The complete belt conveyor system shall include but not be limited to the following components: (1)Conveyor belt (2)Idler set (3)Pulley set (4)Drive unit (including motor, reducer, mechanical coupling, drive unit base, etc.) (5)Disc brake (6)Backstop (7)Take-up device (8)Skirtboard (9)Belt cleaner (10)Structural components: Middle frame, legs, pulley brackets, receiving plate, safety guards, handrails, etc. (11)Paint and solvent for field touch-up; oils and lubricants for trial operation (12)All consumables and wearing parts required for installation, commissioning and trial operation (13)Special tools, instruments for installation, maintenance, inspection and operation; testing instruments.
Schematic diagram of the structure is shown in Figure 1:
Conveyor Belt
The primary component for traction and material handling. It must possess adequate strength and load capacity. Selection options include: flame-resistant anti-static PVG solid-woven belts (PVG680S-PVG2500S); flame-resistant anti-static PVC solid-woven belts (PVC680S-PVC2500S); flame-resistant steel cord belts (ST/S630-ST/S4000 N/mm) (Standard: MT668-1997).
Belt Jointing: Vulcanized splicing required with ≥100% static strength retention at joints and service life ≥10 years.
Permanent/elastic elongation ≤0.2%. Compliance with MT668 standards mandatory.
Manufacturers must provide: splicing methodology and materials; environmental requirements for splicing; vulcanizer specifications; operator training programs.
Drive Unit
Integrated assembly comprising: motor, reducer, hydroviscous soft starter, brake, backstop, high/low-speed shaft couplings, mounted on fabricated steel base fixed to foundation.
Motors: Explosion-proof mining asynchronous motors with ±5% voltage/±1% frequency tolerance. For mining roadway conveyors, motors interchangeable with face equipment are preferred for maintenance efficiency.
Reducers feature high-capacity, efficiency, lightweight and long service life. See manufacturer's manual for selection and maintenance.
Couplings shall have excellent elasticity, high strength, reliability, safety, load capacity and extended service life.
(1) Serpentine spring-type couplings provide shock absorption and enhanced torque transmission for high-power systems with heavy impact loads.
(2) Rated capacity ≥1.5× transmitted torque.
(3) High-speed compensation for axial/radial/angular displacement with easy maintenance (no motor/equipment movement required).
(4) Extended service life with minimal maintenance requirements.
Drive Unit Frame
Reducer and motor mounted on common machined steel base with adjustment shims and screw adjusters.
Frames shall have adequate rigidity/strength/stability with properly anchored bolts and vibration-free operation. Manufacturing tolerances per relevant standards.
Materials shall meet chemical/mechanical standards. Premium steel with shot blasting (Sa2½) and primer coating. Stress relief for welds/machined areas.
Pulleys
Drive and bend pulleys. Fabricated from shells and end discs: seamless tubes for <320mm OD, rolled/welded plates for >320mm OD, or cast-welded construction.
Drive pulleys: Single (210-230° wrap), double (350°), or multi-drum (high power). Surfaces: smooth steel (short conveyors), lagged rubber/ceramic (long-distance). Lagging types: smooth, diamond, herringbone (directional). Underground applications require flame-resistant lagging.
Pulley Shells
Shell materials shall meet national standards with shot blasting pretreatment.
Hubs
Hubs shall undergo MT/UT inspection. CO₂ welding for circumferential/longitudinal seams with NDT and stress relief.
Bend Pulleys
For direction changes or wrap angle increase, with smooth rubber surfaces.
Forged shafts with NDT reports and design-compliant torque/load ratings.
Shaft deflection between bearings under max load (excluding shell stiffness)...
Idlers
For supporting belt and load. Types include: troughing idlers (35° carrying side), transition idlers (5°-30° near pulleys).
Self-aligning idlers (35°) for belt tracking correction.
Impact idlers (rubber-ring 35°) under loading zones absorb kinetic energy.
Return side: V-return/pallet idler alternation for belt centering.
Idler Spacing:
Carrying side: 1000-1200mm; Return side: 2400-3000mm; Convex/concave curves: 500-600mm; Impact zones: 1/2-1/3 troughing spacing.
Idler Performance Standards:
① Simulated friction coefficient f ≤0.020 under full load.
② Service life: 30,000 hours (≤3% failure rate, excluding impact idlers).
③ Rotation resistance: ≤3.0N @ 550r/min (≤4.5N after 1h static).
④ Radial runout: ≤0.5mm (excluding impact idlers).
⑤ Axial displacement: ≤0.7mm @ 500N.
⑥ Dust/water ingress: No coal dust in grease after 200h; ≤150g water after 72h spray.
⑦ Axial load capacity: 15kN.
⑧ No damage/cracks in drop tests.
Take-up Systems
Types: screw, cart, vertical, hydraulic, winch. Functions: prevent slip, limit sag, allow splicing.
Frames
Main structure with three standard types (head/tail/drive/bend stations) and intermediate sections. Fabricated H-beam triangles with machined mounting surfaces. NDT for critical welds.
Frame Types:
01-frame: Discharge terminals.
02-frame: Drive/bend pulley stations.
03-frame: Tail terminals.
Two-piece design for transport (field bolting/welding).
Intermediate frames: Standard (6m), non-standard (<6m), convex/concave curves. Standard hole spacing: 1000/1200mm.
Convex radii: 12-34m (400-600mm spacing). Concave radii: 80-150m.
Legs: Type I (no bracing), II (braced). Bolt-on for transport (optional field welding).
Skirtboards
For centralizing material flow with 50-67% belt width opening.
Modular construction (lead/tail sections + variable mid-sections).
Cleaners
For removing carryback: blade-type, P/H alloy cleaners, return belt ploughs.
Install P/H cleaners per manufacturer's instructions.
Return ploughs prevent material ingress to tail/take-up pulleys (mounted on upstream frames).
Safety Guards
Handrails and Safety Meshes
Required at exposed moving parts:
Anti-ejection nets along walkway sides.
Pulley guards, take-up railings, and rotating equipment covers.
Galvanized mesh guards for easy handling.
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