Large Angle Belt Conveyor
Large-angle belt conveyors, also known as sidewall belt conveyors or corrugated sidewall belt conveyors, are special belt conveyor equipment designed for conveying bulk materials at large angles or even vertically lifting them.
The core innovation of the large-angle belt conveyor lies in its unique conveyor belt structure—freely stretchable rubber corrugated vertical "skirts" are glued to both sides of the flat rubber conveyor belt, and horizontal partitions with a certain strength and elasticity are glued between the skirts, together forming a box-shaped bucket structure, so that materials can be continuously conveyed in the bucket. This structural design enables the equipment to convey materials at inclination angles ranging from 0° to 90°. At the same time, the large-angle belt conveyor retains the advantages of general belt conveyors, such as simple structure, reliable operation, and convenient maintenance, and has unique advantages such as large-angle conveying, compact structure, and small footprint.
In practical applications, the steep-angle belt conveyor effectively resolves the operational limitations faced by standard belt conveyors when dealing with steep inclines. By enabling vertical or steep-angle material lifting within a confined space, it significantly reduces both the equipment's footprint and civil engineering investment costs. A single steep-angle belt conveyor can replace the traditional combination of a horizontal conveyor and a bucket elevator. The system boasts a maximum conveying capacity of 6,000 tons per hour and can handle materials with particle sizes of up to 400 mm.
Equipment Structure And Composition
The large-angle belt conveyor is mainly composed of the following core components: (I) Corrugated sidewall conveyor belt: This is the most core traction and load-bearing component of the equipment, consisting of three parts: base belt, corrugated sidewall, and cross partition. The base belt resembles a standard conveyor belt but possesses greater transverse rigidity; the sidewalls are corrugated (e.g., sine wave, square wave, or W-shaped wave) to allow the belt to navigate the convex and concave arc sections of the pulleys. Cleats are spaced at intervals between the sidewalls; based on their cross-sectional shape, they are classified into types such as T, TS, C, TC, and TCS. T and TS types are suitable for inclination angles β ≤ 40°; the C type is suitable for β > 40° with materials having good flowability; TC and TCS types are suitable for β > 40° with materials that are sticky or have large particle sizes.
(II) Drive unit: This is the power source of the conveyor, consisting of a Y-series electric motor, a ZJ-type shaft-mounted reducer, and a wedge-type backstop. The installation levelness error of the drive unit must be controlled within 0.5 mm.
(III) Drive pulley and bend pulley: The drive pulley is the primary component for power transmission, enabling the belt to move via friction; these pulleys come in rubber-lagged and smooth-faced versions, with rubber lagging used to increase adhesion between the pulley and the belt. Bend pulleys are used to change the running direction of the conveyor belt.
(IV) Idler sets: These include various types such as upper flat impact idlers, parallel upper idlers, dual-roll lower idlers, friction-type upper flat self-aligning idlers, and friction-type lower self-aligning idlers.
(V) Tensioning device: This includes either a screw tensioning device or a gravity-type carriage tensioning device, used to adjust belt tension and prevent slippage on the drive pulley.
(VI) Frame and supports: These utilize a "Z"-shaped layout, with the entire machine divided into an upper horizontal section, a lower horizontal section, and an inclined section. Smooth transitions for the conveyor belt between the horizontal sections and the inclined section are achieved using convex and concave curved frame segments. Intermediate frame supports are available in low, medium, and high configurations.
(VII) Belt Cleaners and Safety Devices: Includes head-end cleaners and return-strand cleaners to remove material adhering to the conveyor belt; also equipped with safety protection devices such as belt misalignment alarm systems and bidirectional pull-cord switches.
Application scope of the equipment
Large-angle belt conveyors have a wide range of applications. In the coal industry, they are used for the underground and surface transport of raw coal, clean coal, and coal gangue. In the metallurgy and mining sectors, they transport materials such as ore, mineral powder, sintered fines, and iron concentrate. The building materials and cement industries utilize them for handling sand, gravel, aggregates, cement, limestone, and gypsum. In the chemical and fertilizer sectors, they are used for transporting raw materials, finished products, and chemical powders. In agriculture and the grain industry, they handle grains (such as wheat, corn, and rice) and feed ingredients. Power generation and port industries employ them for coal handling systems in thermal power plants and for the loading and unloading of bulk cargo at terminals. They also serve environmental protection and solid waste treatment sectors by transporting materials for projects such as municipal sludge and waste processing. Furthermore, multiple steep-angle belt conveyor units can be combined into a system to meet specific process requirements, enabling the continuous transport of materials over long distances, across large spans, and at steep angles.
Types of usable raw materials
Steep-angle belt conveyors are capable of transporting a wide variety of materials. They are suitable for operation in ambient temperatures ranging from -25°C to +40°C and can handle various bulk materials with a bulk density of 0.5–2.5 t/m³. Regarding particle size, they can accommodate materials up to 550–600 mm. Typical materials include coal, coke, ore, mineral powder, sand and gravel, aggregates, sand, cement, lime, chemical fertilizers, grains (wheat, corn, rice, etc.), wood chips, crushed stone, limestone, clay, and sintered fines. Special materials: For materials with specific handling requirements—such as those involving high temperatures, acidity or alkalinity, oil content, or organic solvents—specialized sidewall conveyor belts must be used.
The working principle of the equipment
The working principle of a large-angle belt conveyor is basically the same as that of a general belt conveyor, but its core difference lies in the use of a special conveyor belt with corrugated sidewalls and cross diaphragms.
Its operation proceeds as follows: the conveyor belt loops around the drive pulley and the return pulley located at either end of the frame, forming a closed circuit. When the drive unit rotates the drive pulley, the friction between the pulley and the belt propels the belt along a predetermined path. Material is fed onto the belt via a loading chute; the corrugated sidewalls, transverse cleats, and the base belt combine to form "pocket-like" containers, enabling continuous material transport. During conveyance, the corrugated sidewalls prevent material spillage from the sides, while the transverse cleats support the load and prevent it from sliding backward on inclined sections. It is precisely this "sidewall-plus-cleat" pocket structure that allows for the safe, stable, and continuous transport of materials across a wide range of steep angles—from 0° to 90°. Upon reaching the discharge end, the material is unloaded through the discharge chute under the combined influence of centrifugal force and gravity.
Equipment operating instructions
Pre-start Preparation: Before operation, carefully inspect the conveyor belt for misalignment and ensure the load is properly positioned. Check the gearbox oil level and ensure all fastening screws are tight. Inspect the area between the belt and the pulleys for any trapped raw materials. Check the belt joints for abnormalities (such as cuts or cracks). Signal to start the machine only after confirming that no personnel or debris are on the conveyor belt.
No-load Startup: High-angle belt conveyors must be started and stopped without a load; starting under load is strictly prohibited. When multiple conveyors are connected in series, they must be started sequentially in the direction opposite to the material flow.
Operational Monitoring: Closely monitor the equipment for normal operation. Promptly address any factors causing belt misalignment. Reduce the material drop height to minimize impact on the conveyor belt. It is strictly forbidden to use tools to clean material adhering to the pulleys while the machine is running.
Shutdown Procedure: Stop the units sequentially in the direction of the material flow; stopping under load is strictly prohibited. Maintain proper records of equipment usage and maintenance, and ensure a smooth shift handover.
Equipment maintenance methods
Daily Inspections: During every shift, inspect the conveyor belt joints for abnormalities such as cuts or cracks. Check the top and bottom rubber layers and the sidewalls for wear. Inspect the rubber scrapers on the cleaning devices for excessive wear. Ensure all idlers rotate freely and promptly replace any that are seized or damaged. Prevent belt mistracking and ensure the belt runs along the centerline.
Periodic Maintenance: Regularly lubricate all bearings. Re-tighten all anchor bolts and cross-beam connection bolts. Repair or replace worn conveyor belts and other components. Periodically inspect material-scraping devices installed on idlers, hold-down wheels, and pulleys; ensure their surfaces remain smooth to minimize wear on the belt.
Lubrication Management: Apply grease to drive unit bearings at the prescribed intervals. Regularly check the oil level in the gear reducer and promptly top up or replace the gear oil.
