SIDEWALL-ENGINEERING-HANDBOOK-ENGINEERING
- 2. 2 Introduction “Sidewall is born of the experience of three Italian companies, which put in a network their history, their skills, their men believing that produce a good belt is a mission. All the belts’ components are produced in Italy with first class raw materials regularly tested in our internal laboratories. Three production lines, with a manufacturing capacity of about 150m per day, are able to grant flexibility and promptness in deliveries to satisfy the demand of today’s international markets. Our team of specialists can also support you with a complete after-sale service, which includes assembly, start-up and belt’s vulcanization on plant, if required. Our commercial and technical staff is at your full disposal for any explanation and/or information you may need.”
- 3. 3 Sidewall® conveyor belts Sidewall® corrugated steep angle conveyor belts consist of a cross stabilized base belt, corrugated sidewalls and cleats. Sidewall® conveyor belts are the most efficient and reliable system for bulk material steep angle or vertical conveying and they are used in several industries: • Steel plants • Mines • Cement plant • Foundries • Batching plants • Power plants • Tunneling • Recycling and waste industries • Sand, gravel and stone quarries Main Advantges of the system Sidewall conveyor belt system has many advantages if compared with conventional belt conveyors, bucket elevators or mechanical elevators: • No Transfer Points from the feed hopper to the discharge point • Higher handling capacity • No material spillage • Minimum maintenance • Minimum horizontal occupation • Low Power Requirement Lifespan of a corrugated sidewall conveyor belt mainly depends on the connection between the profiles (sidewalls and cleats) and the base belt. Sidewall hot vulcanization system and exclusive profiles design ensure the highest, strongest and most reliable adhesion in the market.
- 4. 4 Sidewall® belt design Our Technical team can support you in designing the right belt to fit your needs. In order to set correct Sidewall® belt dimensions, specific geometrical formulas have to be used based on speed, elevation, slope, center distance and coveyed material. In particular pay attention to free lateral spaces working tension and relative safety factor; take also care of possible cleats interference during the belt loading.
- 5. 5 ß L = 2,3 x S P = 1,8 x S B = S x ( ß + 0,6 ) 100 L B P S Sidewall® belt design The material lump size is also important in belt designing. With the aim to avoid the spillage or projection of material during the transportation or possible choke accidents, it is necessary to pay attention to the following criteria depending on maximum material lump size (S).
- 6. 6 15 DRIVE PULLEY 18 BELT CLEANING 16 DEFLECTION WHEELS 23 STUB IDLERS 9 CLEATS 20 GUIDE WHEELS 12 RUBBER CONVEYOR BELTS 10 ACCESSORIES SIDEWALLS AND CLEATS
- 7. 7 8 SIDEWALLS 17 TOP DEFLECTION CURVE 18 BOTTOM DEFLECTION CURVE 15 TAIL PULLEY Index
- 8. 8 Sidewalls D C B A HEF fabric Ø pulley weight A B C D mm mm mm mm mm mm Kg/m - - - - - - - - - - - - - - - 30 50 50 50 50 50 70 80 80 100 75 75 75 75 75 75 100 100 40 40 60 80 100 120 160 200 240 300 160 200 240 250 280 300 400 500 5 6 6 6 6 6 6 8 8 9 9 9 9 9 9 9 12 12 25 50 50 50 50 50 55 65 65 90 60 60 60 60 60 60 83 83 - 250 250 280 360 360 480 600 720 900 480 600 720 750 900 900 1200 1500 - 280 280 315 480 480 640 800 960 1200 640 800 960 1000 1200 1200 1600 2000 0,5 0,8 1,2 1,4 1,6 2,2 3,7 5 6 8,2 4,6 5,6 6,6 7 7,8 8,3 18,7 23,7 40/30 40/50 60 80 100 120 160 200 240 300 160/75 200/75 240/75 250/75 280/75 300/75 400 500 article code HEL no fabric Ø deflection How to compose the article code With or with out fabric reinforcement Cleats shape Rubber quality (p.11) Profile height HBF TC 140 FRK
- 9. 9 B A B A B D C B D C Cleats T TW B mm C D mm mm article code TW280 TW360 TW380 TW480 280 360 380 480 30 30 30 30 99 99 99 99 HBL no fabric HBF fabric - - - - C C55 C75 C110 90 90 110 A mm 55 75 110 B mm 1,2 2,0 2,7 weight Kg/m article code HBL no fabric HBF fabric - - TCW TCW280 TCW360 TCW380 TCW480 228 228 228 228 280 360 380 480 30 30 30 30 99 99 99 99 B A mm mm C D mm mm article code HBL no fabric HBF fabric - - - - T20 TB30 TB40 TB50 T55 T75 T90 T110 T140 T180 40 80 80 100 80 100 110 110 110 150 A mm 20 30 40 50 55 75 90 110 140 180 B mm 0,2 1,1 1,2 2,3 0,9 1,6 2,4 3,0 3,6 4,7 weight Kg/m article code HBL no fabric HBF fabric - - - - - HBL-TC70 HBL-TC90 HBL-TC110 HBL-TC140 HBL-TC180 HBL-TC220 HBL-TC230 HBL-TC240 HBL-TC250 HBL-TC260 HBL-TC280 70 110 110 140 170 175 175 175 175 175 190 A mm 70 90 110 140 180 220 230 240 250 260 280 B mm 1,24 2,7 3,0 4,3 6,3 7,4 7,8 8,2 8,5 8,7 11,9 weight Kg/m article code HBL no fabric HBF fabric - - - - - TC B A
- 10. 10 Sidewalls and cleats accessories Ø B C D A E F FIX-S FIX-B 55 98 19 23,5 A D mm mm 8,5 25,5 18 20,8 19 23,5 12,5 13,9 5,5 6,5 B E C F Ø mm mm mm mm mm article code cleat reference article code BLK-70 BLK-110 BLK-140 BLK-180 BLK-220 BLK-280 BLK-360 BLK-380 BLK-480 BLK-580 BLK-600 HBF-TC70 HBF-TC110 HBF-TC140 HBF-TC180 HBF-TC220 HBF-TC280 HBF-TCW360 HBF-TCW380 HBF-TCW480 HBF-TCW580 HBF-TCW600 BLINKERS FIX
- 11. 11 Rubber quality Abrasion Resistant: AY Standard abrasion-resistant rubber ( Y Grade - DIN 22102 / RMA II ). Working Temperature range -20 +60°C. AW Extra abrasion-resistant and Cold resistant rubber ( W grade - DIN 22102 / RMA I ). Working Temperature range -50 +60°C. Heat Resistant: HR130 Heat resistant rubber for continuous service up to 130°C with peaks of 150°C HR150 Heat resistant rubber for continuous service up to 150°C with peaks of 180°C Oil Resistant: OR Oil and grease resistant rubber. This rubber guarantees a good belt resistance against the chemically aggressive effects due to the transport of materials with moderate oil presence, like corn, fertilizers and solid urban waste materials. Working Temperature range -20 +60°C. Self Extinguish: FRK Self-extinguish rubber according ISO 340, equivalent Grade K DIN 22102. Working Temperature range -20 +60°. Self Extinguish and Oil Resistant: ORK Mild Oil resistant, Self-extinguish rubber according ISO 340, equivalent Grade K DIN 22102. This rubber guarantees a good belt resistance against the chemically aggressive effects due to the transport of materials with moderate oil presence, like corn, fertilizers and solid urban waste materials. Working Temperature range -20 +60°. All compounds are antistatic according to ISO284 and ozone resistant.
- 12. 12 One of the most important characteristics of sidewall belts for high inclined and vertical systems is the use of base conveyor belts with cross stabilized insertions. Sidewall conveyor belts are characterized by elevation changes from horizontal to inclined and/or vertical, and in the return strand, they are held up only on the free lateral spaces. These deflection and support zones require a very rigid and stiff belt. These cross stabilized base belts are then a fundamental component of sidewall belts; since they are manufactured with a huge range of rubber compounds, they can meet any conveying exigency. TEXRIGID Texrigid is a cross stabilized belt based on textile carcass EP type (Polyester - Polyamid) with two layers of rigid fabrics made of Polyester. Texrigid Belts are suitable for medium - heavy applications. Different tensile strengths and/or cover thickness are available on demand. In the table below you can find some standard types. Rubber conveyor belts TEXRIGID 315 TEXRIGID 500 TEXRIGID 630 TEXRIGID 800 TEXRIGID 1000 TEXRIGID 1250 TEXRIGID 1600 315 500 630 800 1000 1250 1600 tensile strength N/mm 2 + 1 3 + 2 4 + 2 5 + 2 5 + 2 / 6 + 2 5 + 2 5 + 2 fabrics n. 3 + 1,5 5 + 3 5 + 3 5 + 3 5 + 3 5 + 3 5 + 3 250 400 500 630 800 800 1000 cover Ø min. pulley mm mm article code
- 13. 13 CROSSRIGID Crossrigid Belts are based on textile carcass EP (Polyester - Polyamide) with stiff steel cord inserts assuring stability and rigidity of the belt also for long center distances and high elevations. Different tensile strengths and/or cover thickness are available on demand. In the table below you can find some standard types. Rubber conveyor belts CROSSRIGID 500 CROSSRIGID 630 CROSSRIGID 800 CROSSRIGID 1000 CROSSRIGID 1250 CROSSRIGID 1600 500 630 800 1000 1250 1600 tensile strength N/mm 3 + 2 4 + 2 5 + 2 5 + 2 / 6 + 2 5 + 2 5 + 2 fabrics n. 5 + 3 5 + 3 5 + 3 5 + 3 5 + 3 5 + 3 400 500 630 800 800 1000 cover Ø min. pulley mm mm article code
- 14. 14 CROSSRIGID HR Steel cord belts with high transversal rigidity and minimum longitudinal elongation. The rigid reinforcement can be tailor made to obtain the required transversal rigidity, especially with very heavy application and with high elevations. Crossrigid HR is also available with free zone under the sidewall base. Belts made on demand and under specific design. Rubber conveyor belts CROSSRIGID HR 1000 CROSSRIGID HR 1250 CROSSRIGID HR 1600 CROSSRIGID HR 2000 CROSSRIGID HR 2500 CROSSRIGID HR 3150 CROSSRIGID HR 3500 1000 1250 1600 2000 2500 3150 3500 tensile strength N/mm 6 + 4 6 + 4 6 + 4 6 + 4 6 + 4 6 + 4 6 + 4 630 800 800 800 1000 1250 1250 min. cover thickness Ø min. pulley mm mm article code
- 15. 15 Drive and tail pulley Drive Pulley In most cases the discharge pulley is also the drive drum. The pulley is normally fixed after installation and requires no adjustment. For most applications the pulley face is rubber coated. However, it is not advisable to crown the pulley when you use Crossrigid or Crossrigid HR belts, damage may result to the base belt, please contact the Sidewall technical department in case of doubt. Tail Pulley The tail pulley is also the tensioning drum, tension normally being applied via screw take-up or counterweight depending on the plant dimensions and service heaviness. When calculating the amount of take-up please take into account that the maximum stretch of a belt will be 1.5%, plus an amount for safety. Notes The above pulley diameters are based on sidewall height. Larger pulley diameters may be required depending on the tensile strength of the base belt. E mm 400 <-> 700 700 <-> 1400 1400 <-> 2000 2000 <-> 2400 Bw 50 75 100 125 Ø H BW E 40/30 40/50 60 80 100 120 160 200 240 300 250/75 280/75 300/75 400 500 600 630 SIDEWALL height Ø pulley mm mm - 250 250 280 360 360 480 600 720 900 750 900 900 1200 1500 1800 1900
- 16. 16 The general formula to calculate the deflection wheel diameter is 4 x H where H = sidewall height. Consideration should be given to material lump size and cleat pitch to ensure a big enough radius to prevent pinching the material in the curve. Dimension Fw shown above is normally the minimum value and it can vary according to the required belt support. Allowances must be made for clearance between the deflection system and the sidewalls. Deflection wheels Ø FW FW = 0,8 x FS FS FW FS 40/30 40/50 60 80 100 120 160 200 240 300 250/75 280/75 300/75 400 500 600 630 mm mm - 280 280 315 480 480 640 800 960 1200 1000 1200 1200 1600 2000 2400 2500 Ø deflection SIDEWALL height
- 17. 17 mm mm SIDEWALL height The change in angle can be achieved either by a series of idlers positioned as per the sketch or by a single pulley. The minimum recommended idlers diameters for the corresponding sidewall heights are as follows. The amount of deflection ”α” for each idler depends on the Sidewall type as follows: Type HEL: Max 15° Type HEF: Max 10° In addition the maximum pitch of the idlers is set at 1.5 x D where D = Idler Diameter. The radius is determined by the belt speed and by the method of deflection, angle of inclination, friction value of the material and the profile type/height. The idler shaft diameter must also take into account radial loadings and may therefore need to be increased accordingly. On installations with high lifts it may be necessary to install small pulleys with external bearings. Top deflection curve α 1,5 x Ø Ø 40/30 40/50 60 80 100 120 160 200 240 300 250/75 280/75 300/75 400 500 600 630 60 60 60 89 89 89 108 108 108 133 133 133 133 please ask please ask please ask please ask
- 18. 18 Bottom deflection curve Belt cleaning At bottom deflection curve a single drum system is the advisable. The drum may be rubber lagged for better frictional contact with the base belt aiding belt alignment at this point. For Crossrigid and Crossrigid HR belts the drum must be flat without any crown. The diameter of the drum is the same as the recommended minimum pulley diameters for the drive and tail pulleys. Note The system needs to be adjustable to allow for belt tracking, please see the section on belt tracking (page 22). Sidewall® Conveyor Belts have self cleaning properties, but in case of sticky materials, the assistance of a cleaning device will be required. Sidewall® Shake Rolls must be positioned at discharge point as per above drawing. Note The actual position of the discharge hopper will depend on the length of the horizontal section, it may also be necessary to install additional support. Please consult our technical department for advice on the hopper design. D1+Bd Bd D1
- 19. 19 Shake roll 2 x Sw Sw Bd d2 Note Drums are positioned so that the outer face is directly above the Sidewall outer edge. The dimension Bd is one size below the installed drum diameter. The steel rods (d2) must be made of hardened steel, when installing it is very important that the rods (d) are off-set. The system works at the best with belt speed over 1 m/sec. For particularly sticky material we recommend to adopt a par (Tandem) unit. d2 d ° mm 315 500 Bd 6 x 60° 6 x 60° 20 25 d
- 20. 20 Guide Wheels Sidewall® Guide Wheels can be used with all cross-rigid belt constructions. The hollow sections inside the wheels allow for compression of the guiding wheel thus protecting the edges of the belt. The wheels are made of polyurethane ensuring self cleaning properties. The wheels are also available in heat resistant and self extinguish rubber. These wheels are highly recommended and ensure a high degree of security in both normal and diffcult applications. Typical cross-section of a belt showing the correct positioning of the Guide Wheels. 5 60 160 25 200
- 21. 21 Guide Wheels The positioning of the Guide Wheels is important. By placing the guiding system in the recommended places potential damage to the belt edges and sidewalls is eliminated. It is recommended that the fixing of the Guide Wheel shafts be adjustable of +/– 50 mm. The dimension of 2.5 x Bw is an approximation and can be varied between 2 and 3 times belt width. For a better belt tracking, in case of elevation higher than 20 m, placing extra wheels is advisable In case of doubt please contact our technical service. Note The belt should always track correctly, the Guide Wheels are used to prevent damage, for maximum life the belt needs to be checked for straight running regularly. 2,5 x Bw Bw
- 22. 22 Belt tracking The Guide Wheels are used to prevent damage, for maximum life the belt needs to be regularly checked so that it should always track correctly and straight running. Please check the below drawing in order to verify all possible adjustment. direction of adjustment direction of adjustment direction of adjustment adjustable as one piece
- 23. 23 Stub idlers Stub idlers are mainly used on return side. By setting the idlers at 3° or 5° (depending on belt construction) belt tracking is assisted. It is important that only stub idlers with rounded dome end caps are used and are slot mounted for adjustment. The pitch of the stub idlers on the return side is max 1000mm. fs fg fg= 20% fs α α = 3° Steel cord belts 5° textile belts rounded dome cap M16
- 24. 24 value u.m. A F D B G Belt length Endless closed Endless prepared Fix Blinkers C E mm mm yes one side yes yes no no no no Notes Belt dimensions Reference Mail value u.m. A D B C F G E Cleat “TC“ Cleat “T“ Cleat “C“ Quantity mm mm mm mm mm mm Customer Questionnaire
- 25. 25 M N ß1 ß2 L H I α R = I/2 H I R = I/2 Base belt C° Materials to be conveyed Bulk density Moisture Temperature Technical remarks Rubber quality value u.m. Oil presence yes no % Belt speed Lump size mm Chemicals presence yes no value value u.m. u.m. Belts Material Mass flow Volume flow value u.m. Capacity t/h m3 /h System dimensions value u.m. Installation existing new M L H I α I R = I/2 ß1 M α I I H mm N ß2 M H I α I R = I/2 I L M N α ° ß1 ° ß2 ° mm mm mm mm m/min
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- 28. Thanks for your interest distribuited by sidewall.it Sidewall legal office Piazza IV Novembre, 4 20124 Milano (MI) headquarters via Amaducci 50 61021 Carpegna (PU) info@sidewall.it +39 0722 72721 manolibera.net