Equipment Overview
The large-angle belt conveyor, also known as a corrugated sidewall belt conveyor or DJ-type large-angle belt conveyor, is a continuous conveying device based on a conventional belt conveyor, employing a special conveyor belt structure. Its core feature is the replacement of the ordinary flat belt with a corrugated sidewall conveyor belt, significantly expanding the conveying angle from the conventional belt conveyor's 18° or less to 30°–90°, and even enabling vertical lifting.
This equipment combines the advantages of general belt conveyors—simple structure, reliable operation, and convenient maintenance—with the outstanding characteristics of large-angle conveying, compact structure, and small footprint. It can replace the traditional "belt conveyor + bucket elevator" combined layout, directly achieving continuous horizontal-inclined-vertical conveying, resulting in significant overall economic benefits.
Equipment Structure Composition
The entire machine is divided into five main modules: dedicated conveyor belt, segmented frame system, drive tensioning unit, anti-deviation belt pressure assembly, and cleaning and safety accessories.
1. Core Corrugated Sidewall Conveyor Belt (Dedicated Component): Composed of a base belt, two corrugated rubber sidewalls, and transverse partitions, integrally vulcanized. The partitions and sidewalls form an independent compartment. For fertilizer applications, three types of base belts can be customized: wear-resistant, acid and alkali-resistant, and heat-resistant. Sidewall heights range from 40 to 240 mm, selectable as needed.
2. Segmented Welded Frame
1) Lower Horizontal Feed Section: Buffer rollers and a centrally located guide chute reduce material impact.
2) Concave Arc Transition Section: Equipped with pressure rollers to press the sidewalls and prevent them from flipping out of the chute (core leak-proof structure).
3) Inclined Main Conveying Section: Bearing rollers + double-sided anti-deviation vertical rollers.
4) Convex Arc Discharge Section: Gentle arc for smooth material removal from the belt.
5) Upper Horizontal Discharge Section: Discharge chute and head cleaning device.
3. Drive and Tensioning Assembly: Head-mounted rubber-coated drive roller, motor + frequency converter reducer; tail-mounted spiral/counterweight tensioning mechanism to maintain belt tension throughout; standard backstop to prevent material backflow during machine stop.
4. Dedicated Anti-Belt Deviation Assembly: Concave arc belt pressure pulley set, double-sided limiting vertical rollers, self-aligning idler rollers to solve the problems of belt deviation on one side and side scraping of the frame under large inclination angles.
5. Cleaning and Safety Features: Head spring sweeper, bottom beater wheel (to shake off adhering wet fertilizer clumps); emergency stop rope, belt deviation alarm switch, grounding protection, fully enclosed dust cover (optional).
Applicable Raw Materials
1. Main Materials for the Fertilizer Industry
1) High-moisture organic raw materials: fermented chicken manure, cow manure, pig manure, wet straw, mushroom residue, distiller's grains, kitchen sludge (moisture content 20%~45%);
2) Granular fertilizers: disc/drum granulated organic fertilizer, compound fertilizer, BB fertilizer, cooled coated finished granules;
3) Powdered materials: humic acid, bentonite, talc coating powder, chemical fertilizer powder;
4) Small-lump raw materials: crushed cake fertilizer, fermented compost fragments.
2. Materials for Cross-Industry Application
Grains, feed pellets, chemical powders, sand, gravel, coal slag, with a bulk density of 0.5~2.5t/m³ and a particle size ≤180mm, can all be transported.
3. Materials Prohibited from Transport
Sharp hard stones with a particle size >180mm, highly corrosive liquid materials, flammable and explosive ultrafine dust (explosion-proof customized models required), high-viscosity slurry.
Working Principle
1. Closed-loop transmission: The motor drives the head rubber-coated roller, relying on the friction between the roller and the base belt to continuously circulate the entire sidewall belt.
2. Bucket loading: Material falls from the tail guide chute into the sidewalls and partitions to form an independent bucket. The wavy sidewalls prevent material from scattering laterally.
3. Stable lifting at large angles: The belt is constrained by the concave arc pressure pulley, preventing it from folding outwards. The partitions mechanically support and counteract the downward force of gravity, ensuring no backflow or spillage at angles of 30°~90°.
4. Head unloading: The belt passes around the head arc-shaped roller, and the material is discharged from the unloading chute by gravity and centrifugal force, and sent to the next equipment.
5. Return self-cleaning: When the empty belt descends, the bottom beater vibrates, and the spring cleaner scrapes away any clumps of fertilizer adhering to the belt surface, preventing material accumulation and blockage on the return trip.
Summary table of common faults and solutions for inclined belt conveyors
| Fault Classification | Fault Phenomenon | Main Causes | Solutions |
|---|---|---|---|
| Belt System Faults | Belt Deviation | Incorrect frame installation, non‑parallel rollers, offset feeding, material accumulation on idlers | Re‑calibrate frame level and center alignment; adjust head‑tail rollers parallelism; clean accumulated materials on idler surface; install automatic centering idler to prevent deviation |
| Baffle / Skirt Board Wear & Tearing | Excessive material feeding impact, over‑limit lump material size, mechanical interference between baffle and frame, excessive scraper pre‑tightening force | Strictly control feeding speed and conveying flow to reduce material impact; inspect and eliminate mechanical interference; reasonably adjust scraper pre‑pressure; replace high‑wear‑resistant skirt rubber | |
| Belt Slippage | Insufficient belt tension, worn driving pulley lagging, equipment over‑loaded operation, excessive conveying inclination angle | Adjust tensioning device to raise belt tension; replace worn pulley lagging; check actual conveying capacity and reduce overload; properly increase motor power under heavy‑load conditions | |
| Material Spilling / Backflow | Excessive gap between baffles, excessive belt running speed, material jumping over baffle caused by feeding impact | Reduce baffle clearance or properly lower belt speed; optimize hopper structure to buffer feeding impact; add flexible retaining plate at machine head to block material spilling and backflow | |
| Structure & Environmental Faults | Idler Adhesion Causing Belt Wear | Wet & sticky materials adhere to idler surface to form irregular bulges, continuously abrading belt | Install high‑efficiency belt cleaning device; adopt anti‑adhesion coating idlers; strictly control material moisture content to reduce sticking at source |
| Baffle Tearing at Convex Arc Section | Repeated tensile & compressive stress on baffle at convex turning position, resulting in fatigue crack and tearing | Optimize radius of convex‑arc section to avoid excessive stress; fully inspect idlers at convex‑arc section to guarantee complete and flexible rotation and reduce local stress concentration | |
| Reverse Rotation After Shutdown | Under large‑inclination conveying condition, material component force exceeds belt friction force, leading to belt reverse rotation after stop | Equip driving system with disc‑type / ratchet‑type back‑stop device; install external anti‑reversing brake for long‑distance large‑inclination working conditions to prevent material back‑flow |
