STRUCTURE
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Steel cable rubber conveyor belts are commonly used for transport of products at lengthy ranges and heavy loads which have high resistance. The steel cable conveyor belts are used also in high-speed transport at brief distances. These conveyor belts need only a very short take-up stroke.
The belt structure with its longitudinally ordered steel cables skeleton is resistant to fatigue because of flexing.
Thus, smaller diameter drive pulleys can be used to design equipment of smaller size. The steel wires are bonded with high level of adhesion to the fabric on their ground.
The rubber of the rubber conveyor belt with steel wires is therefore firmly attached to the steel cables and shockproof, enhancing the belt life. Steel cables are structured uniformly and have the same strain, which makes the belt upright and functional.
As the carcass doesn't have longitudinal yarns, the steel wire rubber conveyor belt carry more stuff within greater inclination.
CORD STRUCTURE
7×7 : Applied to low tension lines
7×19 : Applied to high tension lines used.
The REMA Guide to Conveyor Belting
The quality of a conveyor belt is always relative to the quality of the material used, the quality of the machinery used, and most importantly, the attitude and experience of the person making the belt.
At the REMA TIP TOP-owned Dunlop Industrial Product factory situated in Howick South Africa, belting is manufactured using state-of-the-art technology, high-quality pre-tested materials, and experienced, motivated personnel.
Click here for our full range of high-performance conveyor belts. The following conveyor belting portfolio is discussed below:
PowaPLY
Multi-ply textile reinforced conveyor belting forms the backbone of many mines, and REMA TIP TOP supplies a product referred to as &#;PowaPLY&#;. This would be a belt with a carcass constructed from between 2 to 6 fabric plies, depending on the user&#;s requirement.
These belts are used typically on surface installations, as opposed to underground facilities, to convey material between processes and onto stockpiles and can be manufactured in strengths from 200 kN/m to kN/m.
PowaSOL
For underground installations, especially in coal mines, a solid-woven carcass conveyor belt has become very popular.
This is mostly due to the ability to be able to make use of a mechanical splice and still retain a high belt strength.
Strength ratings of the PowaSOL belt vary from 800 kN/m to kN/m. Protection to the solid woven PVC impregnated carcass is achieved by hard-wearing, fire-retardant synthetic rubber covers of variable thickness from 1 mm to 6 mm to suit the application.
PowaCORD
In many installations, the material requires to be transported over long distances. In such a case, using a belt with a textile reinforced carcass may not be suitable as the elongation of the belt may be such that take-up carriage and counterweight travel may be excessive, resulting from a relatively low belt modulus, which implies that the belt will stretch a particular distance when subjected to a specific tension.
Furthermore, the carcass of a textile reinforced belt may not be strong enough to withstand the operating tensions applied, especially in the splice area.
Steel cord reinforced conveyor belting, better known as PowaCORD, has a low modulus and superior strength eliminating the requirement for long take-up carriage travels and tall counterweight towers.
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Strength ratings for such belt construction vary from 500 kN/m to 6 300 kN/m. Protection to the cords is provided by hard-wearing rubber covers of variable grades and thicknesses from 4 mm to 40 mm, to suit the application.
PowaFLEX
When handling hard ore, such as gold ore, there is typically a requirement for a belt that can withstand impact while also having a high tear resistance. Such requirements relate to carcass construction.
The unique FlexTECH construction of the PowaFLEX 1 single-ply straight warp EpP belt provides extreme impact and tear resistance as well as excellent lateral rigidity for supporting heavy loads. Its excellent longitudinal flexibility allows it to bend around small diameter pulleys.
As the carcass is a straight warp construction, elongation of this belt is limited and much reduced when compared to a multiply textile reinforced conveyor belt. The strengths of this belt would vary between 315 kN/m to 800 kN/m.
If the requirement exceeds the strength of a PowaFlex 1 belt as mentioned above, a two-ply straight warp EpP carcass belt could be used, namely the PowaFlex II belt.
The strength of this unit is derived from using a second ply, and its strengths vary from kN/m to kN/m. For academic purposes, the characteristics are the same as for the PowaFLEX I construction.
Though, the slightly thicker carcass provides even better impact and tear resistance. These belts are most suitable for handling sharp ore, having a high bulk broken density, dropping onto the belt from an increased height.
PowaMAX
PowaMAX is a straight warp Aramid carcass conveyor belt. The strength ratings for aramid-reinforced belts vary from kN/m to kN/m. The belt is typically constructed using a single-ply DpP (Aramid) carcass.
Protection to the carcass is achieved by hard-wearing rubber covers of variable thicknesses from 2 mm to 12 mm to suit the application.
PowaMAX is manufactured with the unique FlexTECH construction that provides the highest tenacity (strength to mass ratio) of any conveyor belting. Selecting this type of belting rather than a steel cord reinforced equivalent may have significant long-term cost benefits.
Due to its reduced thickness, significant more belting can be stored on a reel of 2.5 m diameter. The benefit herein lies in that for long overland conveyors, the number of splices will be significantly reduced, having an impact on the project cost and time.
As the belt is so much lighter than a steel cord reinforced equivalent, it is much easier to install and manhandle, reducing potential safety risks during the execution of the installation of the belt. REMA TIP TOP has perfected the finger splices for this type of belt. The ultimate benefit of using an Aramid reinforced conveyor belt occurs in its use.
Summary
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When the mechanical design of a conveyor is performed, the engineer will determine a value referred to as an &#;empty belt tension&#;, and the mass of the belt, being a mass, the drive must rotate, is taken into account.
Using an Aramid reinforced belt, the mass of the equivalent steel cord reinforced belt may be as much as 10 kg/m more. For a humble 500 m long conveyor ( m of belting), the drive would be required to turn an additional 10 t of belting should a steel cord reinforced conveyor belt be selected.
This will have a profound impact on the drive selection. An additional benefit of using the Aramid reinforced carcass is the fact that due to the reduced running tensions, it may be that a lower belt class is required as well as reduced pulley bearings and shafts.
Furthermore, the reduced running tension will result in a lower take-up and counterweight requirement.
What else we offer
Over and above the range of REMA TIP TOP conveyor belting on offer, they also offer a full portfolio of products and service systems, tailored to the customers&#; needs, providing economically efficient and technically proven solutions.
Click here to see the full range of REMA's offerings of conveyor equipment such as idlers, belt cleaners, impact points, skirts and seals, and conveyor consulting services
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If you are looking for more details, kindly visit Metal Reinforced Conveyor Belts.