flexowell manual en

FLEXOWELLManual

20

06

...genuine FLEXOWELLthe first

and all ways the best to lift or lower bulk materialsFLEXOWELL and FLEXOLIFT-Systems:

reliable, efficient,outstanding performance!

FLEXOWELL FLEXOLIFT FLEXOTURN FLEXOFAST POCKETLIFT are registered trademarks

105 / 2006

1

moegerhaanVersion 1

105 / 2006

2

Co

nve

yor

Bel

ts

FLEXOWELL-HandbuchManual

Metso Minerals (Moers) GmbH, Product Group FlexowellP.O. Box 10 22 28, Clausthalstr. 2, D-47441 Moers, GermanyPhone +49 28 4114 40, Fax +49 28 4114 41 29www.flexowell.net, www.metsominerals.com

Innen_1 04.03.2003 17:42 Uhr Seite 1

Table of contents ; numerical

Number Title

1.7 1.8; 1.9 1.10E - 1.16E

General conversion factors nomenclature table bulk density

2.1 2.2 2.3 2.4 2.5; 2.6; 2.7; 2.8 2.9E

FLEXOWELL product line belt description (cross-rigid) cross rigid fabric and steelcord belts sidewall qualities sidewall sizes cleat profile sizes and qualities guidelines for the application of FLEXOWELL belts for the transport of hot materials

3.1 3.2 3.3 3.4

3.5

3.6

FLEXOWELL design criteria length of surface relating to lift and conveying angle configuration with FLEXOLIFT systems comparison of conveying cross section at 1000mm belt width Calculation of volume flow and mass flow in dependence of angle of repose and cleat filling factor. ranges of velocity relating to the lump size of material to be conveyed with FLEXOLIFT systems FLEXOWELL -belt dimensions relating to the lump size

4.1 4.2 4.3 4.4 4.5; 4.5.1 4.6; 4.6.1 4.7; 4.8 4.9 4.10 4.11 4.12 4.13

4.14 4.15 4.16 4.17 4.18 4.19 4.20

FLEXOWELL system design and accessoires main components standard application main components special application drive pulley arrangement take-up and bend pulley arrangement deflection curve for carrying strand bend pulley for carrying strand trajectory condition clause of centrifugal force and by gravity discharge deflection discs belt support in the return strand on stub idlers carrying idlers impact idlers belt support in the return strand on solid rubber return discs and stub idlers on FLEXOWELL belts without cleats FLEXOWELL solid rubber return discs belt cleaning device belt cleaning device with supporting wheels belt guide device with FGR FGR for lateral belt guide feed hopper proposal for bottom station with spillage reclaiming device (laterally open)

1 3 E 05 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Table of contents ; numerical

Number Title

4.21 4.22 4.23 4.24 4.25 4.26

proposal for bottom station with spillage reclaiming device (chain scraper) proposal for head station with spillage reclaiming device (chain scraper) proposal "encased system" proposal "guide rollers" (with snap closure) proposal for fixed, combined pulley and plow scraper proposal for placing of scrapers at bottom station

5.1E 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10E; 5.11E

FLEXOWELL belt alignment and trouble shooting main rules for the alignment of the belt travel adjustment of belt running: procedure in numerical order function of the FLEXOWELL guide rollers FGR adjustment of the deflection curve adjustment of the bend pulley packing (steelcrate) for belts with cleats packing (steelcrate) for belts with 300ES-400ES packing (steelcrate) for belts with 500ES-630ES cleat assembly TC-GS280 TC-GS470 ; TB-GS500 and TB-GS630 FLEXOWELL trouble shooting

6.1; 6.2 7.1; 7.2 7.3

7.4

8.1; 8.2 9.1; 9.2

FLEXOWELL systems example FLEXOLIFT INNERCONVEYOR FLEXOTURN system table torsion angle relating to the effective torsion length and belt width for fabric belts table torsion angle relating to the effective torsion length and belt width for steelcord belts FLEXOWELL C-system FLEXOFAST system

10.1.1 - 10.1.7 10.2.1 - 10.2.20 10.3.1 - 10.3.4 10.4.1 - 10.4.5 10.5.1 - 10.5.5

FLEXOWELL references (Extract of over 55.000 installations) horizontal and steep inclined systems vertical systems shiploaders selfunloading vessels shaft systems for underground mining and tunnelling

11.1

11.2

nomograms nomogram for cleat types TC-G110 up to TC-G220 (preliminary net belt width selection) nomogram for cleat types TC-GS280 up to TC-GS600 (preliminary net belt width selection)

12.1E 12.2E

FLEXOWELL inquiry data sheet inquiry sheet for technical calculation inquiry sheet for replacement belts

1 4 E 05 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Table of contents ; alphabetical

Title Number

A adjustment of belt running: procedure in numerical order

adjustment of the bend pulley

adjustment of the deflection curve

5.2

5.5 5.4

B

belt support in return strand on solid rubber return discs and stub idlers on FLEXOWELL belts without cleats

belt cleaning device belt cleaning device with supporting wheels belt description (cross-rigid) belt guiding device with FGR belt support in the return strand on stub idlers bend pulley for carrying strand

4.13

4.15 4.16 2.1 4.17 4.10 4.6; 4.6.1

C

calculation of volume flow and mass flow in dependence of

angle of repose and cleat filling factor carrying idlers cleat mounting TC-GS280 TC-GS470 ; TB-GS500 and TB-GS630 cleat profile sizes and qualities comparison of conveying cross section at 1000mm belt width configuration with FLEXOWELL systems conversion factors cross-rigid fabric and steelcord belts

3.4

4.11; 4.12 5.9 2.5; 2.6; 2.7; 2.8 3.3 3.2 1.7 2.2

D deflection curve for carrying strand

deflection discs

drive pulley arrangement

4.5; 4.5.1

4.9 4.3

F

feed hopper

FGR for lateral belt guide

FLEXOFAST system

FLEXOLIFT INNERCONVEYOR

FLEXOTURN system FLEXOWELL C-system FLEXOWELL belt dimensions relating to the lump size FLEXOWELL solid rubber return discs FLEXOWELL trouble shooting function of the FLEXOWELL guide rollers FGR

4.19

4.18

9.1; 9.2

6.1; 6.2

7.1; 7.2 8.1; 8.2 3.6 4.14 5.10E; 5.11E 5.3

G guidelines for the application of FLEXOWELL belts

for the transport of hot materials

2.9E

I impact idlers inquiry sheet for replacement belts

inquiry sheet for technical calculation

4.12 12.2E 12.1E

1 5 E 05 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Table of contents ; alphabetical

Title Number L length of surface relating to lift and conveying angle

3.1

M main components special application main components standard application main rules for the alignment of the belt travel

4.2 4.1 5.1E

N

nomenclature nomogram for cleat types TC-G110 up to TC-G220 (preliminary net belt width selection) nomogram for cleat types TC-GS280 up to TB-GS600 (preliminary net belt width selection)

1.8; 1.9 11.1

11.2

P

packing (steel crate) for belts with 300ES-400ES packing (steel crate) for belts with 500ES-630ES packing (steel crate) for belts with cleats proposal "encased system" proposal "guide rollers" (with snap closure) proposal for bottom station with spillage reclaiming device (chain scraper) proposal for bottom station with spillage reclaiming device (laterally open) proposal for fixed, combined pulley and plow scraper proposal for head station with spillage reclaiming device (chain scraper) proposal for placing of scrapers at bottom station

5.7 5.8 5.6 4.23 4.24 4.21 4.20 4.25 4.22 4.26

R

ranges of velocity relating to the lump size of material to be conveyed with FLEXOLIFT systems references (Extract of over 55.000 installations) : -horizontal and steep inclined systems -vertical systems -shiploaders -selfunloading vessels -shaft systems for underground mining and tunnelling

3.5

10.1 - 10.41 10.1.1 - 10.1.7 10.2.1 - 10.2.20 10.3.1 - 10.3.4 10.4.1 - 10.4.5 10.5.1 - 10.5.5

S sidewall qualities sidewall sizes

2.3 2.4

T

table bulk density table torsion angle relating to the effective torsion length and belt width for fabric belts table torsion angle relating to the effective torsion length and belt width for steelcord belts take -up and bend pulley arrangement trajectory

1.12E - 1.19E 7.3

7.4

4.4 4.7; 4.8

1 6 E 05 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Umrechnungsfaktoren Conversion factors

Nr. No. Metrisch Englisch English Metric

1 mm x 0,03937 inch inch x 25,4 mm

2 cm x 0,3937 inch inch x 2,54 cm

3 m x 3,2808 ft ft x 0,3048 m

4 m x 1,0936 yards yards x 0,9143 m

5 km x 0,6214 miles miles x 1,6093 km

6 m2 x 10,764 square / ft square / ft x 0,0929 m2 7 m2 x 1,196 square / yards square / yards x 0,8361 m2

8 kg x 2,2046 lbs lbs x 0,4536 kg 9 kg/cm x 5,618 lbs / inch lbs / inch x 0,1786 kg/cm 10 kg/m x 0,6719 lbs / ft lbs / ft x 1,4881 kg/m

11 t/ m3 x 62,43 lbs / cubic ft lbs / cubic ft x 0,016018 t/ m3

12 m3/h x 35,314 cubic ft/h cubic ft/h x 0,0283 m3/h 13 m3 x 1,308 cubic yards cubic yards x 0,7645 m3

14 m/sec x 196,85 ft / min ft / min x 0,00508 m/sec

15 t x 1,102 short tons short tons x 0,9072 t

16 t x 0,9842 long tons long tons x 1,016 t

17 PS x 0,9863 horse power horse power x 1,014 PS 18 KW x 1,341 horse power horse power x 0,7457 KW

19 l x 0,2642 gallon gallon x 3,785 l 20 hl x 2,8377 bushels bushels x 0,3524 hl

21 g x 15,43 grains grains x 0,0648 g 22 g x 0,035 ounces ounces x 28,35 g

23 N/mm x 0,571 PIW PIW x 1,7513 N/mm

24 N/mm x 142,2273 lbs / inch (PSI) lbs / inch (PSI) x 0,007031 N/mm 25 0 Kelvin = - 273 C 0 C = 273 Kelvin

26 n Grad C = 32 + 9 / 5 = Grad F n degree F = 5 / 9 (n 32) = degr C

1 7 05 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Nomenklatur ; Nomenclature

Symbol Einheit Beschreibung Description Symbol Dimension

Frderwinkel, Aufgabestrecke conveying angle, feeding section Frderwinkel, Steigungsstrecke conveying angle, inclined section Frderwinkel, Abgabestrecke conveying angle, discharge section Winkel, Verdrehung angle, torsion Stummelrollenwinkel stub idler angle Schttwinkel, dynamisch angle of repose Muldungswinkel troughing angle Reibungszahl coefficient of friction Schieflaufwinkel twisting angle Schurrenwinkel feed hopper angle % Stollenfllungsgrad cleat fill factor Bw mm ; m Gurtbreite belt width bt mm Wellenkantenkopfbreite sidewall top width bw mm Wellenkantenbreite sidewall width Ch mm Stollenhhe cleat height Cp mm ; m Stollenabstand cleat pitch Cs m2 Fllquerschnitt (Wasserfllung) conveying cross section (water level) Cv m3 Stollenvolumen, theoretisch cleat volume, theoretical

Dmin. mm ; m Trommeldurchmesser pulley diameter Db mm Durchmesser der Klopfscheibe beater disc diameter Db1 mm Durchmesser der Sttzscheibe supporting wheel diameter Dd mm Durchmesser der Ablenkscheiben deflection disc diameter Dr mm Auendurchmesser der Rcklaufringe outside diameter of return discs Dw mm Ablenkscheibenbreite deflection disc face width d1 mm Tragrollendurchmesser carrying idler diameter d2 mm Stummelrollendurchmesser stub idler diameter

d3 mm Durchmesser der Rundsthle fr Klopfvorrichtung diameter of rods for cleaning device

d4 mm Pufferrollendurchmesser impact idler roll diameter dv mm Teilung Spacing

dr1 + dr2 mm Innendurchmesser der Rcklaufringe inside diameter of return discs f %

Fllfaktor fill factor Fht mm

Wellenkantenhhe sidewall height

1 8 05 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Nomenklatur ; Nomenclature

Symbol Einheit Beschreibung Description Symbol Dimension

fs mm profilfreie Randzone free lateral space F1 N max. Gurtzugkraft max. belt tension F2 N min. Gurtzugkraft min. belt tension

FVsp N Vorspannkraft take up tension force G1 kg/m Komponentengewicht weight of components G2 kg/m2 Gurtgewicht belt weight g (9,81) m/s2 Fallbeschleunigung gravitational constant

gp1 mm Stummelrollenabstand in der Breite stub idler pitch in width H m Hubhhe vertical lift height Im t/h Massenstrom mass flow Iv m3/h Volumenstrom volume flow KN N/mm Zugfestigkeit tensile strength

Lf min. m Lnge der Aufgabeschurre length of feed hopper lg1 mm Stummelrollenlnge stub idler length Ls mm Korngre lump size Lw mm Spannweg take up travel nw mm;m Gurtnutzbreite net belt width p t/m3 Schttgewicht bulk density pd Umfangsteilung circular pitch of rods r mm Radius radius

Rmin. mm Radius Ablenkkurve radius deflection curve Rth mm Radius Ablenkkurve theoretisch theoretical radius deflection curve Rw mm Gesamtbreite Rcklaufring overall return disc face width S1 mm theoretische Gurtdicke theoretical belt thickness S2 mm Decklagendicke oben cover thickness top S3 mm Decklagendicke unten cover thickness bottom sf mm Schlagfaktor impact factor t s Zeit time v m/s Gurtgeschwindigkeit belt speed V1 m/s Geschwindigkeit Beschleunigungsgurt Acceleration belt speed v2 m/s Geschwindigkeit Abdeckgurt cover belt speed

W1 + W2 kg/m Gewichtsanteile proportion by weight w mm Rcklaufringbreite return disc face width

1 9 05 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Table bulk density

Angle of repose Bulk density

static dynamic Material to be conveyed Material to be conveyed

(german) t/m lbs/ft

alum, lumpy Alaun, stckig 0,8 - 1 50-60 40 25 alum, pulverized Alaun, Pulver 0,7 - 0,8 45-50 40 25 Alumina Tonerde, fein 0,8 - 1,0 50 - 65 30 - 40 10 alumina hydrate Aluminiumhydrat 0,3 18 30 25 alumina sul fate Aluminium - Sulfat 0,85 54 30 10 ammonium chloride Ammoniumchlorid 0,7 - 0,8 45 - 52 30 - 45 10 ammonium nitrate Ammoniumnitrat 0,7 45 30 - 45 25 ammonium sulfate, granular Ammoniumsulfat, Granulat 0,7 - 1,3 45-80 32 20 asbestos ore/rock Asbest Mineral 1,3 81 30 10 asbestos shredded Asbest - Faser 0,4 20 - 25 45 30 ashes, coal dry Schlacke 0,6 35 - 40 30 - 35 25 - 30 ashes, wet coarse Asche, Na grob 0,7 - 0,8 45-50 45 25 ashes, wet fine Asche, Na fein 0,7 - 0,8 45-50 45 25 asphalt, binder for paving Strassenasphalt 1,3 - 1,4 80 - 85 30 30 bagasse (sugar cane) Bagasse,ausgepr.Zuckerrohr 0,1 7 - 10 45 30 baking powder Backpulver 0,7 - 0,9 40 - 55 30 10 bark, wood, refuse Rinde, Holzabflle 0,2 - 0,3 10 - 20 30 30 barytes, coarse Baryt, stckig 2,1 - 2,4 130 - 150 30 15 barytes powder Barytpulver 1,9 - 2,2 120 - 140 35 10 basalt, coarse Basalt, gebrochen 1,4 - 1,7 90 - 105 25 15 basalt, fine Basalt, fein 1,3 - 1,4 80-90 25 12 bauxite, crushed Bauxit, gebrochen 1,3 80 35 25 bauxite, ground, dry Bauxit, trocken 1,1 68 30 20 bauxite, mine run Bauxit aus der Grube 1,3 - 1,45 80 - 90 35 20 beet pulp, dry Rbenschnitzel, trocken 0,2 - 0,25 12 - 15 25 - 30 30 beet pulp, wet Rbenschnitzel, feucht 0,4 - 0,72 25 - 45 30 30 beets, whole Rben, ganz 0,8 48 25 20 bentonite, crude Bentonit, roh 0,6 35 - 40 45 30 bonemeal Knochenmehl 0,9 - 1,0 55 - 60 30 20 bones Knochen 0,6 - 0,8 35-50 40 20 borax Borax 1 60 - 65 30 25 borax, fine Boraxpulver 0,7 -0,9 45 - 55 30 10 bran Kleie 0,3 18 10 12 brewers grain, dry Brauereigerste, trocken 0,4 - 0,5 25 - 30 20 10

1 10 E 05 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Table bulk density

Bulk density Angle of repose static dynamic

Material to be conveyed Material to be conveyed (german)

t/m lbs/ft brewers grain, wet Brauereigerste, feucht 0,9 55 - 60 20 10 brick, hard Ziegel, gebrannt 2,0 125 30 30 brick, soft Ziegel, ungebrannt 1,6 100 30 30 buckwheat Getreidemehl 0,6 - 0,7 40 - 42 25 - 35 10 calcium carbide Calziumcarbid 1,2 75 20 18 carbon pellets Rupellets 0,3 - 0,4 20 - 25 - 5 carbon, powder Kohlenstaub 0,1 6 10 12 carborundum Karborund 1,6 100 10 15 cashew nuts Cashewnsse 0,6 35 30 22 cement portland , aerated Zement, trocken 1,0 - 1,2 60 - 75 10 5 cement portland bulk Zement, Portland 1,4 - 1,5 94 30 - 45 25 cement portland, clinker Zementklinker 1,2 - 1,5 75 - 95 30 - 45 25 cement solid Zement, grobstckig 1,6- 1,8 100 - 110 30 - 45 25 chalk Kreide, pulverig 1,05 - 1,2 65 - 75 30 - 40 25 chalk, lumpy Kreide, stckig 1,2 - 1,4 75 - 85 30 - 40 10 charcoal Holzkohle 0,3 - 0,4 18 - 25 45 25 chips, papermill Holzhackschnitzel 0,2 - 0,5 12 - 30 40 - 45 30 chrome ore Chromerz 2,0 - 2,3 125 - 140 30 - 35 10 cinders, blast furnace Hochofenflugschlacke 0,9 57 25 - 30 20 cinders, coal Kohlenschlacke 0,65 40 25 - 30 20 clay, calcined Ton, gebrannt 1,3 - 1,6 80 - 100 30 25 clay, dry, fines Ton, fein, trocken 1,6 - 1,9 100 - 120 30 20 clay, dry, lumpy Ton, stckig, trocken 1,0 - 1,2 60 - 75 30 20 clover seed Kleesamen 0,77 48 30 10 coal anthracite Anthrazitkohle 1 60 35 12 coal anthracite, sized Anthrazitkohle 0,9 55 - 60 30 - 45 10 coal bituminous Fettkohle, fein 0,8 - 0,9 50 - 54 30 - 45 30 coal bituminous run of mine Fettkohle, gebrochen 0,7 - 0,9 45 - 55 30 - 40 25 coal lignite Braunkohle 0,7 40 - 45 30 - 40 25 cocoa nibs Kakao gemahlen 0,6 35 30 - 40 25 cocoa powder Kakao Puder 0,5 30-35 30 - 40 25 coconut meat Kokosnsse Fleisch 0,3 - 0,35 20-22 25 15 coffee fresh bean Kaffeebohnen, grn 0,5 32 25 18 coffee roasted bean Kaffeebohnen, gersted 0,4 22-26 22 15

1 11 E 05 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Table bulk density



t/m lbs/ft coke loose Koks, lose 0,4 - 0,6 23 - 35 45 30 coke petroleum calcinated Petrolkoks kalziniert 0,6 - 0,7 35 - 45 30 - 45 10 coke, breeze Kleinkoks 0,4 - 0,6 25 - 35 40 - 45 10 concrete, in place, solid Betonplatten 2,1 - 2,4 130 - 150 30 - 45 25 concrete, wet Beton, feucht 1,7 - 2,4 110 - 150 30 - 40 10 copper ore Kupfererz 1,9 - 2,4 120 - 150 30 - 45 20 copper ore, crushed Kupfererz, gebrochen 1,6 - 2,4 100 - 150 30 - 45 20 copper sulfate Kupfersulfat 1,2 - 1,35 75 - 85 30 - 45 20 copra cake ground Koprapellets 0,6 - 0,7 40-45 35 25 copra, lumpy Kopra, stckig 0,32-0,35 20-22 25 20 copra meal Kopramehl 0,6 - 0,7 40-45 35 30 corn , ear Maiskolben 0,9 56 30 - 35 25 corn, shelled Mais, geschlt 0,72 45 25 - 30 10 cornmeal Maismehl 0,6 38 - 40 30 - 45 20 cottonseed cake crushed Baumwollsaatkuchen, gebr. 0,6 - 0,7 40 - 45 30 - 45 25 cottonseed cake lumpy Baumwollsaatkuchen stckig 0,65 40-45 35 20 cottonseed dry dehulled Baumwollsamen, getrocknet 0,6 35 30 - 40 25 cottonseed dry not dehulled Baumwollkapseln, getrock. 0,3 - 0,4 18 - 25 30 - 45 20 cottonseed hulls Baumwollkapsel 0,2 12 45 25 cottonseed meals Baumwollkerne, Mehl 0,6 35-40 35 20 cryolite, lumpy Kryolith, stckig 1,44 - 1,6 90 - 100 30 - 45 20 cullet, glass scrap Glasbruch 1,3 - 1,9 80 - 120 20 - 45 20 dolomite, lumpy Dolomit, stckig 1,45 - 1,6 90 - 100 30 - 45 20 earth, dry loamy Erde, trocken 1,1 - 1,2 70 - 80 30 - 45 20 earth, wet, containing clay Erde, tonhaltig, feucht 1,6 - 1,8 100 - 110 30 - 45 30 feldspar, lump Feldspat, grob 1,4 -1,5 90 - 100 35 20 feldspar, fines Feldspat, Sand 1,6 100 30 - 45 20 feldspar, screened Feldspat, gesiebt 1,1 - 1,35 70 - 85 38 25 ferrous sulphate Eisensulphat 0,8 - 1,2 0,5 - 0,75 30 - 45 20 fish meal Fischmehl 0,5 - 0,8 31 50 40 - 45 30 fish scrap Fisch, Abflle 0,6 - 0,7 40 - 45 45 15 flaxseed cake Leinsamenkuchen 0,77 - 0,8 48 50 30 - 45 20 - 25 flour, wheat Weizenmehl 0,6 - 0,7 35 44 30 - 40 25 - 30 fluorspar Fluspat 1,4 - 1,9 85 - 120 35 - 45 25 - 30 fluorspar, lumpy Fluspat, grob 1,75 - 1,9 110 - 120 45 25

1 12 E 05 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Table bulk density



t/m lbs/ft fly ash, dry Flugasche, trocken 0,5 - 0,7 31 45 42 30 fly ash, wet Flugasche 0,7 - 0,9 45 - 55 30 5 foundry refuse sand cores Giessereisand, alt 1 -1,8 60 100 35 25 foundry sand loose graded Giessereisand, krnig 1,3 - 1,45 80 - 90 32 25 fullers earth dry Walkerde, trocken 0,5 - 0,6 30 - 35 25 10 gelantin, granulated Gelantine, krnig 0,5 32 30 - 45 20 - 25 glue fine Knochenleim Flocken 0,64 40 25 10 gluten, meal Futterpellets (Strke) 0,6 40 35 30 grain, barley Gerste 0,6 - 0,7 37 - 43 20 - 25 13 grain, distillery spent dry Malztreber, trocken 0,65 - 1 40 - 60 45 10 grain, rape-seed Raps 0,6 37 18 - 20 8 - 10 grain, rye Roggen 0,75 44 - 48 25 - 30 15 grain, wheat Weizen 0,75 44 - 48 25 - 30 15 granite, crushed Granit, gebrochen 1,4 - 1,6 85 - 100 30 - 45 20 granite, screened Granit 1,3 - 1,4 80 - 90 30 - 45 10 graphite, flake Graphitschuppen 0,6 40 - 5 gravel, bank run wet Flukies 1,4 - 1,6 90 100 30 - 40 20 - 25 gravel, dry, sharp Kies, trocken, scharfkantig 1,44 - 1,6 90 - 100 30 - 45 22 - 27 gravel, pebbles Kies, rund 1,44 - 1,6 90 100 30 - 40 20 - 25 guano, dry Guano, getrocknet 1,1 70 30 - 40 10 gypsum, aerated Gips, Porengips 1,0 - 1,1 60 - 70 30 - 40 25 gypsum, coarse Gips, grob 1,1 - 1,3 70 - 80 30 25 gypsum, powder Gips, Pulver 1,5 93 25 20 hay loose Heu, lose 0,8 5 40 30 hops spent dry Biertreber trocken 0,55 35 45 25 hops spent wet Biertreber na 0,8 - 0,9 50 - 55 45 30 ice, crushed Eis, zerkleinert 0,55 - 0,7 35 - 45 19 5 ilmenite, ore Ilmeniterz 2,2 - 2,6 140 - 160 30 - 45 20 iron ore Eisenerz 1,6 - 3,2 100 - 200 30 - 40 25 iron ore pellets Eisenerzpellets 1,9 - 2,9 116 - 180 30 - 40 20 iron oxide, pigment Eisenoxyd Pigment 0,4 25 30 - 40 25 kaolin clay Kaolin, Korn 1,0 63 30 - 45 20 kaolin talc Kaolintalkum 0,7 - 0,9 42 - 56 30 - 45 25 - 30 lead arsenate Arsenblei 1,15 72 45 18

1 13 E 05 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Table bulk density



t/m lbs/ft lead ores, fines Bleierz, fein 3,0 - 4,3 200 - 270 30 - 45 20 lead oxides Bleioxyd 1,0 - 2,4 60 - 150 30 - 45 25 lignite, air dried Braunkohle, trocken 0,7 - 0,9 45 - 55 30 - 40 20 lime fine crushed Kalk, fein gebrochen 1 60 - 65 45 30 lime, hydrated, pulverized Kalk, gelscht 0,5 - 0,6 32 - 40 30 - 45 25 lime, pebble Kalkstcke 0,85 - 0,9 53 - 56 30 - 45 20 limestone agricultural Kalk, Dngekalk 1,1 68 35 10 limestone, crushed Kalkstein, gebrochen 1,35-1,45 85 - 90 30 - 45 25 limestone, dust Kalksteinmehl 1,4 - 1,7 80 - 85 < 45 30 linseed meal Leinsamenmehl 0,43 27 30 - 35 20 litharge, pulverized Bleiglanz, pulverig 3,2 - 4,0 200 - 250 30 - 45 20 magnesium chloride Magnesiumchhlorid 0,53 33 30 - 35 30 magnesium sulfate Magnesiumsulfat 1,12 70 35 - 45 10 manganese ore Mangan Erz 2,0 - 2,25 125 - 140 - 25 manganese sulfate Mangansulfat 1,12 70 30 - 45 10 marble, crushed Marmor Korn 1,28-1,52 80 - 95 30 - 45 10 marl Mergel 1,28 80 30 - 45 25 mica, flakes Glimmer, Flocken 0,3 - 0,4 17-22 19 8 mica, ground Glimmer, gebrochen 0,2 13 - 15 30 - 45 20 mica, pulverized Glimmerpulver 0,21-0,24 30 - 45 10 milk whole powdered Milchpulver 0,32 20 45 5 mill scale Sinterpellets 2,24 140 40 20 molybdenite , ore Molybdnit, Erz 1,71 107 30 - 45 20 mortar, wet Mrtel, feucht 2,4 150 30 45 10 nickel - cobalt sulfate ore Nickelkobaldsulphat 1,28 - 2,4 80 - 150 30 - 45 20 oats Hafer 0,4 - 0,6 26 - 34 20 - 25 13 oats, rolled Haferflocken 0,3 18 30 - 45 15 oyster shells whole Austern mit Schale 1,3 80 35 10 peanuts, in shells Erdnsse mit Schalen 0,2 - 0,3 15 - 20 30 - 45 10 peanuts, shelled Erdnsse ohne Schalen 0,6 - 0,7 35 - 45 30 - 45 10 peas, dried Erbsen, getrocknet 0,7 - 0,8 45 - 50 < 30 5 peat Torf 0,3 - 0,4 20-26 35 30 phosphate acid fertiliser Phosphatdnger 0,96 60 30 10 phosphate rock broken dry Phosphatgestein, gebr. 1,2 - 1,36 75-85 30 10 phosphate rock ground Phosphatgestein 0,96 60 35 25

1 14 E 05 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Table bulk density



t/m lbs/ft phosphate rock, pulverized Phoshphatgestein pulver 0,96 60 30 - 45 25 phosphate sand, wet Phosphatsand, feucht 1,7 105 30 - 45 20 phosphate fertilizer, high-grade

Phosphat, Superphosphat 0,8 - 0,9 50 55 30 45 20

potash, ore Pottasche, Erz 1,2 - 1,36 75 - 85 30 - 45 20 potassium nitrate Kaliumnitrat 1,2 76 35 25 potassium sulfate Kaliumsulfat 0,7 - 0,8 42 - 48 35 25 pumice Bimstein Korn 0,6 - 0,7 40 - 45 30 - 45 30 pyrites, pellets Pyrit, Pellets 1,8 - 2,3 116 - 145 30 - 45 20 quartz screened Quarz, gefiltert 1,3 - 1,5 80 - 95 35 25 rice, polished Reis, poliert 0,72-0,77 45 - 48 < 30 10 rock, crushed Fels, gebrochen 2,0 - 2,3 125 - 145 30 - 45 20 rubber, pelletized Gummipellets 0,8 - 0,9 50 - 55 30 - 40 25 rubber, reclaim Gummiregenerat 0,4 - 0,5 25 - 30 30 - 40 20 salpetre Salpeter 1,28 79 30 - 45 18 salt cake, dry, coarse

Natriumsulfat, trocken, grobkrnig

1,36

85

30 45

25

salt cake, dry fine Natriumsulfat, trocken fein 0,96-1,36 60 - 85 35 25 salt common dry, coarse Salz, getrocknet, grob 0,64-0,88 40 - 55 30 - 45 10 salt, common dry, fine Salz, getrocknet, fein 1,13-1,28 70 - 80 30 - 45 10 sand, bank, damp Sand, Ufersand 1,762,1 110 - 130 30 - 45 30 sand, foundry , shakeout Formsand, alt 1,4 1,6 90 - 100 30 - 40 25 sand, foundry, prepared Formsand, aufbereitet 1,3 1,4 80 - 90 30 - 40 30 sand, silica, dry Sand, trocken 1,441,6 90 100 30 - 45 5 sandstone, broken Sandstein, gebrochen 1,36-1,44 85 - 90 30 - 45 20 sewage, sludge Abwasser 0,6 - 0,8 40 - 50 0,7 10 sinter, iron Sinter, Eisen 1,6 - 2,16 100135 30 - 45 10 sinter, lead Sinter, Blei 2,88 180 40 25 slag Schlacke 1,2 75 35 30 slag, blast furnace, crushed Schlacke, Hochofen 1,28-1,44 80 90 30 - 45 10 slag, furnace, granular, dry

Schlacke, Hochofen, Krnig, trocken

1

62

25

10 16

slag, furnace, granular, wet

Schlacke, Hochofen, Krnig, nass

1,5

95

30

25

slate, dust Schiefer Staub 1,1-1,3 70 80 35 20

1 15 E 05 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Table bulk density



t/m lbs/ft slate, crushed Schifer, gebrochen 1,3 - 1,6 80 100 28 20 soap chips Seifenschnitzel 0,24 - 0,4 15 - 25 30 - 45 10 soap detergents Seife 0,24 - 0,8 15-50 30 - 45 10 soap flakes Seifenflocken 0,08-0,24 5-15 40 16 soap granules Seife, Granulat 0,24 - 0,4 15-25 30 - 45 10 soap powder Seifenpulver 0,32-0,40 19 - 25 30 - 45 10 soda ash , light Soda - Asche , leicht 0,32-0,56 20 - 35 30 - 45 25 soda ash, briquettes Soda-Briketts 0,8 50 30 - 45 10 soda ash, heavy Soda, kalziniert 0,88-1,04 55 - 65 30 - 45 20 sodium aluminum sulfate Natriumaluminiumsulfat 1,2 75 30 - 45 20 sodium bicarbonate Natriumbikarbonat 0,66 41 30 - 45 30 sodium nitrate Natriumnitrat 1,1 - 1,3 70 - 80 30 - 45 10 - 11 soil, overburden Abraum 1,6 - 1,8 100 - 112 30 15 soybean flour Sojabohnenmehl 0,43 27 30 - 45 18 - 20 soybeans Sojabohnen 0,7 - 0,8 45 - 50 30 - 45 10 starch Strke 0,4 - 0,8 25 - 50 30 - 45 10 steel punching scrap Stahl, Stanzabflle 1,2 - 2,4 75-150 35 20 sugar beet wet Zuckerrben na 0,9 - 1,0 55-60 30 20 sugar powdered Zucker, Puder 0,8 - 1,0 50-60 15 10 sugar, granulated Zucker, granuliert 0,8 - 0,9 50 - 55 30 - 45 10 sugar, raw cane Zucker, roh 0,9 - 1,0 55 - 65 30 - 45 25 sulphur crushed Schwefel, gemahlen 0,8 - 1,0 50-60 30 - 45 15 sulphur, lumpy Schwefel, stckig 1,2 - 1,4 75 - 85 30 - 45 20 sulphur, powdered Schwefelpuder 0,8 - 0,9 50 - 55 30 - 45 10 sulphur, ore Schwefelerz 1,4 87 30 - 45 25 talc powdered Talkumpulver 0,8 - 1,0 50-60 20 10 titanium ore Titanerz 2,2 - 2,6 140 - 160 30 - 45 20 titanium sponge Titan Schwamm 1,0 -1,1 60-70 35 30 tobacco leaves dry Tabakbltter trocken 0,2 12-14 40 25 urea prills Urea Granulat 0,7 - 1 45 - 60 27 23 urea, granular Harnstoff, Granulat 0,7 - 0,75 43 - 46 27 23 walnut shells crushed Walnuschalen, gebrochen 0,6 - 0,7 35-45 30 23 wood, shavings Holzspne, Rinde 0,1 - 0,25 8-15 35 25 zinc ore roasted Zinkerz, gebrannt 1,8 110 35 25 zinc ore, crushed Zinkerz, gebrochen 2,6 160 30 - 45 25

1 16 E 05 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Gurtbeschreibung (quersteif)

Einer der wesentlichen Vorteile des FLEXOWELL-Gurtes liegt darin, eine Gurtfrderanlage mit einem einzigen Gurt einmal oder mehrfach auf kurzer Distanz von der Horizontalen in eine Steigung oder umgekehrt ablenken zu knnen (z.B. S-Frderer). Diese Ablenkungen und die Rckfhrung auf der profilfreien Randzone ber Stummelrollen setzen eine Querstabilitt des Gurtkrpers voraus.

Unsere Entwicklung fhrte zu besonders querstabilen FLEXOWELL-Basisgurten. Die Querstabilitt wird durch die Gewebekonstruktion, einen speziellen Gurtaufbau und das von uns entwickelte Fertigungsverfahren erreicht. Fr den Festigkeitsbereich >1000 N/mm kommen Stahlseilgurte mit speziellem querstabilem Aufbau zur Anwendung.

Dieser Spezial-Gurtkrper ist immer Bestandteil eines FLEXOWELL-Gurtes und bildet mit den Wellenkanten und den Stollenprofilen ein komplettes technisches System. Fr die optimale Lsung gibt es fr den jeweiligen Anwendungsfall fnf verschiedene Gurttypen, die unter 2.2 beschrieben sind.

Belt description (cross rigid)

One of the main advantages of the FLEXOWELL belt is that cross rigid base belts can be deflected from the horizontal to an incline or vertical and back again without bowing or sagging (e.g. S-conveyors). These deflection points as well as the belt return on free lateral space by stub idlers definitely require the cross-rigidity of the base belt.

This development led to the special cross rigid FLEXOWELL base belts. The cross rigidity is achieved by the fabric construction, a special belt composition and by a special production procedure which we have developed. For a tensile of >1000 N/mm steelcord belts with a special cross-rigid belt composition must be used.

This special base belt is always part of a FLEXOWELL belt and represents a complete technical system together with the corrugated sidewalls and cleats. In order to grant optimal solutions for each purpose there are five different types of belts, described under 2.2.

Quersteife Textilgurte sind in folgenden

Qualitten lieferbar

cross-rigid fabric belts listed here are available

in the qualities Index Beschreibung index description

Y Standard, hochabriebfest Y standard, abrasion-resistant GP bedingt l-, fett- und harzbestndig GP mild oil-, grease- and resin-resistant T hitzebestndig T heat-resistant S schwer entflammbar (ISO340/EN20340) S flame-resistant (ISO340/EN20340)

MSHA schwer entflammbar (US-MSHA) MSHA flame-resistant (US-MSHA) vt selbstverlschend (bertage) vt self-extinguishing (surface applic.)

Quersteife Stahlseilgurte sind in folgenden

Qualitten lieferbar

cross-rigid steelcord belts listed here are available

in the qualities Y Standard, hochabriebfest Y standard, abrasion-resistant

GP bedingt l-, fett- und harzbestndig GP mild oil-, grease- and resin-resistant MSHA schwer entflammbar (US-MSHA) MSHA flame-resistant (US-MSHA)

vt selbstverlschend (bertage) vt self-extinguishing (surface applic.)

* Alle Qualitten antistatisch; all qualities antistatic

2 1 10 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Guidelines for the application of FLEXOWELL belts

for the transport of hot materials

Usual temperature ratings applied to flat rubber conveyor belt, can not be applied to FLEXOWELL belts

due to the greater elasticity required by the profiles and cleats. Increased temperature exposure over a long time period results in accelerated ageing and consequently a reduction of the physical elastomer values. The effective continuous FLEXOWELL

belt temperature therefore influences the probable service

lifetime. Heat transmission from the material to be conveyed to the FLEXOWELL

belt must be considered. When

conveying fine materials, e.g. cement, more heat is transferred to the belt than when conveying coarse bulk materials, as there is less surface contact. Example: Cement, with a temperature of 100 C transfers more heat to the belt than coarse cast pieces

of 150C without considerable contact area. An analysis of the hot material to be conveyed with regard to lump size and their components is the first step to an adequate assessment. The next step is the consideration of the environment temperature, e.g. in case of operation in hot climates, as well as in encased conveying systems. Temperature indications should always be made in connection with the service life to be expected, in order to allow the user to assess the economic consequences. Below please find some practical examples for black standard quality: Continuous FLEXOWELL

belt temperature abt. 40 - 50 C: 2 - 3 years

Continuous FLEXOWELL belt temperature abt. 50 - 60 C: 1 - 2 years

Continuous FLEXOWELL belt temperature abt. 60 - 70 C: 0,5 - 1 year

During operation of FLEXOWELL

belts in heat resistant quality, the above mentioned values can be

increased by abt. 30 C. These temperature indications do not relate to the material to be conveyed, but to the FLEXOWELL

belt itself. The belt temperature can be determined by a trial with a sample of belt

and the material to be conveyed in the normal environment temperature.

2 9 E 05 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Main rules for the alignment of the belt travel

After installation of the FLEXOWELL belt the most important task is its precise alignment.

Procedure:

The FLEXOWELL belt has to be correctly tensioned.

The maximum pretensioning of the tail pulley can be found on the second page of the Flexowell Computer Run; F (SP).

If the roller pitch amounts to 1 m this figure corresponds to 10 mm sagging between two rollers.

Free sagging = 4 % of the center distance between bend pulley and tail pulley.

Verify, that the drive and tail pulleys are correctly positioned at 90 to the conveyor centre line.

Check, whether all deflection pulleys and disc wheel stations can be adjusted in direction of the incoming belt (see 5.2). Otherwise shim plates must be used at the corresponding bearings.

Alignment work at S-conveyors starts at the upper roller curve, or at the deflection pulley, if no roller curve has been applied. It should be used to correctly center the belt (see 5.2).

If necessary, the tail pulley can be re-adjusted now.

Note: Inclining the tail pulley results in change of the lateral belt tensions.

Belt running "nearly in the center" is not sufficient. It is always possible to center the cross- rigid FLEXOWELL belt at all deflection and guide stations almost to one millimeter. In case the belt should have a lateral misalignment, e. g. in the splicing zone, a perfect centering is most important.

5 1 E 05 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

FLEXOWELL trouble shooting

Listed below are many of the common complaints related to belt conveyors. We have tried to present them in order of probable occurrence. However, the list is by no means complete. Many of the problems cited can be avoided by planned, preventive maintenance program, which ensures optimal performance and reduced downtime.

Problems and causes

Complaint Cause in order of probable occurrence

Belt runs off tail pulley 7 14 13 16 20 - Entire belt runs off at all points of the line 24 16 14 20 4 15

One belt section runs off at all points of the line 2 10 1 - - - Belt runs off at head pulley 14 21 20 15 - -

Belt runs to one side of the entire length 14 15 20 - - - Belt slip 18 7 20 13 21 - Belt slip on starting 18 7 21 9 - - Excessive belt stretch, belt sagging 12 9 20 6 8 - Belt breaks at or behind mechanical fasteners 2 22 12 21 19 9 Mechanical fasteners tear loose 12 22 9 19 2 - Vulcanised splice separation 2 22 12 19 11 25

Excessive wear, including rips, gauges, ruptures and tears 11 23 16 20 8 5 Excessive bottom cover wear 20 13 5 18 19 21 Excessive edge wear, broken edges 24 4 16 8 1 20 Cover swells in spots or streaks 8 - - - - - Belt hardens or cracks 8 22 21 17 - -

Covers became checked or brittle 8 17 - - - - Longitudinal grooving or cracking of top cover 25 13 20 11 - - Longitudinal grooving or cracking of bottom cover 13 20 21 - - - Fabric decay, carcass cracks, ruptures, gauges 11 19 5 9 - - Soft spots in belt 5 8 11 19 - - Ply separation 12 22 10 8 3 -

Causes and cures

1. Belt bowed. - Avoid telescoping belt rolls or storing in damp locations. A new belt should straighten out when "broken in" or it must be replaced.

2. Belt improperly spliced or wrong fasteners. - Use correct fasteners. Retighten after running for a short while. If improperly spliced, remove belt splice and make new splice. Set up regular inspection schedule.

3. Belt speed too fast. - Reduce belt speed. 4. Belt strained on one side. - Allow time for new belt to "break in". If belt does not break in

properly or is not new, remove strained section and splice in a new piece. 5. Breaker strip missing or inadequate. - When service is lost, install belt with proper

breaker strip.

5 10 E 05 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

6. Take-up tension too high. - Recalculate tension required and adjust take up accordingly. Reduce take-up tension to point of slip, then tighten slightly.

7. Counterweight too light. - Recalculate weight required and adjust counterweight or screw take-up accordingly.

8. Damage by abrasives, acid, chemicals, heat, mildew, oil. - Use belt designed for specific condition. For abrasive materials working into cuts and between plies, make spot repairs with cold patch or with permanent repair patch. Seal metal fasteners or replace with vulcanised step splice. Enclose belt line for protection against rain, snow, or sun. Don't over-lubricate idlers.

9. Drive underbelted. - Recalculate maximum belt tensions and select correct belt. If line is over-extended, consider using two-flight system with transfer point. If carcass is not rigid enough for load, install belt with proper flexibility when service is lost.

10. Edge worn or broken. - Remove badly worn or out-of-square section and splice in a new piece. 11. Excessive impact of material on belt or fasteners. - Use correctly designed chutes and baffles.

Make vulcanized splices. Install loading idlers. Where possible, load fines first. Where material is trapped under skirts, adjust skirtboards to minimum clearance or install cushioning idlers to hold belt against skirts.

12. Excessive tension.- Recalculate and adjust tension. Use vulcanised splice within recommended limits.

13. Frozen idlers. - Free idlers. Lubricate. Improve maintenance. (Don't over-lubricate) 14. Idlers or pulleys out-of-square with centre line of conveyor. - Realign. Install limit switches for

greater safety. 15. Idlers improperly placed. - Relocate idlers or insert additional idlers spaced to support belt. 16. Improper loading, spillage. - Feed should be in direction of belt travel and at belt speed, centered on

the belt. Control flow with feeders, chutes and skirtboards. 17. Improper storage or handling. - Refer to Flexowell for storage and handling tips. 18. Insufficient traction between belt and pulley. - Lag drive pulley. In wet conditions, use grooved

lagging. Install correct cleaning devices for safety. See item 7, above. 19. Material between belt and pulley. - Use skirtboards properly. Remove accumulation. Improve

maintenance. 20. Material build-up. - Remove accumulation. Install cleaning devices. Improve housekeeping. 21. Pulley lagging worn. - Replace worn pulley lagging. Use grooved lagging for wet conditions. Tighten

loose and protruding bolts. 22. Pulleys too small. - Use larger diameter pulleys. 23. Relative loading velocity too high or too low. - Adjust chutes or correct belt speed. Consider use of

loading idlers. 24. Side loading. - Load in direction of belt travel, in center of conveyor. 25. Skirts improperly placed. - Install skirtboards so that they do not rub against belt.

5 11 E 05 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

FLEXOLIFT Innenfrderer

Der FLEXOLIFT Innenfrderer bietet den Vorteil einer einfachen Konstruktion mit nur fnf drehenden Hauptkomponenten, mit fnf bis zehn Pufferrollen je nach Lnge der Aufgabestrecke, sowie zwei Paar FLEXOWELL FGR Fhrungsrollen (siehe 4.17).

Die Hauptkomponenten sind die Antriebstrommel mit rautenfrmigem Gummibelag, die obere und untere Scheibenablenkstation mit durchgehender Welle und Stehlagern. Die daraus resultierenden zehn Stehlager knnen einfach durch ein zentrales Schmierungssystem bedient werden, um Wartungskosten zu reduzieren.

Die kleineren Stehlager der Pufferrollen und der FLEXOWELL Fhrungsrollen knnen ebenfalls in das zentrale Schmierungssystem fr einen geringen zustzlichen Kostenaufwand mit einbezogen werden.

Die Materialfrderung auf der Gurtinnenseite ermglicht das Auffangen von Streugut und dessen direkte Wiedereinleitung in den Frderstrom. Ein weiterer Vorteil dieses Systems ist die durch geringere Reibungsverluste erzielte Energieeinsparung.

INNERCONVEYOR

The INNERCONVEYOR has the advantage of simple construction, which requires only five major rotating components, five to ten impact idlers - depending on the infeed length - and two pairs of FLEXOWELL 's FGR guide rollers (see 4.17).

The major components include the diamond grooved rubber lagged drive pulley and the lower and upper deflection drive pulleys, which are mounted on single shafts, as well as pillow block supports. This results in ten external pillow block bearings, which can easily be greased by a central lubrication system to reduce maintenance cost.

The smaller pillow block bearings used with the impact idlers and the FLEXOWELL belt guide rollers can be included in the central lubrication system for minor additional cost.

The material transportation on the inside of the belts enables the collection of spillage material and its direct refeeding into the material flow. Energy saving by lower frictional losses is a further advantage offered by this system.

6 1 05 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Tabelle Verdrehwinkel in Abhngigkeit von der effektiven Verdrehstrecke und Gurtbreite fr Textilgurte.

Table torsion angle relating to the effective torsion length and belt width for fabric belts.

Gurtbreite belt width

Verdrehwinkel torsion angle

Bw in mm 30

45 60 90 120 135 150 180 400 1,4 2,0 2,7 4,1 5,4 6,1 6,8 8,1

500 1,7 2,5 3,4 5,1 6,8 7,6 8,4 10,1

650 2,2 3,3 4,4 6,6 8,8 9,9 11,0 13,2

800 2,7 4,1 5,4 8,1 10,8 12,2 13,5 16,2

1000 3,4 5,1 6,8 10,1 13,5 15,2 16,9 20,3

1200 4,1 6,1 8,1 12,2 16,2 18,2 20,3 24,3

1400 4,7 7,1 9,5 14,2 18,9 21,3 23,6 28,4

1600 5,4 8,1 10,8 16,2 21,6 24,3 27,0 32,4

1800 6,1 9,1 12,2 18,2 24,3 27,4 30,4 36,5

2000 6,8 10,1 13,5 20,3 27,0 30,4 33,8 40,5

2200 7,4 11,1 14,9 22,3 29,7 33,4 37,2 44,6

2400 8,1 12,2 16,2 24,3 32,4 36,5 40,5 48,6

min. Verdrehstrecke in m min. torsion length in m

7 3 05 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Tabelle Verdrehwinkel in Abhngigkeit von der effektiven Verdrehstrecke und Gurtbreite fr Stahlseilgurte.

Table torsion angle relating to the effective torsion length and belt width for steelcord belts.

Gurtbreite belt width

Verdrehwinkel torsion angle

Bw in mm 30 45 60 90 120 135 150 180 400 2,1 3,1 4,1 6,2 8,2 9,2 10,3 12,3 500 2,6 3,8 5,1 7,7 10,3 11,5 12,8 15,4

650 3,3 5,0 6,7 10,0 13,3 15,0 16,7 20,0

800 4,1 6,2 8,2 12,3 16,4 18,5 20,5 24,6

1000 5,1 7,7 10,3 15,4 20,5 23,1 25,7 30,8 1200 6,2 9,2 12,3 18,5 24,6 27,7 30,8 37,0

1400 7,2 10,8 14,4 21,6 28,7 32,3 35,9 43,1

1600 8,2 12,3 16,4 24,6 32,8 37,0 41,1 49,3 1800 9,2 13,9 18,5 27,7 37,0 41,6 46,2 55,4 2000 10,3 15,4 20,5 30,8 41,1 46,2 51,3 61,6

2200 11,3 16,9 22,6 33,9 45,2 50,8 56,5 67,7 2400 12,3 18,5 24,6 37,0 49,3 55,4 61,6 73,9

min. Verdrehstrecke in m min. torsion length in m

7 4 05 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Block C-System

Der Block C-Frderer hat eine typische Materialauf- und abgabegeometrie, vergleichbar mit der eines Selbsentladerschiffes. Der konventionelle Auslegerfrderer fr die Materialentladung an Land bedarf keiner Designnderungen.

Dieses System hat einen geringen Platzbedarf an der Aufgabestelle und einen sehr schmalen vertikalen Schacht fr das Frder- und Rcktrum. Die Gurtgeschwindigkeit eines in Frderrichtung installierten Aufgabefrderers kann an die Geschwindigkeit des vertikalen FLEXOLIFT -Frderers angepat werden, um an der geneigten Aufgabestrecke eine gleichmige Materialabwurfparabel zu erzielen. Ein Stollen- und/oder Gurtverschlei kann durch eine Geschwindigkeitsanpassung bei der Aufgabe nahezu eliminiert und so die Laufzeit des Gurtes deutlich verlngert werden. Fr anbackende Materialien kann eine Gurtklopfvorrichtung (siehe 4.15) zwischen der oberen Ablenkstation und der Antriebstrommel installiert werden. Die Klopfscheiben werden durch Reibung angetrieben und lassen den Gurt in Lngs- und Querrichtung schwingen.

Zu den zustzlichen Vorteilen zhlen niedrigerer Energieverbrauch, leiser Lauf mit verringerter Staubentwicklung durch Einhausung, minimaler Einsatz von rotierenden Komponenten, resultierend in geringeren Wartungsaufwand (Siehe auch 6.1).

Block C-system

The Block C-System maintains a typical infeed and discharge geometry, relative to standard self-unloader layouts. The usual boom conveyor for shore discharge needs no modification either.

This system requires minimal space at the feed point and a very small vertical shaft for the lifting and return strands. The belt speed of the longitudinal feed conveyor can be tuned to the FLEXOLIFT belt speed to result in a smooth parabolic feed trajectory at the inclined feed section. Cleat and belt wear due to feed acceleration can be nearly eliminated, extending the belt life significantly. For sticky material cargoes, a belt cleaning device (see 4.15) may be placed between the upper deflection station and the drive pulley. This beater wheel is driven by belt friction and vibrates the belt in longitudinal and torsional modes.

Additional benefits include lower power consumption, quiet operation with reduced dust easily controlled in the enclosed shaft, improved reliability through minimal use of rotating components and lowest maintenance (see also 6.1).

8 1 05 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

FLEXOFAST -System

Seit dem Jahre 1979 haben sich vertikale FLEXOLIFT-Systeme im praktischen Einsatz weltweit bewhrt. (Hubhhen von > 100 m, Massenstrme > 1000 t/h, Gurtgeschwindikeiten < 3 m/s). Die durchgesetzten Massenstrme sowie deren Hubhhen sind gemeinsam bzw. alternativ- durch die Zugfestigkeit der eingesetzten Basisgurte nach oben hin begrenzt.

Eine Vergrerung ist nur durch breitere und leichtere Zugtrger und/oder durch grere Frdergeschwindigkeiten zu erreichen.

Im Rahmen eines Forschungsvorhabens mit der TU-Hannover wurde gemeinsam eine schnell-laufende Senkrechtfrderanlage (FLEXOFAST) mit einer Hubhhe von 21,5 m und einer maximalen Gurtgeschwindigkeit von 8 m/s konstruiert und errichtet (siehe 9.2). Fr die speziellen Vorrichtungen zum Be- und Entladen des FLEXOWELL-Gurtes bestehen folgende Schutzrechte: G 8300456.4; US 4.580,677; Europa 0088774.

Die erreichten Versuchsergebnisse lassen den Schlu zu, da mit den z.Z. zur Verfgung stehenden Zugtrgern (Stahlseile) FLEXOFAST-Systeme mit Hubhhen von 500 m und Massenstrmen von 2000 t/h bei Gurtgeschwin-digkeiten von 6 m/s zum Einsatz kommen knnen.

FLEXOFAST system

Since 1979 vertical FLEXOLIFT systems have been proven in the international market in practical applications. (Vertical lifts of > 100 m, capacities of > 1000 t/h, belt speeds of < 3 m/s).

Capacities and vertical lifts are limited only by the tensile strength of the base belts.

Higher vertical lifts can only be achieved by wider belts and lower weight tensile members and/or higher conveying speeds.

In connection with research work with the Technical University in Hannover, a fast running vertical conveyor (FLEXOFAST) with a vertical lift of 21.5 m and a max. belt speed of 8 m/s has been designed and erected (see 9.2).

Following patent rights for the special loading and discharge devices of the FLEXOWELL belt are: G 8300456.4; US 4.580,677; Europe 0088774.

The research results indicate that with the presently available tensile strengths (steel cords) FLEXOFAST systems can be applied with vertical lifts up to 500 m and capacities of 2000 t/h at belt speeds of 6 m/s.

9 1 05 / 2006

Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

Co

nve

yor

Bel

ts

FLEXOWELL- HandbuchManual


Co

nve

yor

Bel

ts



Innen_1 04.03.2003 17:42 Uhr Seite 1

1 GENERAL-AREA OF APPLICATION 1. Our terms and conditions shall apply exclusively; we reject any terms and conditions of thecustomer to the contrary or deviating from our terms and conditions, unless we have expresslyconsented to their validity in writing. Our terms and conditions shall apply even if we effect thedelivery to the customer without reservation with knowledge of terms and conditions of thecustomer to the contrary or deviating from our terms and conditions.2. All agreements which are made between the customer and us for the purpose of executinga contract shall be laid down in writing in this contract. Any amendments of or supplements tothe contract shall be made in writing.3. Our terms and conditions shall only be applicable vis--vis entrepreneurs ( 14 section 1German Civil Code (BGB)), and legal entities according to public law or public special funds wit-hin the meaning of 310 section 1 German Civil Code.4. Our terms and conditions of delivery shall also apply to all future transactions with thecustomer within the framework of current business relations.

2 OFFERS DOCUMENTS CONCLUSION OF CONTRACTS1. Our offers are not binding unless otherwise stated in the confirmation of the order or other-wise expressly declared by us in writing.2. If, contrary to 2 section (1), an offer is binding it has to be accepted within ten workingdays. Unless otherwise stated, the acceptance period shall be calculated as from the dateof our offer.3. We reserve title to and/or the copyright in illustrations, drawings, samples, calculat

flexowell manual en

Documents

e flexowell belt alignment

belt travel adjustment

application of flexowell

flexowell system design

return strand

plow scraper proposal

strand bend pulley

fgr fgr