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.
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.
Objective: To protect workers from all areas of conveyor systems that create a safety hazard, yet allow for easy removal of conveyor guarding, and replacement, when maintenance on the conveyor system is required. Read more
At this copper mining operation, the return idlers that track the belt on the conveyor system were very hard to access. The only way to change the idlers on this 36” wide conveyor belt, was to clear out all of the material on the ground and rent a 135’ man lift to access the conveyor belt tracking return idlers. Read more
ASGCO’s Conveyor Belt Guarding products have one, top priority in mind – employee safety. Maximizing years of collected data on workplace accidents, our conveyor guarding equipment is innovative in it’s design and can be customized to fit any application.
To ensure safety in the workplace, ASGCO has developed the Safe-Guard return idler cage to protect workers and provide an affordable and durable solution for guarding needs at a belt conveyor.
Return idlers should be guarded wherever employees could contact them. Guarding return idlers may be required where employees work or travel beneath the belt.
The ASGCO Return Idler Guard was designed to prevent injuries from pinch points and to catch the return idler if it should fall. Read more