Big-angle incline conveyor

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.

Standard Operation and Full-Cycle Maintenance Methods

(I) Standard Start-up and Shutdown Procedures

Start-up Sequence

1. Pre-start Inspection: Check for tears in the sidewalls and partitions; ensure the idler rollers and pressure rollers rotate freely; ensure the sweeper adheres to the belt; check that the emergency stop and belt misalignment protection functions are normal;

2. Start under no-load, run idle for 5 minutes, observe for no belt misalignment, no sidewall flipping, and no abnormal noises;

3. Feed material evenly, avoiding large amounts of wet fertilizer impacting the belt at once.

Shutdown Sequence

1. First, shut down the front-end feeding equipment, waiting for the material on the belt to be completely emptied;

2. Turn off the main motor, clean the sweeper and any clumps of fertilizer adhering to the belt;

3. For long-term shutdowns, loosen the belt tension to prevent the rubber sidewalls from deforming due to prolonged pressure. (II) Safety Operation Procedures

1. During operation, it is strictly forbidden to cross the belt or reach in to clean the pressure rollers and idlers; power must be disconnected and a sign posted before maintenance;

2. When performing circuit maintenance, wear insulated gloves, and ensure the entire machine is properly grounded before starting;

3. When conveying and drying high-temperature fertilizer, it is forbidden to allow the belt to idle for extended periods to bake the rubber at high temperatures;

4. Install a debris removal screen at the front end of the material to prevent iron wires and hard stones from scratching or tearing the side guards.

(III) Graded Lubrication and Maintenance Procedures

1. Daily Inspection: Clean any clumps on the belt surface; check for delamination at the base of the side guards and detached partitions; test the misalignment and emergency stop switches;

2. Weekly Lubrication: Add lithium-based grease to the bearings of the head and tail rollers, pressure rollers, and self-aligning idlers;

3. Quarterly Maintenance: Check the gear oil level in the reducer, and replace all gear oil every 4 months; tighten all bolts on the frame and pressure rollers;

4. Annual Overhaul: Conduct a comprehensive inspection of the belt vulcanization joints; localized cracks can be repaired on-site with cold bonding; replace jammed idlers and worn cleaning scrapers. (iv) List of vulnerable parts: corrugated sidewall conveyor belt, transverse partition, cleaner rubber scraper, concave arc pressure roller, idler roller, roller bearing, anti-backflow brake pad, tension screw.

Summary table of common faults and solutions for inclined belt conveyors