Conveyor belts have become a necessity in modern industries. They help move materials from one point to another effortlessly. However, many seem confused about the manufacturing of conveyor belts. That’s because they consist of many complex parts. This raises a question: How to make a conveyor belt?
Interestingly, building a conveyor belt isn’t as tough as it seems. There are a few steps you must follow to make a fully functional conveyor belt. Remember, you’ll need some basic machines, materials, and other components. In this article, I’ll discuss the manufacturing of conveyor belts in easy-to-follow steps. So, let’s get started!
Components of Conveyor Belts
In a previous article, I wrote a detailed guide on the components of conveyor belts. You must read that if you don’t have the know-how about these components. Each component of a conveyor belt is crucial to its functionality and operation. A malfunction of a single component can cause belt failure. Here is the list of those key components of conveyor belts:
- Belt
- Frame
- Rollers
- Motor & Pulley
- Control system
While making the conveyor belt, you’ll have to carefully craft each part listed above. The frame is the skeleton of the conveyor belt, on which other components are mounted. Rollers support the belt from underneath. The belt is wrapped around a pulley, and the motor powers the pulley, causing the belt to move and transport materials. The control system is only for controlling things like switching it on and off, and adjusting the belt speed.
Materials and Tools Needed to Make a Conveyor Belt
When making a conveyor belt, you’ll need some equipment. Without them, you won’t be able to complete the manufacturing process. Here is the list of some key tools:
- Cinta métrica
- Wrench and Screwdrivers
- Drill & Welding Machine
- Saw or cutting tool
As I said earlier, you’ll need components such as pulleys, rollers, belts, etc. Many companies offer each of these components. You should buy ready-made materials to make the manufacturing process a lot easier. The common materials include:
- Electric motor
- Shaft for rollers
- Rollers & pulleys
How To Make A Conveyor Belt? Step-by-Step Guide
You should arrange the above materials and tools before starting the conveyor belt manufacturing. In the section below, I’ll discuss each step involved in making a conveyor belt:
Step 1: Decide the Purpose and Select the Conveyor Belt Material
The first step in making a conveyor belt is to determine its purpose. Why? The reason is that the purpose for which the belt is being made can affect its specification. For example, if you need a conveyor belt for transferring light material, you may not need a heavy-duty belt.
Additionally, if the materials are smaller, e.g., in a box, you’ll need a smaller conveyor belt.
For large, heavy materials, you’ll need robust conveyor belts that can withstand the load. Secondly, you must decide on the conveyor belt material before starting. Various materials are available for making conveyor belts.
If your use case is light, I recommend using either PVC or tela. These materials are cheaper and can be used to make conveyor belts at a low cost. On the other hand, you should use high-quality rubber materials if your use is more intense. The belt made with reinforced rubber layers can withstand the harshest materials with ease.
Step 2: Design & Frame of Conveyor Belt
After material selection, the next step is to design the conveyor belt. Designing includes the shape and size of the conveyor belt. You’ll have to decide how big the belt will be. Remember, belt length, width, and height play key roles in its working. A belt with more thickness and width is generally more durable and performs better. For this measurement, use tape for accurate readings.
Once the belt measurement is complete, you’ll build the conveyor belt frame. This frame must be sized to the conveyor belt. If the frame is too small or too large, the components won’t align perfectly on it. Various materials are available for making conveyor belt frames. However, aluminum and steel are the most popular as they provide excellent strength to the frame of these conveyor belts.
When making frames, you’ll need cutters and a welding machine to join the pieces. The frame must be robust to withstand the load from other components. Additionally, loads of materials also affect the frame of the conveyor belt. It is highly recommended to apply a thin coat of any paint. This paint coat will protect the conveyor belt frame from corrosion in the long run.
Step 3: Install Rollers and Pulleys
After making the frame of the conveyor belt, you’ll then attach the rollers and pulleys to this frame. As mentioned before, the frame is the most crucial part as it supports all other components. First, attach pulleys on both sides of the frame and secure them. It is essential to keep the pulleys perfectly aligned.
If these pulleys aren’t aligned, the belt may come off when the conveyor is operating. Remember, both sides of the frame will have pulleys. One of these pulleys will be the drive pulley, and the other will be the idler pulley. After installing the pulleys, you’ll need to install multiple rollers. These rollers will support the belt and prevent it from sagging during its movement.
Step 4: Attach the Belt to Pulleys & Side Guards
As I mentioned above, the belts are wrapped around the pulleys. In this step, you’ll have to loop the belt around both pulleys so it’s centered on both. Once the belt is wrapped, use fasteners to secure both ends. This way, the belt will fit perfectly around the pulleys. And maintain optimal tension. You must check the belt tension before proceeding to the next step.
If the belt is too loose, you can cut it to fit the pulley with the correct tension. Some people might suggest using a side guard or a railing. However, it’s optional, and you may not need it if you’re transferring solid material that doesn’t slip off the belt. These side guards are attached to the conveyor frame to prevent items from falling off the belt.
Step 5: Attach the Motor and Test the Conveyor Belt Operation
The last step is to mount the motor to the conveyor frame. Remember, conveyor belts get their energy from the motor. This motor is mounted on a dedicated mounting plate attached to the conveyor belt frame. You should try to keep the mounting plate close to the pulley. Why? That’s because you’ll have to attach a motor to the drive pulley through the shaft.
If the distance between the motor and the drive pulley is long, you’ll have to use a long shaft, which isn’t ideal. Once the motor is mounted, connect it with the drive pulley and ensure the motor provides power to the drive pulley for its movements. You must test the motor after installation. During testing, it is key to check if the belt moves smoothly and has optimal tension.
Things to Consider When Making Conveyor Belts
Undoubtedly, DIY projects such as building conveyor belts can be fun. However, there are a few key factors to consider when designing a conveyor belt. Ignoring them can result in the production of low-quality or incorrectly sized conveyor belts. Here is the list of those factors:
- You must keep the belt and conveyor frame sizes within acceptable limits. If these two are not compatible, your conveyor belt may not perform optimally.
- It is a good idea to analyze your use case before choosing belt materials. You should select heat-resistant materials when making mining conveyor belts. Similarly, moisture-resistant materials should be preferred when making construction belts.
- The conveyor belt’s speed is another crucial parameter you must consider. If the conveyor belt is to run faster, it must be lightweight and use a larger motor. Additionally, you should use a belt wide enough to accommodate more materials.
- Motor power is crucial for conveyor belts. Small motors cannot run bigger conveyor belts that carry heavy-duty materials. Even if it does, it would consume more power during operation. You must use a larger motor for the conveyor belt used for heavy-duty material transportation.
Conclusión
In summary, making a conveyor belt as a DIY project is certainly possible. However, it is not a zero-cost process and requires some budget. Why? The reason is that you’ll need materials and tools that cost big bucks. The parts, such as pulleys, rollers, motors, etc., cannot be made and are generally bought ready-made from the market.
The equipment is costly, so you shouldn’t expect this DIY project to be free. Additionally, multiple steps are involved in manufacturing conveyor belts. Each step requires some time, so patience is key in this belt manufacturing process. However, if you follow the above-mentioned steps, you’ll be able to make a quality conveyor belt by yourself.