Aero mechanical conveyors are essential in the efficient handling and transportation of bulk materials. This guide offers essential maintenance tips for their rope and discs, which are crucial components that drive their performance. Ensuring their proper care not only extends the lifespan of these conveyor technologies but also enhances operational efficiency and safety.
What Are Aero Mechanical Conveyors and How They Work?
Aero mechanical conveyors are sophisticated industrial conveyor systems designed for the high-speed transfer of bulk materials. They operate by propelling a continuous loop of rope with evenly spaced discs through a sealed tube.
As the rope and discs move, they generate an air stream that fluidizes the material, allowing it to flow smoothly and efficiently from the inlet to the discharge point. This unique conveying method minimizes product degradation and cross-contamination, making it an ideal solution for various industries requiring precise and clean material handling.
Ensuring Optimal Rope Tension – A Guide to Preventative Maintenance
One of the first things to look at when servicing your aero mechanical conveyor is the rope tension. You should always check the tension when the conveyor is empty with no product in it. That way, you can make adjustments accordingly via the access to the feed housing. It is advisable not to adjust the tension from the discharge housing due to the weight of the rope assembly on longer conveyor solutions. It could appear to be tensioned correctly but, in fact, is not placed in the inlet sprocket.
Checking this tension regularly is a key step in preventative maintenance as often it will not need to be adjusted. Remember that the longer the aero mechanical conveyor, the longer the rope is used on heavy products this will cause more significant stretching in the rope so we advise you to check these more regularly for signs of wear.
Under Tension
A slack rope will continue to loosen as the conveying system runs. Eventually, the discs will drag along the underside of the feed housing and will wear the rope and discs. An easy way to spot a loose rope is to pay attention to the sound of the conveyor. A slack rope will start to flap around in the tube, which will get noisier as you run the conveyor.
Over Tension
Just like an overly slack rope can cause excess wear in a rope, so can over-tension. The most common cause of an over-tensioned rope is staff errors. So, training is essential to keeping the rope correctly tensioned. The most obvious sign of an over-tensioned rope is that you cannot move the discs by hand in the notch.
DART – Dynamic Automatic Rope Tensioner
The DART Automatic Rope Tensioner provides unparalleled ease of maintenance and reassurance for Aero Mechanical Conveyor operators. By choosing an automatic rope tensioning system, you can significantly prolong the lifespan of your aero mechanical conveyor’s rope with little need for manual intervention.
- Basic Model
Utilizing clean, dry air ranging from 0.35 to 4 bar (5 to 60 psi), a regulator ensures a steady force is applied to the rope and disc assembly of the conveyor. In case of any disruption in air supply, the pneumatic circuit is designed to keep the force constant. Additionally, there is an option to install a pressure switch that can halt the conveyor’s operation if the air supply is cut off, ensuring safety until restoration.
- Air Purged Seals
Incorporating air-purged seals is critical in scenarios where product entrapment in the seals could potentially reduce the tensioning system’s efficiency. This feature plays a vital role in maintaining the integrity and effectiveness of the conveyor’s operation.
- Basic Control Panel
This version is equipped with sensors attached to the pneumatic cylinder responsible for rope tensioning. The sensors alert users to the need for rope inspection and notify them when the rope has stretched to its maximum limit, indicating the necessity for replacement. Additionally, this model can be provided with a Motor Starter, enhancing the conveyor’s functionality.
- Control Panel & Tension Feedback System
This variant employs a load cell system to verify that the tension force is accurate, a measurement influenced by the conveyor’s diameter and length. It automatically modulates the air supply to maintain consistent tension, adapting to any alterations in conditions. This feature is particularly advantageous in environments where either the product or surrounding air experiences substantial temperature fluctuations.
Get the Needed Help & Advice From Spiroflow – One of the Top-Notch Conveyor Manufacturers
Proper maintenance of your Aero Mechanical Conveyor’s rope and discs is not just about prolonging the lifespan of your equipment – it’s about maximizing efficiency, ensuring safety, and maintaining the quality of your product during transportation.
If you are struggling with the tension in your aero mechanical conveyor and need some advice, get in touch with our Service & Support team. We have over 45 years of experience in the solids and bulk handling industry and there is no problem we can’t solve!
