Archive → February, 2010
6, tape repair
(A) Purpose: Tape covers any part of the glue and the core layer is damaged, rather than the timely repair of water and dirt intrusion, will cause a scar to expand, resulting in shortened life expectancy tape, in order to extend the belt life, the timely detection of defects, early treatment, the economic significance will be enormous.
(B) An ordinary polyester tape repair
1. Face covered by plastic damage
1) According to the damaged state of plastic cover can be used for round or diamond-shaped patch along the broken outline of four weeks at least be a 15 ~ 20mm, cut patch to draw lines to 45 º angle oblique, and ripped the cover has been damaged plastic. Be careful not to damage the cutting of the fabric layer below.
2) Prepare patch film, size, and cutting surface fit, the thickness is consistent with the original plastic cover (for example, can be multi-layer laminate thickness is not enough,) 4 peripheral cut Oblique (cold curing adhesive film with the already hot sticky use of non-sulfide film).
3) The Department and the repair patch to play hair, clear plastic dust impurities, wash clean, in the office and back-on-chip repair mortar brushing at least twice, and fully dry. conveyor belts
4) laminating film and fully rolling patch firmly indeed, the existence of excess glue around the edges with a knife gently Katagiri film formation.
5) If the hot-curing adhesive patch device can be used. Reference tape bonding process.
2. Canvas layer damage repair
1) Check the damage size and the fabric layer is damaged floors, the general Break maximum can not exceed 20% of the bandwidth.
2) marker to draw repair parts of sizes. Area is calculated by layer by 30mm. For example, four damaged. Repairing an area of 4 × 30 = 120mm. The patch area of 120mm × 120mm.
3) Cut strip into a hierarchical ladder incision. Hair brush layer by layer and then hit mortar subsidies cover plastic canvas and press firmly.
4) In the tape around the back side surface at least be damaged by 50mm, crossed polishing, brush mortar, adhesive plastic cover make up, rolling firmly indeed.
3. With a longitudinal tear and the tape within 20% of the width of the edge tear repaired Polyester Conveyor Belt
1) with a longitudinal tear, generally only need to press half the canvas layer to segment its patch size
Vertical direction: (need to replace the layers +1) × 50mm
Horizontal direction: (need to replace the layers +1) × 30mm
2) the edge of tear tape, we must first check, the damage of the band-edge is a straight-line running, if necessary, should be transferred straight to eliminate tape tension.
3) to draw the edge of patch size line of position, each 30mm layer of fabric as measured across from the tear edge and tear on both sides of the end, start, such as the load is large, the size of the direction of the tape should be doubled.
4) The vertical and the edge of tears with core operating procedures and the repair of damaged fabric layer method is basically the same, but the edge of the patch should be glue on the edge of the vertical strips.
Note: The cutting, with the tape center line into a 45 º angle.
(C) repair of steel cord conveyor belt
1. Plastic cover injury and damage repair glue edges
With ordinary polyester tape.
2. Steel Cord pull off Nylon Conveyor Belt
A) Repair damaged when removed (or tilt of the) wire rope, use bolt cutters cut, can not use gas cutting, welding, etc..
2) The patch has a rope breaking the tape when the adhesive does not cover damage to the site, will cut the rope and then curing.
3) If two or two or more adjacent broken rope, the ripped plastic cover repair section, from the broken parts of wire rope on both sides of every one to insert a 800mm wire, damaged section of the polished, clear plastic dust, gas cleaning, coating slurry, laying into the new gluing rope, brush a small increase of gasoline and mortar filling the isolation tape, and then glue on the core, cover glue, rolling vulcanization.
3. Longitudinal tear through the patch
1) along the gap of about 60 ~ 100mm for each mark, Alice with a knife cut out the damaged core glue and cover glue and make ramps.
2) polished, and its scope beyond the marked line is about 10-20mm.
3) The first in the gap between the core and upper gum paste, paste plastic cover, cover plastic face thicker than 1 ~ 1.5mm. Than the polished parts of width 10 ~ 20mm.
4) The curing process vulcanization.
(D) Patch Notes
1) repair damage before the conveyor belt around the Department of wiping clean with gasoline.
2) covering a smaller part of gum damage can be repaired directly to fill the cold glue.
3) to fill to fill the surface should be 1.5mm above the belt surface as the amount of shrinkage after curing.
4) Repair parts before curing is best to use wood or iron clamp fixed.
5) The incision direction as far as possible and cover the gel at 45 degrees, to avoid incision and the tape length direction at right angles.
5,tape bonding process
(A) the tape joint method:
1. Mechanical connection method: conveyor belt system
Metal Buckle fixed to the two joints, the penetration pin, so that the two heads connected. Features: simple operation speed, detachable, but the intensity is low, only the intensity of the original tapes of 30% to 60%, flexible joints at the poor and other items easily damaged roller, vibration, noise big, there is leakage.
2. Cold adhesive connection method:
With specific adhesive will peel the first adhesive layer 2, adhesive to fully roll, the static discharge for more than two hours, the same operation and hot-sticky. Features: No leakage, noise, vibration, without expensive equipment, but its drawback is that the lower connection strength, reliability is poor, can only be used in temperature limited, low security requirements and the general wear-resistant cases, does not apply wire rope core tape. Sidewall Conveyor Belt
3. Hot sticky connection method: — curing method.
HTV Joint of the modern ideal tape joints law, if the connection quality is high, their joint life expectancy can be compared with the tape itself, the life, the joint can be in any type of reinforcing materials with a core carried out using a Portable, flat vulcanizing machine to connect the pressure treatment, curing, or to provide financial access required pressure and temperature.
Joint construction of many forms, depending on the tape structure is multi-layered, double deck, single layer, pvc entire core, or wire rope cores.
Connector should be using the new plastic materials, plastic sheets, and mortar, adhesives, their composition and properties must be used with the manufacture of belt materials in line. The use of semi-vulcanized rubber and adhesive gel has a bad effect, the joint may be premature fracture, accident incidents. For the heat, cold, Steel Cord Conveyor Belt oil, acid, alkali flame-retardant and other special tape, should pay attention to use the appropriate adhesive rubber material, or joint effect of achieving the desired effects.
Joint operation of establishments, we must absolutely dry, clean, no dust, can not be exposed to the sun, for damp places and need to repeatedly remove the water vapor, if necessary, puts up tents.
Curing equipment: vulcanizing machine, peeler, cutting knives.
Thermal curing of shortcomings: long, costly.
(B) heat curing Joints form and connector length of
1. Fabric core conveyor belt
1) single-layer fabric form the core zone of the connector
Minimum ladder length LS = 200 ~ 300mm
LV = 250 ~ 350mm
2) multi-layer fabric form the core zone of the connector.
According to fracture with a type that is the fabric layer to decide the length of the length and connector
Ls = 150 ~ 350mm
Lv = 50 ~ 100 + (fabric layer -1) × Ls
For more than two levels using oblique joints, plagioclase La = 0.3 × bandwidth
Total joint length Lu = (geotextile layer -1) × Ls +50 ~ 100mm
2. Steel cord conveyor belt
Steel cord conveyor belt to be vulcanized with hot method, the length of lap joints and the geometry of the connection must be in accordance wire diameter, pitch, wire rope breaking strength and with rubber adhesive strength of the extract, depending on joints in the wire rope should be a certain degree of Lap length, so that joint Department of steel cord and rubber adhesion is greater than the rope breaking rally.
If the spacing of wire rope can be placed in the middle of a rope and the necessary glue (1.5 ~ 5mm), then the connection will be steel cord conveyor belt has a good state, may be an overlap, if the rope is not enough space to place tensile steel wire rope and conduction force the middle of the rubber, then the need for multi-level overlap.
Belt Model ST630 ~ ST1000
Lv = 600 ~ 700mm
Lst = 300 ~ 400mm
Belt Model ST1250 ~ ST3150
Lv = 1250 ~ 1750mm
Ls ≥ 3d (wire rope diameter)
The rest of the dimensions of a connector size
Belt Model ST4000 ~ ST5000
Lv = 2950 ~ 3550mm
The remaining dimensions with a
(C) Ordinary polyester tape bonding process (EP-200, B = 1400mm, Z = 25 layers, the plastic 6mm, under the plastic 3mm)
1. Pre-bonding preparation.
1) Site requirements:
Clean, dry, non-exposure, no dust, easy to work, take the work platform.
2) Tools to prepare:
A variety of cutting knives, pressure roller, cutting pliers, wrench, screwdriver, electric grinding tools, wire wheels, wire brush, paste brush, cleaning brush, stripping pliers, traction devices (winches), tape measure straight, angle square, marking with on a (ink fountain, chalk), thermometer, stainless steel bucket (with lid), stainless steel pots, rubber gloves.
3) The required material preparation:
120 # aviation gasoline, flour glue, core adhesive, mortar with plastic, and will mortar soaked 24 hours in advance. Petrol and rubber feed ratio of 5:1
2. Operating Procedures
A) a crossed
Will be placed on the tape flat work platform on the joints wipe clean, and set aside while the joint centerline, the base line, cut off the line, cutting line, cutting edge glue line, ladder pitch line.
2) cut peel
Accordance with the size of lines, oblique cutting, peeling, pay attention to the lower blade can not cut canvas.
3) play Mao
Electric wire brush with the canvas with a clear ladder of surface residual glue joints, pay attention to avoid polish polish or produce scorch phenomenon.
4) The joint step with the
Will be stacked two to test the accuracy of their joints with each layer is the same fabric layer 5-15mm gap between the stay, if not accurately be amended.
First cleaned with gasoline peeling layer, and then coating syrup at least twice, each post-secondary dry before coating the next mortar. Office space in the same fabric layer of paste buffer strip, note that if the adhesive does not dry, will produce bubble, resulting in reduced adhesive properties.
Mucilage, after solvent evaporation, thoroughly dry, the two fit. Should be made the same tape on both sides of the joints tight or too loose ladder alignment, centerline alignment, from the middle to both sides of the laminate adhesive tape to facilitate the escape of air from both sides. In order to ensure joint quality, appropriate to cover the rubber seal at plus glue to strengthen canvas, its shape size at no more than the width of tape to prevent moisture absorption. After the fitting, full roll to prevent the accumulation of bubbles. Harvesting is not vulcanized rubber cover, first made of sealing tape, adhesive tape in the tape and glue on the interfaces of pulp, and fully rolling real prison.
Connector pads on both sides of the tape width 40 ~ 50mm, thickness ratio with a thin body of 0.5 ~ 1mm, length 300mm longer than the length of the edge connector Department of horn, and use splint grip tape joints. (In two joints fit will be preceded by curing machine for the next frame, pressure plate pressure device, under the heating plate, white, in turn put away, in the tape joints cloth shop, and then stamped on a curing machine electric heating plate, insulation board, on the rack, and the next frame to find positive, aligned, tighten evenly.
Note: If more than one curing devices work side by side, in the upper and lower heating plate seams pad 0.2 × 50 × 1400mm of thin metal plates. For our on-site belt vulcanization, is two 1400 × 830, 1400 × 1000 specifications curing machine, when you need to use two simultaneously vulcanized.
Alignment of the upper and lower racks, looking for positive, you use bolt nut fastening the upper and lower racks, pay attention to bear in power should be homogeneous. Connected to the control box, pressure pumps and other equipment, connected to the power began to vulcanization.
Curing time of the control of process parameters: the first side of the heat, while suppressed, when the temperature about 70 ℃, the pressure to achieve 10kg/cm, when the temperature reaches 100 ℃, the pressure to achieve 16kg/cm, stop trying to restrict and continue heating, When the temperature reaches 145 ℃, has begun to count cure time, stop heating, heat 35 minutes after the end of curing, cutting off power supply, so that curing machine naturally cooled by cooling water is about 70 ℃ demolition vulcanizing machine.
from mold, finishing tape
Relieved vulcanizing machine, it will overflow adhesive tape on the connector and flash removal, finishing smooth and clean, the whole curing bonding completed.
3. Conveyor Belt Joint Attention
1) When laying should pay attention to the conveyor system, as well as around the face and non face into the direction, not a mistake, adjust the belt to center and center line roller frame.
2) The cutting should be the proper use of cutting knife, not cut canvas, otherwise it will reduce the tape strength, this cutting is usually in the layer with the canvas layer to stay 0.5mm residual layer, between layers in the canvas to stay 0.3mm residue layer.
3) to prevent undesirable or damage joints grinding canvas.
4) The adhesive surface should be kept clean from start to finish to prevent viscosity oil, water, or dust.
5) The canvas damp, it should be drying or drying further bonding, nylon canvas absorbent strong, operations should pay particular attention, there would be bubbles, delamination and other defects.
6) then the last one first, attention should be tightening the belt conveyor travel.
7) stripping the first time, pay attention to the determination of the upper and lower joints, to ensure that the above connection and operation in the same direction
to prevent the ladder overlap, otherwise the result in premature peeling.
9) coating evenly, avoid plastic or holes caused by ischemic
10) affixed bubbling appears timely, it should be pierced, exhaust after the compaction.
11) The use of plastic materials the same as the original tape and pay attention to the validity of rubber.
12) are equipped with appropriate mortar, and the foam into a paste with a seal kept in the cold after dark.
(D) fire-retardant steel core of the bonding process
With ST1600 type, bandwidth, 1400mm steel wire rope 12mm diameter and 5.1mm pitch down the middle of 3mm thick plastic 6mm thick plastic cover, for example.
1. Pre-bonding preparation work: with the ordinary flame-retardant polyester belt, tool coupled with off Pliers, wallpaper knife.
2. Operating Procedures
A) a crossed:
The joint part of the cleaning in the net, draw up the construction Size Line: base line, center line, cutting line, cutting line, cutting edge glue lines and core plastic incision line.
2) cut peel
Cut along the dash cover gasket adhesive strip, and then the direction along the rope cut out of steel wire rope steel wire rope scraped the surface layer, steel wire rope according to 1400mm, 700mm and white cut off.
3) play Mao
Disc with electric wire rope steel wire brush remove surface residue glue (or wallpaper knife), polish all parts of joints, note that the boundaries can not be polished edge of the exposed wire can not be beat Coke.
Steel wire rope and joints at bonding and cleaned, and coated twice mortar.
Under the first curing machine rack, pressure plate, followed by the next heating plate put away, and then in white above the shop. Shop down adhesive plastic sheet, plastic cover in the next, the core glue in the pre-drying a good composite surface coating on the curing press after the heating plate (at actual size connector 1500 × 1400). Then the upper and lower cover rubber joints 45 ℃ bevel slope posted 1mm thick strips. The glue joints on the plastic sheet under the bonding, the pull to find are two joint center, was later to find the center of connector wire rope, according to two take joint approach from the center to edge both sides were ordered, and embedded filled plastic rope section, the wire rope as far as possible, straight edge rubber belt on both sides of Canada, in the butt rope gap (25mm) Department and other void fill in fill plastic and finally covered with adhesive plastic sheet on the first on the core glue, then glue the superstructure, in the middle Brushing mortar should be the last hand roller compaction, to improve the strength, can be built in between the plastic and the core layer of plastic hanging plastic canvas strengthened.
(Note: steel wire rope placed lap later, both sides plus the width of 50mm side edge glue, then glue on the core, cover glue, its thickness not less than the thickness of the original tape)
Trim edge, while iron and tape placed firmly fixed in the final capped with white plastic cover, placed on heating plates, insulation panels, on the rack, and the next frame to find positive, aligned, tighten evenly.
Connection control box, pressure pumps, connected to the power to conduct vulcanization. Parallel use of two vulcanizing machine interface plus pad at 0.5mm thickness iron.
Curing parameters of control: first, heating, pressure, when the temperature to 80 ℃, the pressure required to achieve 18-20kg/cm2, then stop pressure and continue heating to 145 ℃, stop heating, count the curing time to 40 minutes later, curing the end, cut off power supply, so that curing machine natural cooling, the temperature dropped to 80 ℃, demolition vulcanizing machine.
7) from mold, tape trimming
Relieved curing machine, Office of the tape joint edges remove excess glue and finishing smooth and clean, thus, the entire curing completed.
3. Sulfide Note: the same as with ordinary polyester tape, another plus one to avoid being polished steel wire rope light, wear and tear.
4, conveyor belts repair or replace the condition (that is, the boundaries of patches allowed size)
Cold-curing adhesive repair patch cut, replacement
Wear rubber cover – glue residue cover more than the thickness of 1 mm covered plastic Mochuan, steel cord exposed
Cuts 1 / 2 more than the thickness of plastic cover, 300mm length less than 1 / 2 more than the thickness of plastic cover, 300mm long or more –
Peel 1 / 2 more than the thickness of plastic cover, 300mm length less than 1 / 2 more than the thickness of plastic cover, 300mm long or more –
Side length of 50 mm or more plastic tear – –
Cut to achieve the overall level has boundless glue –
Nylon Conveyor Belt dewy-core diameter of less than 100 mm diameter greater than 100 mm overall fracture, large-scale floor stripping
Fracture – 10% below 10% of broadband over broadband
Exposed core wire core diameter of less than 100 mm diameter greater than 100 mm steel core exposed, or with the surrounding degumming
Break off 2 off 3 or more 10% off the total dissatisfaction with the core of more than 10% of the total number of
Longitudinal tear length of 500 mm below the length of 500 mm or more too long to repair
Curing joints of the steel cord conveyor belt at the sides and the middle of the first sulfide to make pitch for the L, respectively, punctuation, use changes were observed during the pitch, if the 4 mm when the pitch increases, heavy joints.
Notes: 1. Due to contaminated with oil, heating plastic cover damage caused by severe trauma or multiple, horizontal fracture more than 1 / 3 of bandwidth required to cut off the replacement. Pipe Conveyor Belt
2. Core body repair multiple injuries can not be increased or repaired in need of replacement.
Defects in the general operation of the conveyor system can all be repaired, but requires an accurate assessment of its effect, when the fabric conveyor belt rubber cover damage to the limit, broken and torn plastic cover more than 7 per meter, hole 15-17, transverse fracture (perforation) amounted to 1 / 3 of bandwidth, band intensity decreased by 40%, the damaged section must be cut, re-connected to the new section.
According to literature offered a cross-section of steel cord conveyor belt has five or more broken rope, that can not be repaired because the stress concentration will be more than three times the 1.5 when the rope break, but in general the strength of steel cord conveyor belt safety factor, it is necessary lower than the fabric core band.
With the tape level strong improvement in tape prices significantly increased in general with the difficult part of the core layer, if the damaged tape core body is still intact, you should consider the possibility of repair to use.