Conveyor efficiency, safety and productivity are critical components to any mining operations or bulk shipping terminal. Therefore conveyor belt mis-tracking or mis-alignment can be a major concern.
The problem, as shown in the pictures of the right, conventional training idlers are not effective. Some of the problems are; the side-guide rollers and exposed center pivot will seize, which can creates sever belt edge damage, the trainer in most cases is tied off in one direction therefore not allowing the trainer to actuate when need and lastly conventional tracking idlers will not work on reversing conveyor systems. On one particular reversing conveyor system the customer had a conveyor belt mis-alignment switch sending and alarm nearly every day.
After a complete survey of the conveying systems and the biggest problems were identified, it was recommended to the customer that they install ASGCO Tru-Trainer® series of conveyor belt tracking idlers approximately 20’-30’ (7m-10m) prior to any conveyor pulley. After the installation of the Tru-Trainers the customer has not had a single belt mis-alignment alarm on any conveyor that now has a Tru-Trainer; including the reversing conveyors.
The Tru-Trainer series of Conveyor Belt Tracking idlers employs a patented, unique highly effective tracking action, which in non-damaging to the conveyor belt and reacts immediately if the belt begins to steer off center. Because it does not rely on contact with the belt edge in order to guide the belt, belt edge damage which frequently occurs with conventional tracking systems, is avoided.
This copper mill facility was processing crushed ore the consistency of sand. They were using conventional guide roller trackers that kept failing. Due to the design of the guide rollers they continually came in contact with the belt’s edge which made them slow to react and caused premature “side wear” on the belt. The operators were prone to “tying the guide rolls off” which eliminated “the ability for it to train/align the belt.” Also, “build-up” of carry-back on the external pivot caused freeze-up (stop working) making it vulnerable to the elements of the harsh environment.
Install ASGCO 36” Troughing Tru-Trainer® prior to where the problem of miss alignment occurred on the “load-carrying side of the belt.” Conventional training devises utilize “guide rolls” that cause premature belt wear and are slow to react to belt miss tracking. At no time does the ASGCO Troughing Tru-Trainer wing’s contact the belt’s edge.
ASGCO Tru-Trainer Troughing Idler’s unique center roller does all the belt’s steering. It’s quicker to react than conventional trainers with guide rolls. The internal sealed pivot was protected from the harsh elements and fugitive build-up in the copper mill, which caused the other conventional guide roller pivots to “freeze up” and not perform. ASGCO’s Tru-Trainer Troughing Idler’s superior belt tracking performance is saving them money due to less spillage, less downtime and less belt wear.
The driving force behind this project was initiated out of a safety issue. The existing bucket design would require 3 to 4 operators to manually flip the buckets, which would put the operators in a dangerous position, as the buckets are very heavy and could cause an injury during the process of flipping the bucket to change direction. Therefore, corrective actions resulting from an incident investigation were to redesign and re-engineer the bucket to enable the bucket wheel to change direction without flipping the buckets. Due to the split design of the new bucket, the challenge was to ensure the same tonnage would flow thru the bucket without any restriction.
The existing bucket wheel was modeled and a 3-DEM analysis was performed to establish a baseline of existing performance levels. We then incorporated the client’s models of the new split bucket design into the 3-DEM simulation and then compared the differences between the two designs and provided data to the client to show the results of the simulations. The client was able to view the results and make modifications to their design to improve the material flow and capacity.
After the new split buckets were installed on the bucket reclaimer, they were able to realize the time-savings of not having the maintenance downtime to flip the buckets, while maintaining the same capacity. They also found another benefit to the split bucket was that it evened out the distribution of the material on the belt, previously with the original bucket, when the material was transferred to the conveyor belt it would leave piles of material on the belt and, with the split bucket the material was more evenly distributed on the belt. Therefore, reducing the impact and wear on the belt.
This coal mine facility faced many challenges, as all bulk handling facilities do. Overcoming obstacles in improving the safety of their conveyor system was a top priority. These type of conveyor systems have tendency to mis-track causing the belt to cut into the hanging metal brackets holding the return roller in place. If and when the bracket gives way, the large return roller will be sent tumbling downward, creating a dangerous safety hazard.
After a thorough inspection of the conveyor it was pointed out that in addition to resolving the belt mis-tracking issue, there needed to be further changes made to ensure safety in the workplace and to comply with OSHA and MSHA requirements. It was recommended that they install ASGCO Safe-Guard Return Idler Cages to protect the return rollers and objects from falling, preventing injuries to workers and equipment.
ASGCO Safe-Guard Return Idler Cages were installed in the work areas and along the roadways to catch the return rollers if they fell. This brought the conveyors into compliance with MSHA title 30 regulations and helped the mine to reach its safety compliance goal! The customer was very pleased with the success.
The customer is a larger coal burning power plant that has had FGD Scrubber Conveyors in service for many years to help control the plants emissions. The product that is being conveyed is a synthetic gypsum product that is either conveyed or shipped to a nearby gypsum board plant. This product is very sticky and corrosive and builds up on the conventional return idlers and return trainers. This causes the belt to mis-track and rub the conveyor structure.
After ASGCO representatives surveyed the conveyor and pointed out some of the problems that were causing the belt mis-tracking, the benefits of installing two return Tru-Trainers to help keep the conveyor belt centered on the conveyor were discussed.
After installing the Tru-Trainers the belt immediately centered itself on the conveyor system. The customer watched the performance of the Tru-Trainer Flat Return Idlers and was extremely impressed.
In today’s manufacturing environments where the cost of downtime is measured in thousands of dollars per hour, polyurethane’s incredible durability actually increases your company’s profitability.
The diverse properties of castable polyurethane make it the leading choice of engineers looking for long lasting materials for their high load, high stress environments. Polyurethane routinely outperforms plastic, rubber and steel in its overall ability to resist harsh environmental factors such as abrasion, heat, solvents, oil and acid. In addition, polyurethane‘s noise abatement ability makes it the preferred material in chain-drive designs, conveyor belt systems and assembly line environments.
Advantages of a Custom Molded Urethane Part:
- Prints are not required. We can reverse engineer an existing part.
- Considerably tougher than plastic.
- One step molding process is more cost effective than machining blocks of plastic.
- Can produce custom molded parts to replace brass parts which require expensive machining. The parts can be slick with low friction if needed.
- Tooling for compression-molded parts is very inexpensive in comparison to other forms of molding such as injection and transfer.
- Delivery for a custom molded urethane part is very quick.
- Able to mold intricate shapes with or without metal inserts.
- We can quote from 1 custom molded part to over 1000 custom molded parts.
- We can bond custom molded urethane parts to other substrates such as phenolic, steel, aluminum and plastic
ASGCO manufactures urethane cast products as per customer requirement under strict confidentiality agreements with our customers, respecting any and all patents on the products they have designed and given us the opportunity to manufacture.
Urethane Classifier Shoes
ASGCO Urethane Classifier Shoes feature our special wear-resistant urethane material at the outer edge of the shoe (the area that sees the most abrasion) to extend the wear life of the shoe. Longer shoe life means you experience less maintenance downtime and lower operating costs, resulting in higher productivity and profits.
Urethane Lagged Pulleys & Rollers
ASGCO manufactures Urethane Cast Rollers and Pulleys as per customer requirement under strict confidentiality agreements with our customers, respecting any and all patents on the products they have designed and given us the opportunity to manufacture.
Urethane Hydrocyclone Liners
At ASGCO we manufacture Hydrocyclone Urethane Liners as per customer requirement under strict confidentiality agreements with our customers, respecting any and all patents on the products they have designed and given us the opportunity to manufacture.
Pipeline Products and Pigs
ASGCO manufactures quality Pipeline Products and Pigs, particularly for the pipeline and offshore oil and gas industry, as per customer requirement under strict confidentiality agreements with our customers, respecting any and all patents on the products they have designed and given us the opportunity to manufacture.
Urethane Sheets and Linings
Our ASGCO-thane® Polyurethane Liners are custom manufactured to solve wear issues related to bulk transport of many types of materials. Urethane’s exceptional abrasion resistance makes it an ideal solution for protecting metal hoppers and chutes from abrasive compounds, as well as great for sticky materials.
ASGCO’s Impact Bed Cradles prevent large rocks, tramp metal, roof bolts and bucket teeth from stopping your operation!
ASGCO’s Impact Bed Cradles (patent pending) are designed to provide protection to your conveyor belt from impact damage. Our modular style impact beds provide protection for the conveyor belt, as well as a tool to help control spillage in the conveyor-loading zone. Our unique, semi-U-shaped design supports the conveyor belt across the entire width – eliminating any unsupported areas between the rollers or bars found on traditional impact idlers or traditional impact beds where typical damage can occur in the idler junction points. The Impact Bed Cradles consist of a heavy-duty frame with removable (Slide-in or Slide-out) sides with center sections for ease of installation and maintenance.
- Impact Bed Cradles - no pinch point or idler junction area utilizing our 17.5° bars for 35° idler systems; 10° degree bars for 20° idler systems and 22.5° degree bars for 45° idler systems.
- Absorbs Impact - with heavy-duty steel designed framework and our impact bars that are manufactured with absorbent, 40-durometer rubber that can really take the shock of large material.
- Modular Design - cradles can be manufactured in 2′ (600mm), 3’ (900mm), 4′ (1200mm) or 5′ (1500mm) long, depending upon the size of your material impact area.
Available in either Standard duty (1,000 ft/lbs of impact) or Mine duty (2,000 ft/lbs of impact).