Escolar Documentos
Profissional Documentos
Cultura Documentos
Whatsthebestsolution?
IndustrialWhitePaper
By:MichaelA.Hosch,P.E.
DornerMfg.Corp.
975CottonwoodAvenue
Hartland,WI53029USA
Phone:8003978664
www.Dorner.com
Overview:
Thiswhitepaperwillprovideanoverviewofthemostcommonlyusedmethodsforadjustingbelttensiononsmallpackage
conveyors.Theprimaryadvantagesanddisadvantagesofeachmethodwillalsobepresentedtoassistmanufacturersidentifythe
bestoptionfortheirspecificneeds.
TableofContents:
Overview Pg. 2
BeltTensioningforSmallPackageConveyorsAnIntroduction Pg. 3
BeltTensionMethods Pgs. 48
JackScrewTension Pgs. 5
RackandPinionTension Pg. 6
TipUpTailTension Pg. 7
PneumaticorSpringTension Pg. 8
2 Belt Tensioning Methods for Small Package Conveyors 2009 Dorner Mfg. Corp.
BeltTensioningforSmallPackageBeltConveyorsAnIntroduction:
Smallpackagebeltconveyorsareusedforthousandsofapplicationsincountlessindustrialmarkets.Theseconveyorsmove
individualproductsthroughprocessingapplicationswherefunctionssuchasforming,molding,machining,gluingandassemblyare
performedonmetalorplasticproduct.Theseproductsthenmovetopackagingapplicationswheretheyareinsertedintotheir
individualpackageandsealed,wrapped,heatshrunk,orbandedbeforebeinggroupedandloadedintotheirshippingcontainer.The
useofsmallpackagebeltconveyorsforalloftheapplicationspresentedabovehasseveralbenefits.
Typically,theseconveyorshaveendrollersbetween1and2indiameter.Thisallowssmoothtransferfromprocesstoprocessfor
smallandoftenoddlyshapedproducts.Inaddition,smallpackagebeltconveyorsgenerallyhaveathinprofileandhaveatightbelt
widthtooverallwidthratio.Thisprovidestheabilityfortheconveyortofitintotightspaces,whichmaximizesavailablefloorspace
whileminimizingprotrusionsthatmayinterferewithoperators.
Althoughtheseconveyorsaresmall(astheirclassificationwouldimply)andtheirloadsaregenerallylight,theystillpresentsomeof
thesametechnicalandmaintenancechallengesasmuchlargerconveyorsonesuchchallengeisbelttensioning.ForboSiegling,a
leadingmanufactureroflightmaterialhandlingbelts,notesthefollowingrelativetobelttensioning;thecontactpressureofthebelt
onthedrivedrumrequiredtotransmiteffectivepullisproducedbyelongatingthebeltwithatensiontakeup.Withoutatension
takeupdevice,therewouldbenopressureonthedrivedrumandtheconveyorbeltwouldstop.Whilethisconceptissimple,how
thetensiontakeupmechanismisdesignedtocarryoutthisprocesscanbequitecomplicated.And,ifnotdoneproperly,canleadto
avarietyofresourcedrainingmaintenanceproblems,including:
Poororinconsistentbelttracking
Overtensioning,causingpoorbeltlife
Overtensioning,causingpoorbearinglife
Undertensioning,causingbeltslippage
Confusiontomaintenancestaffontensioningprocedures
Mechanismsthataredifficulttoaccessoradjust
3 Belt Tensioning Methods for Small Package Conveyors 2009 Dorner Mfg. Corp.
Alloftheissueslistedpreviouslycouldeasilyleadtoconveyorbeltshutdown,whichoftenforcesmachineandproductiondowntime
somethingthatobviouslyneedstobeavoidedintodaysbusy,24/7productionfacilities.
BeltTensionMethods:
Thereareseveralcommercialmethodsforprovidingandadjustingconveyorbelttension.Someconsistofstandardcomponentsthat
providethecapabilityofdesigningyourownconveyor.Othermethodsonlyexistindesignsavailableascompleteconveyorsfrom
conveyormanufactures.Inmostcases,thesemethodscanbecategorizedintothefollowingfourgroups:
1. JackScrewTension
2. RackandPinionTension
3. TipupTailTension
4. PneumaticorSpringTension
Letstakeamoredetailedlookateachofthesemethods,beginningwithJackScrewTension.
4 Belt Tensioning Methods for Small Package Conveyors 2009 Dorner Mfg. Corp.
JackScrewTension
Jackscrewtensionisthemostcommonbelttensioningmechanism.Howdoesitwork?Asshowninthefigurebelow(FigureA),the
tensiononthebeltisaccomplishedbyturningthescrewattheendofaconveyor.Thispushesthebearingblocktowardstheendof
theconveyor,whichaddstensiontothebelt.Thereisanother,identicaljackscrewlocatedontheoppositesideoftheroller.The
sameproceduremustbeperformedevenlyforbothrollers.Inmostconveyorinstallations,thistensionmechanismisalsousedto
adjustbelttracking.Jackscrewtensioningissimpletouseandiscommonlyinstalled,butalsopresentsanumberofdisadvantages
whichwellreviewingreaterdetaillaterinthispaper.
FigureA: JackScrewTension
5 Belt Tensioning Methods for Small Package Conveyors 2009 Dorner Mfg. Corp.
RackandPinionTension
Rackandpiniontensionisaccomplishedbyincorporatingarackandpiniondeviceintotheconveyorframe.Anexampleofthis
mechanismisshownbelow(FigureB).Asyoullsee,tworacksareslideablymountedtotheconveyorframe.Turningthepinion
shaftthenpushesonthebearingblockstomovetherollerandaddbelttension.Generally,thepinionrunsthefullwidthofthe
frameandcontactsbothracks,whichmovesthebearingblocksevenlyandparallelwhileturningfromasinglepoint.Sincethe
bearingblocksmovetogether,anadditionaldeviceisneededforbelttracking.Thisbelttrackingdevicemaybeajackscreworcam,
whichistypicallymountedbetweentheracksandthebearingblock.Rackandpiniontensioningdoesnotdisturbbelttracking
if/whenabelttensionadjustmentisnecessary.
FigureB: RackandPinionTension
6 Belt Tensioning Methods for Small Package Conveyors 2009 Dorner Mfg. Corp.
TipUpTailTension
Atipuptailisaccomplishedbyplacingtheendrollerofaconveyoronapivotmechanism.Anexampleofthismechanismisshown
below(FigureC).Usingthismethod,thepivotdevicegenerallyliftstheendrollerabovetheconveyorframe.Whenplacedinthe
lowerlockedposition,thetotalrollertorollerlengthoftheconveyorislongerthanitisintheupperposition.Thisextensioniswhat
providestensiontotheconveyorbelt.Thepivotmechanismmovestheentireendrollerperpendiculartotheconveyorframeand
doesnotneedaccessoradjustmentfrombothsidesoftheframe.Atipuptailmechanismwillnotprovidefinitebelttension
adjustmentitcanonlybesettooneposition.Overtime,asbeltsstretch,theywillrequireadjustment.Toaccomplishthis,adevice
suchasajackscrewwillneedtobeaddedforincrementaltensionadjustment.Thisjackscrewcanthenalsobeusedforbelt
trackingadjustment.
FigureC: TipUpTailTension
7 Belt Tensioning Methods for Small Package Conveyors 2009 Dorner Mfg. Corp.
PneumaticorSpringTension
Pneumaticorspringtensionistypicallyusedonheavilyloadedorlongerconveyors.Itisaccomplishedbytheadditionofatleast
threerollerstotheundersideoftheconveyor.Anexampleofthismechanismisshownbelow(FigureD).Belttensionisachievedby
aconnectionofapneumaticcylinderoraspringloadeddevicetothelowertensionroller.Thecylinderwillpullthelowerroller
down,whichplacestensiononthebelt.Generally,onecylinderisconnectedtotheendsoftherollerbyacrossbracket.Thecylinder
willmovetheendsoftherollerevenlyandparallel.Onebenefitofthismechanismisthatitautomaticallycompensatesforbelt
stretch.Themethodscoveredpreviouslyinthispaperhavebeenstaticdevicesthatrequiremanualadjustmentovertime.Seeingas
longerandhigherloadconveyorshavemorebeltstretch,thisisthebestmethodforthosecircumstances.Belttrackingistypically
accomplishedbyaddingadevicesuchasajackscrewtothesnubrollersjustabovethetensionroller.
FigureD: PneumaticTension
8 Belt Tensioning Methods for Small Package Conveyors 2009 Dorner Mfg. Corp.
AdvantagesandDisadvantagesofTensioningMethods:
Nowthatyouhaveabetterunderstandingofthemostcommonlyutilizedtensioningmethods,welltakeamoredetailedlookatthe
generaladvantagesanddisadvantagesofeach.
JackScrewTension
Advantages:
1. Lowcost.Thismethodhastheleastamountofcomponentsandthecomponentsaresimpleandreadilyavailable.
2. Familiarity.Thisisthemostcommonmethodoftensioningandmostmaintenancecrewsarefamiliarwithitsoperation,soit
cangenerallybefixedquickly.
Disadvantages:
1. Addedmaintenancetimeforbelttracking.Becausethejackscrewistheonlymethodofadjustment,itmustbeusedfor
bothtensioningandtracking.Onceaconveyorbeltrequiresretensioning,thejackscrewswillbeadjustedandthetracking
settingswillbedisturbed.Therefore,atrackingadjustmentmustbeperformedeventhoughitwasntrequired.Thiscauses
muchhighermaintenancetimesastrackingadjustmentcantakesubstantiallylongerthansimpletensioningalone.
2. Highriskofovertensioning.Inmostcases,thejackscrewadjustmentdeviceisasimplethreadedbolt.Threadedboltsare
designedtoapplyextremeforcetoclamporholddevices.Belttensionadjustmentsmadewithjackscrewsaredone
manually.And,withtheshallowpitchangleofthejackscrewthread,thereisverylittlefeedbacktotheoperatormaking
theadjustment.Theyareoftenunawareoftheextremeforcestheyareplacingonthebeltandthebearings.Unfortunately,
intime,thisovertensioningwillresultinreducedbearingandbeltlife.
3. Difficulttoaccessformaintenance.Inmanyconveyordesigns,thejackscrewislocatedattheendoftheconveyorroller
alongthesideoftheconveyorframe.Unfortunately,inmostapplications,theendoftheconveyorisplacedupagainst
anotherconveyorrollerorpieceofequipment,makingitnearlyimpossibletoaccesstheendofthejackscrewfor
9 Belt Tensioning Methods for Small Package Conveyors 2009 Dorner Mfg. Corp.
adjustment.Therefore,tomakeadjustments,theconveyormustberemovedfromitmounts,adjustedandthenreturned.
Thisdramaticallyincreasesmaintenancetimes.
4. Addswidthtotheconveyor.Ifnotlocatedontheendoftheconveyortail,thejackscrewmustthenbelocatedbehindthe
conveyorbearingblock,whichpushesthebearingblockforward(seeFigureA).Thismethodaddsconsiderablewidthtothe
overallconveyor,makingitmuchmoredifficulttoplacetheconveyorintotightapplications.Italsoprotrudesbeyondthe
conveyorsideframe,whichcreatesapotentialsafetyriskforoperators.
5. Requiresperiodicretensioning.Thismechanismdoesnotcompensateforthebeltstretchthatwilloccurovertimedueto
wearorheavyloads.Ifbeltslipoccurs,thejackscrewwillneedtoberetightenedandretrackedtotensionthebelt.
RackandPinionTension
Advantages:
1. Doesnotaffectbelttracking.Rackandpinionmechanismspushevenlyonthebearingblocksfromasinglepoint.Moving
thebearingblockstogetherensuresthatthetrackingadjustmentcompletedpreviouslydoesnotgetdisturbedbytheneed
toretension.Thisgreatlyshortensmaintenancetimes.
2. Easyaccessformaintenanceadjustment.Maintenanceadjustmentonarackandpinionsystemisdonefromthesideofthe
conveyorframe.Generally,thisareaismoreopenthantheend.Inaddition,thepinioncanbeaccessedfromeithersideof
theframe.Therefore,ifonesideisblockedbyanaccessory,theothersidemaybeopen.
3. Lowriskofovertensioning.Inarackandpinionmechanism,theamountoftensionplacedintotheconveyorbeltisdirectly
relatedtothemanualtorqueplacedonthepiniongear.Themechanicaladvantageofthispiniongearismuchlessthana
jackscrew.Thepinioncanbesizedsothatwhenitreachesthedesiredbelttension,itbecomesdifficulttoturn.This
minimizesthedesiretoovertensionthebelt,lengtheningconveyorbeltandbearinglife.
4. Compactdesign.Onlytheendofthepinionneedstobeaccessedbymaintenanceinarackandpiniondesign.Asaresult,the
remainderofthemechanismcanbebuiltinsidetheconveyorframe.Thisensurestheframeisnarrowanddoesnotprotrude
muchpastthebeltwidth,allowingtheconveyortobeplacedintotightspaceswhileeliminatingoperatorbumppoints.
10 Belt Tensioning Methods for Small Package Conveyors 2009 Dorner Mfg. Corp.
Disadvantages:
1. Requiresanaccurateframe.Sincethepremiseforthismechanismistomovethetwobearingblocksevenly,itiscriticalforit
tobeinstalledaccuratelyandparalleltotheroller.Customconveyorsgenerallydonotusethismethodforthatreason.
However,standardconveyorsthatusequalityengineeringandconsistentmanufacturingmethodsareabletoaccomplishthe
accuracyneeded.
2. Requiresperiodicretensioning.Thismechanismdoesnotcompensateforthebeltstretchthatwillhappenovertimedueto
wearorheavyloads.Ifbeltslipoccurs,therackandpinionwillneedtoberetightenedtotensionthebelt.
TipUpTailTension
Advantages:
1. Quickaccessforcleaning.Tipuptailtensionmechanismsaremostoftenutilizedonconveyorsusedinfoodapplications.For
theseapplications,itisimportanttohavefastandtoollessaccesstotheinsideoftheconveyorforcleaning.Tipuptails
providethisfunction.
2. Doesnotaffectbelttracking.Tipupmechanismsswingthebearingblocksevenlyintopositionfromasinglepoint.Moving
thebearingblockstogetherensuresthatthetrackingadjustmentthathasbeenpreviouslysetdoesnotgetdisturbedbythe
needtoretension.
Disadvantages:
1. Requiresanaccurateframe.Sincethepremiseforthismechanismistomovethetwobearingblocksevenly,itisrequired
thatitisinstalledaccuratelyandparalleltotheroller.
2. Onlysetsinitialtension.Atipuptailtensionsystemisasinglepositionsystem.Thepivotarmrotatestherollerintoone
positiononly.Therefore,thistensionsystemcanonlysetinitialtensionandcannotcompensateforbeltstretchovertime.
Toaccommodatethis,anadditionaldevicesuchasajackscrewmustbeaddedtothemechanism.
11 Belt Tensioning Methods for Small Package Conveyors 2009 Dorner Mfg. Corp.
3. Operatorsafetyhazards.Theuseofatipuptailmechanismcreatestwopotentialoperatorhazards.Thefirstisthepotential
toliftthetipuptailintotheupperpositionwhiletheconveyorisrunning.Ifthisisdone,theoperatorhasaccesstodriven
rollersinsidetheconveyorframe.CESafetyStandardsdictatethataccesstoequipmentshallonlybedoneusingatool.Ifthe
tailismanuallyactivated,itmayviolateCEandOSHAsafetystandards.ManuallyactivatedtipuptailsarepreferredinFood
conveyorapplications.Intheseapplications,theneedforsanitationoutweighsthepotentialsafetyrisks.Thesecondsafety
hazardwithtipuptailmechanismsisthepotentialpinchpointcreatedfromloweringthetailbackdownintoitstensioned
position.Thescissorsactioncreatedfromthepivotframetotheconveyorframecreatesadangerpoint.Ifnotproperly
designedorguarded,injurycouldoccur.
PneumaticorSpringTension
Advantages:
1. Automaticallytensionsthebelt.Withtheadditionofapneumaticcylinderorspringloadeddevice,thistension
mechanismmaintainsconstanttensionontheconveyorbelt.Thisisespeciallyimportantonlongerorheavilyloaded
conveyors.Retensionmaintenanceisnotrequireduntilthemechanismrunsoutoftravel.
Disadvantages:
1. Costly.Theadditionofthethreerollersandthetensionmechanismaddssignificantlytothecostoftheconveyor.
2. Longerbeltreplacementtime.Inthistensionmethod,thereturnconveyorbeltisinterwoventhroughthethreerollers.
Whenbeltreplacementisrequired,removaloftheuppertworollersisalsonecessary.Dependingonthedesignofthe
mechanism,thiscanaddsignificantlytothemaintenancetimetoreplaceawornoutbelt.Toincreasemaintenance
efficiency,asystemwithaquickreleasefeatureshouldbeutilized,whichprovideseasyaccesstothetoprollers.
3. Beltsurfacecontamination.Withthethreerollermechanism,thetoptworollerscontactthetoprunningsurfaceofthe
belt.Theserollerscanpickupdebrisandimbeditintothebeltsurface.Insomeapplicationsthismaynotbeanissue,but
infoodorfoodpackagingapplications,thisshouldbeavoided.
12 Belt Tensioning Methods for Small Package Conveyors 2009 Dorner Mfg. Corp.
Conclusion:
So,whichmethodofbelttensioningisbest?Ofcourse,thecorrectanswerdependsonthespecificapplicationathand.But,
generallyspeaking,inasituationwhereaoneoffcustomconveyorisbeingimplementedbynonconveyorpeoplethejackscrew
methodwouldmostlikelybesufficient.Ithasreadilyavailablecomponentstoaideinthedesignanditsalsosimpleand
inexpensive.
However,whenacompanyispurchasingaconveyorfromaconveyormanufacturer,theyshouldexpectmoreutilityfortheirmoney
andhigherqualitytechnology.Atechnologythatdecreasesmaintenancetimes,whileprolongingtheconveyorslifeandimproving
itsoverallfunction.ThetechnologythatmostregularlydeliversthesebenefitsistheRackandPinionmethod.
FormoredetailsaboutRackandPiniontensioning,oranyoftheothermethodspresentedinthispaper,pleasecallDornerMfg.
Corp.at18003978664orvisitDorner.com.
AboutDornerMfg.Corp.
BasedinHartland,Wis.,DornerMfg.Corp.isaworldleaderinthedesign,manufactureanddistributionofhighqualityconveyors
andrelatedequipment.Since1973,companiesfromaroundtheworldhaveturnedtoDornerforgreatlyimprovedefficiencyand
productivity.AdditionalinformationaboutthecompanycanbeobtainedonlineatDorner.com.
13 Belt Tensioning Methods for Small Package Conveyors 2009 Dorner Mfg. Corp.