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TERM PAPERDynamics of Machines (MEC-302)
Belt Conveyor System
SUMITTED BY : Vardhan Mahendru
Roll No : B15
Section : M3R06
SUMITTED TO : Ms. Sumit Shoor
DOS : 04/04/2012
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Index
1. Acknowledgements 32. Conveyor System 43. Whats a Conveyor Belt? 44. Conveyor Belt Construction 55. Belt Conveyor Systems 12
6.
Working of a Belt Conveyor System
13
7. Applications 148. References 15
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Acknowledgements
I avail this opportunity to convey my sincere thanks to Mr. Sumit Shoor our MEC-302
teacher who helped me to use my skill in the right way by giving me and by rendering all
the possible help from all the sides.
Without his kind co-operation and noble assistance this project would not have been
concluded. Therefore, from the nucleus of my heart, I express gratitude to my worthy
teacher for devoting his worthless time and helping me in this project.
I also feel acknowledged to my parents and my friends who encouraged me to work and
complete the project .There have been others also who have motivated; corrected or
customized my thoughts and I would be grateful to them from the interior of my heart.
Thanking You
Vardhan Mahendru
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Conveyor system
A conveyor system is a common piece of
mechanical handling equipment that
moves materials from one location to
another. Conveyors are especially useful
in applications involving the
transportation of heavy or bulky
materials. Conveyor systems allow quick
and efficient transportation for a wide
variety of materials, which make them
very popular in the material handling and
packaging industries. Many kinds of
conveying systems are available, and areused according to the various needs of
different industries. There are chain
conveyors (floor and overhead)as well.
Chain conveyors consist of enclosed
tracks, I-Beam, towline, power & free,
and hand pushed trolleys.
Types of conveyor systems
Gravity roller conveyor Gravity skate wheel conveyor Belt conveyor Wire mesh conveyors Plastic belt conveyors Bucket conveyors Flexible conveyors Vertical conveyors Spiral conveyors Vibrating conveyors Pneumatic conveyors Belt driven live roller conveyors Line shaft roller conveyor Chain conveyor Screw conveyor Chain driven live roller conveyor Overhead conveyors Dust proof conveyors Pharmaceutical conveyors Automotive conveyors
Well be focusing our study on Belt
Conveyors only.
Whats a Conveyor Belt?
A conveyor belt (or belt conveyor)
consists of two or more pulleys, with a
continuous loop of material - the
conveyor belt - that rotates about them.
One or both of the pulleys are powered,
moving the belt and the material on the
belt forward. The powered pulley is
called the drive pulley while theunpowered pulley is called the idler.
There are two main industrial classes of
belt conveyors; those in general material
handling such as those moving boxes
along inside a factory and bulk material
handling such as those used to transport
industrial and agricultural materials, such
as grain, coal, ores, etc. generally in
outdoor locations. Generally companies
providing general material handling type
belt conveyors do not provide the
conveyors for bulk material handling. In
addition there are a number of
commercial applications of belt
conveyors such as those in grocery stores.
The belt consists of one or more layers of
material. They can be made out of rubber.
Many belts in general material handling
have two layers. An under layer of
material to provide linear strength and
shape called a carcass and an over layer
called the cover. The carcass is often a
cotton or plastic web or mesh. The cover
is often various rubber or plastic
compounds specified by use of the belt.
Covers can be made from more exotic
materials for unusual applications such as
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silicone for heat or gum rubber when
traction is essential.
Material flowing over the belt may be
weighed in transit using a beltweigher.Belts with regularly spaced partitions,
known as elevator belts, are used for
transporting loose materials up steep
inclines. Belt Conveyors are used in self-
unloading bulk freighters and in live
bottom trucks. Conveyor technology is
also used in conveyor transport such as
moving sidewalks or escalators, as well
as on many manufacturing assemblylines. Stores often have conveyor belts at
the check-out counter to move shopping
items. Ski areas also use conveyor belts
to transport skiers up the hill.
A wide variety of related conveying
machines are available, different as
regards principle of operation, means and
direction of conveyance, including screw
conveyors, vibrating conveyors,pneumatic conveyors, the moving floor
system, which uses reciprocating slats to
move cargo, and roller conveyor system,
which uses a series of powered rollers to
convey boxes or pallets.
Conveyor Belt Construction
Conveyor belts generally are composed
of three main components:
1. Carcass2. Skims3. Covers (carry cover and pulley
cover)
Carcass
The reinforcement usually found on the
inside of a conveyor belt is normally
referred to as the carcass. In a sense,
the carcass is the conveyor belt since it
must:
Provide the tensile strengthnecessary to move the loaded belt.
Absorb the impact of the impingingmaterial being loaded onto the
conveyor belt.
Provide the bulk and lateral stiffnessrequired for the load support.
Provide adequate strength for properbolt holding and/or fastener holding.
The carcass is normally rated by the
manufacturer in terms of maximum
recommended operating tension
permissible ( pounds per inch i.e., ppi).
Similarly, the manufacturer rates the
finished belt in terms of maximum
recommended operating tension per inch
of width (which is the total of the
preceding, multiplied by the number of
plies in the belt construction) i.e., 4 plies
of 110# fabric = a 440 pound per inch of
width (PIW) working tension belt.
The manufacturer determines the
maximum recommended operatingtension per inch of width with
considerations given to:
Stretch characteristics of the belt. Fastener/bolt holding capability. Load characteristics. Stiffness. Impact resistance of the belt
construction.
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There is a relationship between the
recommended maximum operating
tension per inch of width of the belt and
the ultimate tensile strength (breaking
strength) of the belt which will be
explained later.
Carcass Design
Multi-Plies + Elastomer = Plylok
Supreme Plylok, PHR and PRL
The most common carcass design is
made up of layers or plies of woven
fabrics bonded together (see Illustrationbelow). This conventional plied belt
construction, generally employs a plain
weave or twill weave carcass which is
built up into as many layers as is required
to provide the necessary belt
strengthusually bound together with
rubber.
In the plain weave, the warp yarns
(lengthwise yarns) and the fill yarns
(crosswise yarns) pass over and under
each other. This means that both
members are crimped (Essentially,
each assumes a sine-wave-like
configuration). This fact, plus the basic
characteristics of the fiber used give the
belt its stretch characteristics.
Conventional plied carcass belts havebeen used for decades. Consequently,
they are the most common belt design
used today. Most conveyor engineers and
millwrights are familiar with
conventional plied belting constructions
and their characteristics. Virtually, all
belting mechanics know how to splice
conventional plied belts. This familiarity
with the belts characteristics and the
ease of endlessing gives the
conventional plied belting design its
broad customer acceptance.
When cotton and similar materials were
widely used as carcass components inplied belts, a breaker strip, an additional
layer of open weave fabric was added
between the carcass and the top cover for
heavy abuse constructions, helping
absorb the loading impact. The switch to
modern synthetic carcass materials (like
polyester and nylon) has essentially
eliminated the need for the breaker strip.
Today, breaker strips are seldom found inplied belt constructions except in extreme
impact applications.
Conventional plied belting constructions,
employing all synthetic carcasses and
elastomer covers appropriate to the end
use, are particularly recommended for:
1) Hard Rock Mininga) Aggregate, sand and ore
2) General purpose applications3) Forest products4) Soft Minerals
a) Coalb) Potash, Phosphatesc) Grain
5) Unit Handlinga) Parcelsb) Baggagec) Mail
Skims
The rubber, PVC or urethane between
plies is called a skim. Skims are
important contributors to internal belt
adhesions, impact resistance, and play a
significant role in determining belt load
support and troughability.
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Improper or marginal skims can
adversely affect belt performance in
general and can lead to ply separation
and/or idler junction failure.
Straight Warp Wearlock,
Kordlok, PVK, PHR.
The straight warp carcass design yields a
carcass construction wherein the basic
lengthwise (warp) yarns are essentially
uncrimped. These are the main load-
carrying tension yarns. Fill yarns are then
laid transversely and alternately, aboveand below the main tension yarns. This
construction gives greater dimensional
stability to the belt, and does employ a
beam" effect for better load support and
transverse rigidity.
The yarns used are much thicker than
yarns in conventional fabrics. Further,
they are locked together by means of
another series of lengthwise yarns,known as the binder warp system. The
binder warp system locks the tension and
fill cords tightly together, creating a belt
which is unusually tough and which has
exceptional tear and impact resistance, as
well as good fastener and bolt holding
ability.
The straight warp configuration for the
basic tension yarns essentially eliminates
geometric stretch and results in a
conveyor belt construction with a
minimum stretch characteristic. . .a
significant advantage in most conveyor
belt applications.
Straight Warp constructions are used
for:
1) Hard Rock Mininga) Aggregate, sand and oreb) High impact applications
2) General purpose applications3) Soft Minerals
a) Coalb) Potash, Phosphatec) Grain
4) Unit Handlinga) Parcelsb)
Baggage
c) MailThe solid woven design can be
considered an extension of the straight
warp concept. Polyester filament yarns,
as well as spun polyester staple yarns, are
coupled in a highly complex fabric
construction, which is somewhat similar
to the straight warp. However, because of
the high performance requirements ofthese constructions, more than one layer
of basic, warp yarns are used. The whole
is interlocked and tied into one single
mass by means of a uniquely designed
binder warp system. Spun polyester
staple yarns protect the two faces of the
carcass construction and combined with
the high performance PVC, form the
working surface of the belt itself.
PolyVinylok, a single-ply conveyor and
elevator belting construction, has found
wide acceptance in:
A broad range of industrial applications
Agricultural equipment Food processing; Grain handling (conveyor and
elevator);
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Underground mining, such as coal,potash, and other soft minerals;
Forest products.
Steel Cord + Rubber
Steel Cord-type constructions utilize a
single layer of uniformly tensioned steel
cords as strength members; encased in
rubber. Steel cord belts are generally
found in high tension applications
ranging from 600 PIW to 5,000 PIW
and/or where extremely low stretch is anecessity. Typical elongation for steel
cord conveyor belting is less
than 1/3 of 1%. Steel cord belts must be
manufactured to width.
Strength Designations
In the past, when cotton was the primary
fabric for carcass construction, all fabrics
were designated by the weight of a piece
of fabric 42" X 36", i.e., in cotton 28 oz.,
32 oz. Duck, etc. As new carcass
materials were developed that varied in
strengths and weights, new methods of
designation were required. As a general
rule, current fabrics in use are designated
by the working tension or strength of the
fabric, shown in pounds per inch of width
(PIW), i.e.25, 45, 80, 110, 125,150, 200,
250 and 300 pound fabrics, etc.
When dealing with carcass fabrics, we
work with two separate strength
measurements. The first is the Maximum
Working Tension or strength of
the belt. This is the highest tension
occurring in any portion of the belt on the
conveyor system, under normal operating
conditions. This is the strength
measurement used to determine the
proper belt for the system. The second
measurement is the Ultimate Tensile
Strength of the belt. The ultimate tensile
strength of a belt is the point at which
that belt will rupture and fail due to
excessive tension.
The difference between the maximum
working tension and the ultimate tensile
strength of the belt is often referred to as
the service factor. On top quality
domestic conveyor belting, this servicefactor is 8-10 to 1. Most Georgia Duck
belting has a 10 to 1 service factor. This
means that if the maximum working
tension is 200 PIW, the ultimate tensile
strength would be 2,000 PIW. Belting
utilizing nylon constructions generally
has a service factor of more than 10 to 1.
This higher service factor is necessary to
overcome some of the inherent properties
of nylon, such as excessive elongation.
Most conveyor belt fabrics are produced
today with polyester warps (lengthwise
yarns) and nylon fills (widthwise yarns).
This combines the best properties of both
textiles offering high strength, low stretch
conveyor belt with excellent impact
resistance, troughability, load support,
and fastener and/or bolt-holding ability.
Materials - Fibers
Carcass materials used in belt
manufacture in recent years are listed as
follows. Given is the common name, the
composition and some general comments
about each material. (Please note their
characteristics and current position in the
market place)
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Cotton Natural Cellulose Composition
Only natural fiber used to any great extent in belting manufacture.Increases in strength when wet. High moisture absorption - consequently,
poor dimensional
stability. Susceptible to mildew attack. At one time represented 80% of theraw fiber input into belt manufacture. Currently, something less than 5%.
Rayon Regenerated Cellulose CompositionSlightly stronger than cotton, but tensile strength is lowered by water.
Chemical resistance similar to cotton. High moisture absorption -
consequently, poor dimensional stability. Susceptible to mildew attack.
Almost nonexistent in conveyor belt today.
Glass Glass
Very high strength compared to rayon. Low elongation. Mainly used inhigh temperature applications. Poor flex life. Limited use in belt
manufacture currently.Nylon Polyamide
High strength, high elongation, good resistance to abrasion, fatigue andimpact. While moisture absorption not as high as cotton, it will absorb up
to 10% of its own weight in moisture. Consequently, poor dimensionalstability. High resistance to mildew. At one time, nylon represented 40% of
the raw material input into belt manufacturing. Today, it is something less
than 20%.
Polyester PolyesterHigh strength, exceptionally good abrasion and fatigue resistance.
Extremely low moisture absorption. . .consequently good dimensional
stability. Unaffected by mildew. Georgia Duck selected polyester as its
fabric of choice in 1960. Polyester usage in the manufacture of belting
has grown from 0% in 1960 to something in the range of 70-75% today.
(See Georgia Duck technical data bulletin Polyester, The Fiber ofChoice).
Steel SteelUsed where high strength and extremely low stretch are a necessity. A
small amount of woven steel carcass is found in todays market. However,
more steel is used in steel cord-like belt constructions. Kevlar Aramid
Aramid (the material used in flak jackets and bullet-proof vests) has twice
the strength of steel, with stretch characteristics roughly halfway betweensteel and polyester. It is significantly lower in weight than steel and willnot rust.
Kevlar Aramid
Aramid (the material used in flak jackets and bullet-proof vests) has twice
the strength of steel, with stretch characteristics roughly halfway between
steel and polyester. It is significantly lower in weight than steel and will
not rust.
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Covers
Covers are used in conveyor belt
constructions in order to protect the base
conveyor belt carcass and, if possible, to
extend its service life. In addition, covers
do provide the finished belt with a wide
variety of desirable properties, including
the following:
Textureso To increase frictiono To increase inclinationo To control product
Cleanability A specific coefficient of friction A specific color Cut resistance Enhanced impact resistance, etc. Hardness Fire Resistance, Oil & Chemical
Resistance
Cover type, quality and thickness are
matched to the service life of the belt
involved. A specific cover formulation
used in an individual belt construction is
determined by the material to be carried
and the environment in which the belt
will operate.
Historic belt constructions were highlysusceptible to moisture and chemical
attack because of their cotton carcass
components. Accordingly, it was
common to extend the belt covers over
the edges of the belt in what is known as
the molded edge construction. This
type of manufacturing can be expensive
because of the additional labor and
machine time involved.
Modern day belt constructions, with their
high adhesion levels and synthetic
carcasses, are considerably less
susceptible to moisture and chemical
attack, and do not require edge
protection. They make possible the slit-
edge belt distribution programs
currently used in the Belting Industry.
Costs are minimized since an 84" slit-
edge belt can be manufactured about as
quickly (if not more so) as a 24" molded
edge construction. Further, the labor
involved is somewhat less.
Georgia Duck uses an extremely wide
variety of polymers for our cover needs,
including: Polyvinylchloride, natural
rubber, various synthetic rubbers and
urethane - -to meet individual customer
needs. Quality competitors offer covers
made of similar polymers although their
individual recipe may be somewhat
different. Individual cover formulations
are usually blends consisting of one
principal polymer and assorted modifiers,
such as other polymers, antioxidants,
accelerators, curatives, pigments,
extending and reinforcing fillers,
plasticizers, etc.
Specific conveyor belt applications
seldom require the belt cover to satisfy
one or two conditions. More usually, a
broad variety of required and desired
properties are encountered. The specific
cover formulation is quite likely to be a
compromise, which seeks to meet the
customers criteria and still remain cost
effective. For many applications, the
blending of polymers adds properties that
could not be obtained in a single polymer
compound.
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The Georgia Duck Chemical Resistance
Chart lists characteristics of many belt
covers offered by Georgia Duck. Specific
compound properties are detailed as is
chemical resistance. This list is an
important assist in selecting proper cover
compounds.
In addition to selecting proper
compounds for cover material, it is also
necessary to determine the proper cover
thickness. The thickness of a cover is
influenced by the amount of abuse and
wear the belt will receive. The cover isusually the lowest cost component of the
belt.
The severity of the wear depends on the
nature of the material and on the size,
weight, shape and trip rate of the material
conveyed. Sharp edges, particularly on
large pieces, can quickly cut a cover
badly. On the other hand, if loading
conditions are ideal, with the materialbeing loaded in the direction of travel of
the belt, and with only a slight impact
onto the belt, even very sharp material
may not seriously cut or wear the belt
surface. Cover wear is also influenced by
the loading area being on the horizontal
compared to loading a conveyor belt on
an incline which will result in the product
bouncing around more before the load
settles down. This increased product
movement will adversely affect cover
wear.
Wearability of rubberlike compounds can
be characterized by PICO abrasion test.
This test assigns wearability level or
abrasion numbers to various
elastomers. The higher the number, the
more durable the elastomer. For example,
Grade I rubber normally will test out at a
PICO rating of 135, while a Grade II
rubber will yield a PICO of 100, and
PVC a PICO of 50. The Taber abrasion
test more directly relates to sliding wear (
slider beds, side loading, etc.) and is
therefore used more frequently in
measuring belts used in unit handlingsystems.
Fillers and additives added to a given
recipe can affect the PICO adversely. It is
not uncommon, for example, for an oil
resistant, MSHA, rubber elastomer to
yield a PICO in the 50s or60s.
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Belt conveyor systems
Conveyor belts are basically very widebelts attached in a loop to two or more
turning rotors driven by motors. The loop
is the actual conveyor belt, and is
generally made of two or more layers of
rubber, one layer to give shape and
structure to the belt and one to allow it to
transport its load safely. This conveyor
loop is generally attached to two wheels,
called rotors, which are spun by motors.The conveyor belt has enough friction
between it and the rotor that it sticks to
this rotor. Conveyors are durable and
reliable components used in automated
distribution and warehousing. In
combination with computer controlled
pallet handling equipment this allows for
more efficient retail, wholesale, and
manufacturing distribution. It is
considered a labor saving system that
allows large volumes to move rapidly
through a process, allowing companies to
ship or receive higher volumes with
smaller storage space and with less labor
expense.
Rubber conveyor belts are commonly
used to convey items with irregular
bottom surfaces, small items that would
fall in between rollers (e.g. a sushi
conveyor bar), or bags of product that
would sag between rollers. Belt
conveyors are generally fairly similar in
construction consisting of a metal frame
with rollers at either end of a flat metal
bed. The belt is looped around each of the
rollers and when one of the rollers is
powered (by an electrical motor) the
belting slides across the solid metal frame
bed, moving the product. In heavy use
applications the beds which the belting is
pulled over are replaced with rollers. The
rollers allow weight to be conveyed as
they reduce the amount of friction
generated from the heavier loading on the
belting. Belt conveyors can now be
manufactured with curved sections which
use tapered rollers and curved belting to
convey products around a corner. These
conveyor systems are commonly used in
postal sorting offices and airport baggage
handling systems. A sandwich belt
conveyor uses two conveyor belts, face-to-face, to firmly contain the item being
carried, making steep incline and even
vertical-lift runs achievable.
Belt conveyors are the most commonly
used powered conveyors because they are
the most versatile and the least expensive.
Product is conveyed directly on the belt
so both regular and irregular shaped
objects, large or small, light and heavy,
can be transported successfully. These
conveyors should use only the highest
quality premium belting products, which
reduces belt stretch and results in less
maintenance for tension adjustments. Belt
conveyors can be used to transport
product in a straight line or through
changes in elevation or direction. In
certain applications they can also be usedfor static accumulation or cartons.
On the Time Scale
Primitive conveyor belts were used since
the 19th century. In 1892, Thomas
Robins began a series of inventions
which led to the development of a
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conveyor belt used for carrying coal, ores
and other products. In 1901, Sandvik
invented and started the production of
steel conveyor belts. In 1905 Richard
Sutcliffe invented the first conveyor belts
for use in coal mines which
revolutionized the mining industry. In
1913, Henry Ford introduced conveyor-
belt assembly lines at Ford Motor
Company's Highland Park, Michigan
factory. In 1972, the French society REI
created in New Caledonia the then
longest straight-belt conveyor in the
world, at a length of 13.8 km. HyacyntheMarcel Bocchetti was the concept
designer.[citation needed] In 1957, the B.
F. Goodrich Company patented a
conveyor belt that it went on to produce
as the Turnover Conveyor Belt System.
Incorporating a half-twist, it had the
advantage over conventional belts of a
longer life because it could expose all of
its surface area to wear and tear. Mbiusstrip belts are no longer manufactured
because untwisted modern belts can be
made more durable by constructing them
from several layers of different materials.
In 1963-64, First Indian Small Scale
Industrial Unit with Japanese Plant for
Rubber Belts for Conveyor / Elevator /
Transmission was installed near National
Capital Territory of Delhi and its Mr.
Belts Conveyor Belting has been widely
used in Steel, Cement, Fertilizer, Thermal
Power, Sponge Iron Plants and Coal /
Mineral establishments / Mines, Port
Trusts and similar material handling
applications of Industry for the last over 4
decades.
Working of a Belt Conveyor
System
The Movement of a Conveyor Belt
As a rotor turns, the conveyor belt will
turn as well due to the intense friction
between the rotor wheel and the belt.
This turning motion of the rotor causes
one side of the belt to move in one
direction, while the other moves in the
opposite direction. This means that bothwheels must always be moving in
relatively the same direction, either
clockwise or counter-clockwise. If the
two rotor wheels moved in opposite
directions, the conveyor belt would not
travel at all.
The Transportation Along a Conveyor
The word convey means to send or
transmit; therefore, a conveyor is
something that sends or transmits.
Conveyor belts, mostly used in industry,
convey products or raw materials through
the use of either friction or mounts on the
belt meant to hold the product in place as
the belt moves. As the conveyor belt
moves its product, the product staysaround one place on the conveyor. Many
times, twists or turns are put in
conveyors; these are facilitated by cone
shaped rotors or wheels, which allow the
conveyor to turn.
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Applications
Manufactured with the best quality steel
such as EN 9, EN 8 and EN 24, our
Portable Belt Conveyor has found a
number of applications in cement,
agriculture and paper industries. Ideal to
be used for medium and heavy weight,
our Belt Conveyor System is found in a
number of dimensions to meet the
specific requisites of the clients. Today,
we are counted among the leading Flat
Belt Conveyor Manufacturers and
Suppliers.
Flat Belt Conveyor:
This is normally used for light and
medium weight loads between
operations, departments, levels, and
buildings. It is imperative in places where
incline or decline is included in the
conveyor path. The belt is generally of
roller or slider bed supported for smalland irregularly shaped material.
Portable Belt Conveyor:
The portable belt conveyors are suitable
for light to medium loads and offer
flexible conveying path such as
inclination, curve, long term
dependability and low operational cost.
Our range is used for transport industrialand agricultural materials, such as grain,
coal, ores and many more.
Features:
Consists of rollers mounted on selfaligning frames.
Bearing are incorporated in therollers to minimize the mechanical
losses.
Gantry are provided for stiffeningavailable up to 2000mm width
&infinite length
Walkway is provided on one/ bothsides of conveyor in order to
maintain the conveyor Drive as given
through rubberized rollers andtension is adjusted through gravity
and screw.
Belt Conveyor Systems are
Commercially used in:
Agriculture Construction - heavy building
materials.
Food and beverage processing. Forestry - logging, sawmill, paper
pulp, etc.
Mining and quarrying. Factory production line. Airports.
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References: -
Bulk Material Handling by ConveyorBelt by M. A. Alspaugh
Automation, Production Systems,and Computer-Integrated
Manufacturing by Mikell P. Grover
Theory of Machines by S.S. Ratan R. S. Khurmi Theory of Machines
Websites: -
http://www.ehow.com/how-does_4922797_conveyor-belt-
work.html
http://en.wikipedia.org/wiki/Conveyor_systems
http://garlockrubber.com/primary/products/heavy-duty-conveyor-
belts/hdcb-resources/conveyor-belt-
components/
http://en.wikipedia.org/wiki/Belt_conveyor
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