application design manual-chutes

7/28/2019 Application Design Manual-CHUTES

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APPLICATION DESIGNMANUAL

5100 West 12th Street

Sioux Falls, SD 57107-0514

605-332-3200 PHONE

605-332-1107 FAX

WATS 800-328-1785

www.hiroller.com

email [email protected]

Notice:

Instructions, Designs and Specifications

are subject to change without notice!

Application Design Manual-June 17, 2002.DOC 1/12/2005 Page 1 of 17
http://www.hiroller.com/http://www.hiroller.com/


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Conveyor ComponentsConveyor Orientation - Standard

The conveyor Left(LH) and

Right(RH) Side is determined by

assuming that one is standing at theTail Section and looking in the

direction of the belt toward the Head

Section. The Left(LH) Side is on

your left hand. The Right(RH) Side is

on your right hand.

Conveyor Orientation - Reversible

The conveyor Left(LH) andRight(RH) Side is determined by

assuming that one is standing at the

Non-Drive Section and looking in the

direction of the Drive End Section.

The Left(LH) Side is on your left

hand. The Right(RH) Side is on your

right hand.

Head Sections & DischargesHead Sections are typically in the two different types as shown below. The

Discharge(Overshot) is bolted to the Head Section as shown below. Discharges

have inspection hatch at the top. A four-sided frame is typically included for

discharge transitions.

Standard DischargeSnubber Head Section Discharge



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Motor & Drive MountingsHi Roller mounts all motors and reducers that are supplied by the factory. All of

the manufacturer's specifications are followed. The photograph below illustrates a

right hand mounted drive.

Motor & Drive Mountings

Shaft Mount Drive w/Synchronous

Cog-Belt (Shown) is the most

common type of Drive. In-Line Drive

w/Synchronous Cog-Belt Final Drive

and In-Line Drive w/Direct Coupled

Drive (NOT Shown) are not as

common.

Trunking SectionsHead/Drive End Trunking Sections

Distinguished by High Leg End

Channel, Inspection Door Location &

Special Flanges(Shown).

Tail/Non-Drive End Trunking

Sections Distinguished by High Leg

End Channel, Inspection Door & twoother equal flange channels in the

middle and opposite end of the High

Leg End Channel(NOT-Shown).

Intermediate Trunking Sections

Each Intermediate section has two

equal flange channels. Each section

has an equal flange channel on theend and the other in the middle of

each section.

NOTE: Sections are labeled &

numbered starting with #1 at the

Tail Section.



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Inspection Doors Trunking Channels & Clamps - Trunking

Cover Clamps & Wing Nuts - Inlet/Loader

Inspection Door Clamps & Wing Nuts - Trunking, Head, Tail & Inlet/Loader



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Tail Sections - Standard Tail Section w/Inner & Outer Box Take-Up

Tail Section Back Cover Removal & Installation

The Tail Cover Clamps(Below, Top-Right) release the Tail Cover. Handles on the

Tail Cover(Below, Bottom-Center) should be used to pull the Tail Cover back and

down to release from Tail Section. The Safety Chains(Below, Center) will stop theTail Cover from dropping too far down. Lift the Tail Cover to release the Safety

Chains. Then, slowly allow the Tail Cover to swing down until it releases from the

channel on the bottom of the Tail Section as shown(Below, Top-Left). The

installation is in reverse order of the removal procedure.



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Loaders/Inlets-Extremely Important Loading Considerations!Loaders/Inlets-Extremely Important Loading Considerations!The loader must be installed on the conveyor to load the same direction of belt travel.The loader must be installed on the conveyor to load the same direction of belt travel.

The loading point of a belt conveyor is the critical point. Here the conveyor belt

receives major abrasion and practically all of its impact. The ideal condition is to have the

material pass from the spout to the belt at the same speed and direction of belt travel. This

must be done with a minimum amount of impact and loaded centered on the belt.

Improper loading can cause damage belt, idlers, bearings, pulleys, shafting, and othercomponents. An off-centered load will cause belt alignment problems in that the belt will

run off center.

The loading point of a belt conveyor is the critical point. Here the conveyor belt

receives major abrasion and practically all of its impact. The ideal condition is to have the

material pass from the spout to the belt at the same speed and direction of belt travel. This

must be done with a minimum amount of impact and loaded centered on the belt.

Improper loading can cause damage belt, idlers, bearings, pulleys, shafting, and othercomponents. An off-centered load will cause belt alignment problems in that the belt will

run off center.

Standard Inlets - Flat Top w/Matching Flange & Control GateStandard Inlets - Flat Top w/Matching Flange & Control Gate

Loading Considerations!Loading Considerations!

Control Gate Orientation Control Gate Orientation Controlled Flows from all spouts Controlled Flows from all spouts

Side Loading Problems Side Loading Problems High Velocity Flow Problems High Velocity Flow Problems

Straight Down Flow Problems Straight Down Flow Problems

Turbulent Flow Problems Turbulent Flow Problems

Belt Speed vs. Proper Loading Belt Speed vs. Proper Loading

Level/Even Loading Problems Level/Even Loading Problems

Poor Loading = Belt TrackingProblems

Poor Loading = Belt TrackingProblems

Side Loading Problems!! Hi Rollers Engineering Department must complete

a proper design to eliminate Side Loading Problems.

Side Loading Problems!! Hi Rollers Engineering Department must complete

a proper design to eliminate Side Loading Problems.

Application Design Manual-June 17, 2002.DOC 1/12/2005 Page 6 of 17Application Design Manual-June 17, 2002.DOC 1/12/2005 Page 6 of 17


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Standard Inlet - 45 Degree w/Matching Flange & Control Gate

Gate Orientation & Proper Operation = Flow Controlled Properly



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Loading Goals:

1.Material must flow evenly on to the belt and at the speed anddirection of the belt.

2.Control Gate and Spouting must be installed so that the materialflows down the Back Plate of the Loaders as shown on the

illustrations on the previous page.3.Control Gates must be installed to open from the back(tail end) of

the Loader to the front(head end) so the material flows down the

Back Plate. This must be done for proper loading.

4.Material speed is very important to proper loading. Materialflowing too fast will cause the material to splash as it contacts the

belt. This will cause the material to boil and loading will be a

problem. Material dropping from more than 3-4 feet must be

slowed down with a control gate, dead box, or another type ofmaterial slow down device.

5.The material must be evenly spread across the full width of theBack Plate of the Loader.

6.Spouting from the side will cause material flow problems in theLoader. A control gate, baffle, or another means to turn the

material flow must be included in the design of the Loader.

7.Bi-Directional Loading is very feasible with a properly designedLoader. Contact Hi Rollers Engineering Department for

assistance with this design.



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CoversCovers are made to fit over the width of the conveyor and 5(five) feet of a section.

Note: Do not weld any items to the covers. Covers must be removable. parts

can be obtained from Hi Roller to attach devices to top of conveyor so that

covers will still be removable.

Standard 5 foot Covers

Cover Clamps & Wing Nuts - Installation

Covers can be cut to length in the field during the installation. Cover End

Channels are provided with the conveyor so the contractor can cut the covers

and weld on a new channel to the correct length.

NOTE: Covers can be Cut to Length at the factory if they are ordered to

specific lengths. These specific lengths must be measured and sent to HiRollers Engineering Department as soon as these measurements can be

completed during the installation. The order for these special length covers

will be expedited to ship them out within the shortest possible time.



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Take-Up SectionsTail Take-Up Sections w/Rods & Leveling Rods

The Tail Take-Up Rods are used to

tighten the belt. There is one Take-

Up Rod on each side of the Take-Up

Section. The Take-Up Rods are

located on the centerline of the Tail

Shaft Bearings. The rods are to be

tightened equally to prevent

misalignment of the pulley causing

belt tracking problems. The top rods

are used to level the Tail Section. Do

not use these rods for tightening the

belt.

Leveling Rod

Take-Up Rod

Special Take-Up Sections:

Head Take-Up Sections w/Rods &

Leveling Rods

The Take-Up Head Section works in

the same manner as a Sliding Box

Tail. The take-up rods located on the

sides tighten the belt. The rods are to

be tightened equally to prevent

misalignment of the pulley-causingbelt tracking problems.

Head Take-Up Sections w/ Sliding

Bearing Mounts & Rods

The Sliding Plate Take-Up Head

Section utilizes a sliding plate to

mount the Head Pulley Bearings. The

conveyor belt is tightened with the

take-up rods mounted directly behind

the bearing mounting. The rods mustbe tightened equally to prevent

misalignment, which can cause the

belt tracking problems. The Motor

Drive Belt will have to be adjusted

when tightening the conveyor belt.



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Application Design ConsiderationsThe Proper Installation of the Hi Roller Conveyor is very important! Basic Rules

and Understandings must be used for the installation. Plan ahead to make sure that

the conveyor will be properly installed. Start-Up Problems will be reduced

dramatically if the conveyor is installed correctly. Please take the time to plan and

follow the Basic Rules.Clearances that must be considered:

Idler Bearing & Shaft Removal = Clearance to the Wall or Structure!

Idler Removal = Clearance above the conveyor cover.

Tail Shaft & Bearings = Much wider than standard Trunking Sections!

Take-Up Section = Clearance to access Take-Up Rods!

Head Section = Much wider than standard Trunking Sections!

Motor & Drive = Depending on type, much wider than Head Section!

Tripper Sections = Much wider than standard Trunking Sections!

Bottom Clearances for cleaning & Bottom Removal Inspection Doors & Top Cover Removal

Tail Cover & Inspection Door Removal

Clearances Tail Section Width

Clearances - Head & Discharge

Clearances - Bottom & Covers

Clearances Tail Take-Up Extended



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Extremely Important-Trunking must be

installed in a Straight Line!

Check with Laser, Transit or Wire Line The Trunking must be installed in a

Straight Line. Trunking that is not installed straight and true with cause belttracking problems. The Trunking must be installed installed in a true straight line!

Trunking must be straightand true from the TailSection to the Head Section.



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Monitors:

Motion Monitor/Speed Slow-Down Monitor must be properly installed.

Discharge Spouting or Overshot Plug Monitor must be properly installed.

Other required Monitors required must be properly installed.

Motion Sensor Installed & Tested = Extremely Important!

A Motion Sensor must be Properly Installed and Tested. Head Pulley slippagemust be detected before damage to the belt occurs. This is very important during

the start-up period when the belt may stretch and cause Head Pulley slippage.



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Plug Switch Installed & Tested = Extremely Important!A Properly Installed and Tested Plug Switch or Switches must be included in the

design.

Discharge Considerations:

Spouting angles Materials flow differently in spouting. The proper anglemust be maintained so that the material will freely flow in the spout.

Spouting sized properly Flow characteristics are different for each type ofmaterial. Properly sized spouting must be installed to handle the capacity of

the discharge flow from the conveyor!

Inclines:

Gradual Hi Roller Conveyors can be installed with a Gradual Upbend.This is the lowest cost, horsepower and maintenance option. Hi Rollers

Engineering Department must complete design calculations to determine theamount of Gradual Upbend that can be installed on a specific application.

Sharp Upbends Hi Roller Conveyors can be installed with a Sharp UpbendSection. This is the highest cost, horsepower and maintenance option. Hi

Rollers Engineering Department must complete design calculations to

determine the amount of increase horsepower and cost of this option for a

specific application.

Horsepower Inclined conveyors of any type require additional horsepower.A Straight, Gradual or Sharp Upbend Inclined conveyor will require

additional horsepower to simply lift up the material. This additionalhorsepower will be calculated by Hi Rollers Engineering Department.

Capacity Inclined conveyors of any type will not convey the same amountof material as a flat horizontal conveyor. Hi Rollers Engineering

Department will calculate the capacity of a specific application.



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Aspiration:

General-Dry-Ambient Material

Hot Moist Material



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Condensation Prevention:

Bin Venting Problems Warm Air = Warm and moist air must not beallowed to vent through the conveyor. This will cause condensation to form

on the inside of the conveyor enclosure as the dew point of the air is

reached. The condensation or water can freeze inside the conveyor and

caused many major problems.

Warm/Hot Moist Materials = Warm or hot moist materials will create warmmoist air inside the conveyor enclosure. This will cause the same problems

discussed above.

Proper Insulation = The outside skin of the conveyor enclosure may have tobe insulated to eliminate the formation of condensation from the cold outside

temperatures.

Vapor Isolation = Warm and moist vapors can cause the same condensationproblems discussed above. The conveyor enclosure must be isolated so that

these vapors cannot circulate through the conveyor enclosure.

Product Characteristics Multiple Products Make sure that the conveyor is designed and installed to

handle all of the different types and sizes of the materials.

Bulk Density, i.e. pounds per cubic foot, pounds per bushels, metric tons percubic meter, kg/cubic meter, etc.

Abrasive Materials Design considerations must be reviewed with HiRollers Engineering Department.

Corrosive Materials Design considerations must be reviewed with HiRollers Engineering Department.

Sticky Materials Design considerations must be reviewed with Hi RollersEngineering Department.

Moist Materials Design considerations must be reviewed with Hi RollersEngineering Department.

Hot Moist Material Design considerations must be reviewed with HiRollers Engineering Department.

Hot Oily Moist Material Design considerations must be reviewed with HiRollers Engineering Department.



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Capacity Considerations:

Capacity Inclined conveyors of any type will not convey the same amountof material as a flat horizontal conveyor. Hi Rollers Engineering

Department will calculate the capacity of a specific application.

Multiple Products Make sure that the conveyor is designed and installed tohandle all of the different types and sizes of the materials.

Bulk Density, i.e. pounds per cubic foot, pounds per bushels, metric tons percubic meter, kg/cubic meter, etc.

Belt Speed = Min. for proper Reloading = 350 fpm(granular materials) &400 fpm(powders/fines/meals)

Options:

Heavy Duty Idlers

Heavy Duty Return Liners(1/2)

Etc??

Splices:

Mechanical Flexco splices are standard on all Hi Roller Conveyors. Werecommend different types of Flexco splices depending on the application.

Vulcanized We recommend that the first year of operation be with aMechanical splice before a Vulcanized splice is installed. The belt should be

stretched and stabilized before the permanent Vulcanized splice is installed.

This is because of the limited length of the Take-Up Section of the

conveyor.

Supports:

Supports must be installed at least every twenty (20) feet of the length of the

conveyor. Support Legs or Hangers should always be bolted to the trunking vertical or

bottom flanges. Supports should never be welded to the trunking sides.

Motor and Drive:

Motor, Drive, Couplings, and other Drive Components must be securelymounted in place and properly aligned.

Proper Belt, Chain, Couplings, Cooling Fan or other required Guards mustbe properly installed.

Lubrication Has the Drive lubrication oil been properly filled? The Drive

DOES NOT arrive at the jobsite filled with lubrication oil. The DriveMUST BE FILLED at the jobsite with lubrication oil.

Hi Rollers Engineering Department should be contacted

with any further questions or required information.


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