Bunting has partnered with Smiley Monroe to modify a ToughFlex belt for overband magnets. The new belt is more resistant to excessive wear under demanding operating conditions.
Overband magnets consist of a permanent magnetic or electromagnetic block mounted between two pulleys, over which a cleaning belt runs continuously. During operation, the overband magnet is suspended over a conveyor that moves materials such as industrial and domestic waste, or rock extracted from quarries. The magnetic field of the central magnetic block attracts ferrous metals and other magnetic materials, separating them from the rest of the conveyed material. Between the face of the magnetic block and the separated metal is a moving cleaning belt with raised edges, which transfers the captured material away from the conveyor and out of the magnetic field to a separate collection area.
The separated metal often has angular shapes and sharp edges that can damage the rubber cleaning belt. In certain applications, such as industrial and commercial waste handling, high metal content in shapes that often damage the belt is a common problem.
In particular, customers using the ultra-powerful but lightweight ElectroMax overband magnet achieve high levels of metal separation, which has led to increased belt wear. Permanent overband magnets, with lower magnetic power, separate less metal and therefore experience less wear on the belts.
In evaluating methods to extend belt life in difficult applications, Bunting contacted Smiley Monroe, a leading producer of conveyor belts, rubber and plastic cut parts for the material processing equipment manufacturing sector. Smiley Monroe routinely tests for abrasion resistance, tensile strength and adhesion levels on both the rubber cover and fabric layers of its materials and finished products in its well-equipped laboratories, ensuring compliance with DIN, ISO and company standards.
After considering several options, Smiley Monroe recommended the ToughFlex belt. ToughFlex conveyor belts are designed to handle the most demanding conveying applications, from bulk material handling to mobile crushing. These belts are constructed with a special two-ply fabric weave and an additional bonded weft. The plies are reinforced to resist punctures and are protected with high wear resistant top and bottom covers.
The belt material and design met the criteria to reduce damage caused by ferrous metals puncturing or tearing the belt, even when extremely angular and with multiple sharp edges. This resulted in less maintenance and longer production hours between belt replacements.
Once the belt material was selected, the Bunting and Smiley Monroe engineering design teams worked together to modify the belt and adapt it for use on an overband magnet, adding integrated molded cleats to transfer the captured ferrous metal.
