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Two Primary Methods of Conveyor Belt Splicing
In the operation of quarries and mines, conveyor systems are essential production equipment that help to increase efficiency and reduce costs.
Within these conveyor systems, splicing is a critical process.
Generally, there are two primary methods of conveyor belt splicing: mechanical splicing and vulcanized splicing.
Mechanical splicing uses metal hinges or plates to connect the ends of the conveyor belt, while vulcanized splicing bonds the belt ends tightly together through heat or chemical reactions.
Why is Vulcanized Splicing Superior to Mechanical Splicing?
Compared to mechanical splicing, vulcanized splicing offers significant advantages, especially in high-load and high-tension applications.
Vulcanized splicing eliminates the weak points or gaps present in mechanical splicing, making it less prone to breakage or tearing under pressure.
Additionally, vulcanized splicing improves belt alignment and operational stability, extends the service life of the conveyor belt, and enhances overall performance and safety. The absence of protruding metal parts in vulcanized splicing prevents snagging on pulleys or idlers, reducing wear and tear at the splice and edges, lowering friction and noise, and eliminating sharp or loose metal parts that could pose a threat to workers or contaminate products.
What is Vulcanized Splicing?
Vulcanized splicing is a process that uses heat and pressure to bond the two ends of a conveyor belt tightly together.
Unlike mechanical splicing, which relies on metal fasteners or hinges, vulcanized splicing fuses the belt materials directly, creating a seamless and uniform connection. Depending on the type and condition of the conveyor belt, vulcanized splicing can be performed using either hot vulcanization or cold vulcanization methods.
Advantages of Vulcanized Splicing
- Strength and Durability: The spliced area usually retains much of the original belt's strength, making the splice almost as strong as the continuous belt itself.
- Extended Service Life: A well-executed vulcanized splice can significantly reduce the frequency of maintenance or replacement.
- Smooth Operation: Vulcanized splicing creates a smooth surface that allows the conveyor belt to run evenly over rollers and pulleys, minimizing wear and tear on both the belt and the equipment.
- Moisture and Heat Resistance: Vulcanized splicing is more resistant to the effects of moisture and high temperatures, maintaining its integrity even in harsh conditions.
These advantages make vulcanized splicing the preferred method for high-demand conveyor systems.
Vulcanized Splicing Process
Vulcanized splicing is a complex process, but when performed by experienced professionals, it results in a smooth and durable splice that minimizes the risk of belt jamming, tearing, or other issues.
There are various types of vulcanized splices, including step splices, finger splices, and overlap splices, and these can be done using either hot or cold vulcanization. Each method requires specialized tools and a deep understanding of rubber bonding techniques.
During hot or cold vulcanization, the belt ends must first undergo special preparation to ensure the final splice can achieve its designed tensile strength. In the hot vulcanization process, the splice is heated and cured under pressure using a vulcanizing press, which typically takes several hours. If the belt is tensioned or used before the splice has fully cooled, the splice may fail or completely separate, leading to increased downtime.
To ensure the quality of vulcanized splicing, several key factors must be considered. First, the vulcanization should be performed by professionals with extensive experience and knowledge of various solvents, adhesives, and other materials involved. Second, the working environment must be dry and at an appropriate temperature to ensure a quality splice. Third, some belts may not be suitable for vulcanized splicing, particularly those that are old, dirty, or unevenly worn, as these conditions can lead to uneven curing and weaker joints.
For a 1200 mm wide conveyor belt, vulcanized splicing typically requires 5 to 10 hours, wider belts will take longer.
Additionally, because vulcanized splicing often requires bringing specialized equipment and personnel on-site, the operation may need to be shut down for a while.
In summary, vulcanized splicing is suitable under the following conditions:
- The conveyor belt surface is clean.
- The belt material is compatible with the adhesive used.
- The belt is relatively new or not excessively worn.
- The vulcanization is carried out by certified professionals.
- The working environment has appropriate temperature and humidity levels.
- The splicing area is easily accessible and provides enough working space.
- There is sufficient downtime to properly complete the vulcanization process
The vulcanizing presses from Beltwin are an excellent fit for this solution. If you're interested, feel free to reach out for more information.