary to ensure the integrity of various protection devices of the belt conveyor, such as anti-tearing protection devices, coal pile protection devices, broken belt slip protection devices, automatic water spraying, smoke protection, etc., which can effectively prevent tape damage and prolong Service life of the tape.


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