Conveyor systems are widely used in various industries, like mining, manufacturing, and construction. One of the most critical components of this system is the pulley. It helps move the conveyor belt by applying constant tension. But remember, pulleys alone are not enough. To ensure their smooth performance, several conveyor pulley lagging types are used.
However, all those types of lagging vary in their material and installation method. Choosing the right type is crucial for better alignment of the entire conveyor system. So, how will you know which type suits your conveyor system efficiently? Confused? Worry not! This article will explore some common conveyor pulley lagging types along with specifications.
Overview of Conveyor Pulley Lagging
Before we dive into the types, let’s first understand what conveyor pulley lagging is!
Conveyor pulley lagging refers to covering the outer surface of a conveyor pulley. Several types of materials are used for lagging. This process is performed to increase the friction between the pulley and the conveyor belt. As a result, the belt grips the pulley more tightly and does not slip.
Lagging may seem like a small addition to the conveyor system. However, it has a big impact on the entire system. HOW? Let’s suppose a conveyor system is operating in an environment such as a mine or factory. No doubt, the chances of rust, corrosion, and wear increase in such cases. So, manufacturers add lagging to the conveyor pulleys. It protects the pulleys’ surface.
Not only this, but lagging also helps improve belt grip over the pulley. As you know, the pulley helps move and rotate the belt. If the belt doesn’t have enough grip on the pulley, it will slip. As a result, the chances of wear and tear, as well as maintenance costs, also increase. Therefore, almost every industry that relies on conveyor systems uses lagging.
Conveyor Pulley Lagging Types
I hope you grasp the basic know-how of pulley lagging. Right? But as I said earlier, those lagging vary in several aspects. In this section, I will briefly explain some types. So, let’s dig right in!
1- Plain Rubber Lagging
It is the most basic and common type of lagging used for conveyor pulleys. This lagging involves covering the pulley’s surface with a smooth layer of rubber. That layer is thick but does not contain grooves, cuts, or patterns. Therefore, the pulley surface becomes smooth, resulting in increased friction. As a consequence, the grip between the pulley and conveyor belt increases.
Moreover, the installation of plain rubber lagging is effortless. You can bond it quickly using adhesives or cold bonding methods. Therefore, it becomes the most affordable type of lagging. However, remember that plain rubber lagging has smooth surfaces. That’s why it is ideal for a light to medium-duty conveyor system. So you can find warehouses and packing industries.
2- Diamond-Grooved Rubber Lagging
It is a type of pulley where the surface of the rubber is cut with a diamond-shaped pattern. Instead of being smooth like plain rubber lagging, this one has criss-cross grooves. Those grooves resemble a diamond or checkerboard, which is why it is named so. However, the question arises: why use diamond grooves?
Actually, there are two primary purposes of this pattern. First, it increases the friction between the pulley and the belt. Secondly, it drains away the water and dust from the pulley surface. This means the belt won’t slip even if the pulley is wet or dusty. That’s why diamond groove rubber lagging is used in jenis katrol sabuk konveyor used in mining and cement factories.
3- Herringbone Grooved Rubber Lagging
Herringbone, also known as “Chevron,” is another common type of pulley lagging. This lagging has a V-shaped grooves pattern on the surface. However, unlike diamond grooves, these V-shaped grooves run in angled lines. For example, they start from the center and spread outward.
This type of shape is designed for special purposes. HOW? Suppose that when the pulley spins, any water, mud, or dust particles get stuck between the pulley and the belt. The V-shaped grooves push the debris outward and away, allowing the belt to grip tightly. Such a self-cleaning action of this lagging makes it ideal in muddy and wet industries.
4- Strip Lagging
As the name suggests, this type of lagging contains rubber strips. HOW? The surface of the pulley is covered with narrow, individual rubber strips, rather than a single large rubber strip. These rubber strips are placed side by side and glued together using cold bonding. You may wonder about the purpose of this design, right?
Actually, strip lagging allows easier replacement and maintenance. Suppose one section of the strip lagging gets worn out and damaged. In such a case, you don’t need to replace the entire pulley surface, but you can replace just the damaged strip. This design reduces the time and overall maintenance costs of various conveyor belt components.
5- Slide Lagging
Slide lagging, also known as “replaceable lagging,” is another special kind of conveyor pulley lagging. This lagging type is specially designed for quick and easy replacement. HOW? Slide lagging uses metal holders that are permanently attached to the pulley. Into these holders, rubber or ceramic pads are inserted or slid.
Those pads are inserted separately, which makes the maintenance super fast. For example, if any section of the slide lagging is worn out, you don’t have to replace the entire lagging. Instead, you just slide out the old pad and slide in the new one. Therefore, such pulley lagging types have become a top choice for industries that want to minimize downtime.
6- Ceramic Lagging
Ceramic lagging is a high-performance type of pulley lagging. This lagging contains hard ceramic tiles that are embedded in a rubber base. This rubber base provides flexibility. However, the tiles are shaped like small squares that are very hard. This combination makes the ceramic lagging ideal for heavy-duty conveyor systems.
This is especially helpful for applications involving sabuk konveyor kain. These conveyors typically handle cement and muddy materials that can increase the chances of slippage. But ceramic lagging provides superior durability and reduces slippage almost to zero. That’s why this lagging type has become common in mining operations, power plants, and cement factories.
7- Vulcanized Lagging
Vulcanized lagging is the type of pulley lagging where rubber is vulcanized. In vulcanization, the rubber and pulley are heated together with special bonding chemicals. As a result, the rubber molecules form a tight bond with the pulley surface. Once cooled, the rubber becomes extremely tough and won’t peel off or bubble.
This permanent connection between the covering and pulley makes it very reliable. For example, this type of lagging is helpful for the drive pulley, where slippage and moisture are major issues. Moreover, vulcanized lagging can also withstand high heat and high pressure for an extended period. That’s why it is commonly present in mining and aggregation conveyor systems.
How to Choose the Right Lagging Type?
As I mentioned above, each type of lagging is made for specific conditions. Therefore, choosing the right lagging type is crucial to ensure smooth operations. For this purpose, you should think about several factors. Below is a list of some common factors you must consider before deciding.
- Operating Environment: First, look at where your conveyor is used. For wet and muddy areas, ceramic and vulcanized lagging is the best choice. However, for a dry and clean environment, you should choose plain rubber or strip lagging.
- Pulley Type: There are several types of pulleys. So, also consider the type of pulley. For example, for drive pulleys, high-grip lagging, such as diamond grooves, is best. However, for non-drive or bend pulleys, choose the plain rubber, slide, or strip lagging.
- Type of Belt: Like pulleys, belts also come in various types. Therefore, it is essential to evaluate the kind of belt. For instance, rubber lagging works best with a fabric belt. However, ceramic lagging is safe for sabuk konveyor kabel baja.
- Maintenance and replacement: You should also consider the maintenance and replacements. If minimal maintenance is required, go for vulcanized or ceramic lagging. However, if you need quick and easy replacements, choose slide or strip lagging.
- Budget and Cost-Effectiveness: Each type of lagging varies in terms of price. Hence, you should also keep your budget in mind. For example, plain rubber and strip lagging are the least expensive options. However, ceramic and vulcanized lagging cost more upfront but last longer. So I recommend you try to balance your budget with long-term performance needs.
Kesimpulan
Conveyor pulley lagging seems like minor details. However, it plays a significant role in the overall performance of the conveyor system. Those lagging come in various types depending on their material and installation methods. In this article, I have discussed some common types of pulley lagging.
Each lagging type has a unique design and is specific to different environments. They also vary in their handling of materials and environments. Therefore, selecting the correct type is crucial to maintaining the overall health of your conveyor system. A correct lagging not only prevents slippage but also reduces wear and extends equipment life.