Design challenges of large-inclination-angle conveyor belts: Stability of the skirt + partition combination structure

Ensuring the structural stability of skirt-and-cleat combinations in high-incline (30°–90°) conveyor belts requires multi-dimensional optimization, including structural design, material selection, and operational adaptability. Below is a detailed analysis:

I. Structural Design Challenges

1. Skirt-Cleat Bonding Integrity

• Secondary vulcanization process: Critical for bonding skirts/cleats to the base belt. Poor execution risks delamination or cracking.
• Corrugated skirt design:
  • Facilitates belt flexing around pulleys.
  • Corrugation dimensions require precise calculation to balance flexibility and load-bearing capacity.

2. Cleat Layout and Load Distribution

• Cleat spacing:
  • Optimal spacing prevents material backflow (if too wide) and minimizes drag (if too narrow).
• Cleat geometry:
  • T-type or TC-type cleats are recommended for powdered/granular materials to enhance containment.
  • Height and profile must align with material properties (e.g., bulk density, flowability).

3. Incline Adaptability

• High-angle operation increases lateral pressure on skirts/cleats, risking deformation.
• Finite element analysis (FEA): Essential to simulate stress distribution under varying incline angles and optimize:
  • Cleat thickness and reinforcement.
  • Skirt stiffness-to-flexibility ratio.

II. Material Selection Challenges

1. Base Belt Materials

• Key requirements: High tensile strength (≥1000 N/mm) with flexibility for pulley navigation.
• Common core materials:
  • Cotton canvas core: Economical for moderate loads.
  • Nylon fabric core: Superior impact resistance for heavy-duty applications.
  • Polyester fabric core: Balances strength and low elongation.

2. Skirt and Cleat Materials

• Abrasion resistance:
  • Ultra-high molecular weight polyethylene (UHMWPE) or rubber compounds (e.g., SBR with 80–90 Shore A hardness).
• Chemical resistance:
  • For acidic/alkaline/oily materials: Nitrile rubber (NBR) or chloroprene (CR).
  • Additives like carbon black (15–20%) enhance wear and UV resistance.

Critical Considerations

• Operational validation: Simulate extreme loads (120% of rated capacity) and incline transitions (e.g., 45°→75°) to test fatigue resistance.
• Maintenance protocols: Regular inspection of cleat root stress points and skirt-edge wear patterns.