Motorized Pulley for Conveyor Belt
The motorized head pulley is a device that drives the belt conveyor to operate, this device seals the motor, reducer, stator, rotor, and other important parts in the outer metal drum.
The oil in the drum continuously lubricates the bearings and gears to take away the motor heat, the outer “metal drum” rotates, its surface drives the conveyor belt.
Such a drum motor can prevent dust, water, grease, or other harmful substances from entering, avoids damage to the motor and reducer inside.
It can replace the traditional exposed drive, which installs the motor and reducer outside the drum.
As the power of belt conveyors and lifting equipment, motorized head pulleys are widely used in mining, metallurgy, chemical, building materials, electricity, food, and transportation industries.
Compared with traditional exposed drive, drum motors mainly have the following advantages:
- The structure is simple and compact, and it is space-saving.
- Good sealing, suitable for working places with high dust concentration and damp muddy.
- Convenient use and maintenance, safe and reliable operation, long service life.
- Low energy consumption and easy for centralized control.
- It can meet various needs such as backstops, brakes, rubber-coating, etc.
There are many ways to classify motorised pulleys, which are mainly sorted according to the motor cooling mode, the reducer type, the working environment, and the motor position.
- Motor Cooling Mode
The air-cooled belt conveyor drum does not need to be cooled by oil, it is cooled by conduction, radiation, and convection of wind.
The air-cooled motorized pulley for conveyor belt is divided into 2 types: forced air cooling and natural air cooling.
Such belt conveyor drum is also called indirect oil-cooled belt conveyor drum.
There is a certain amount of cooling oil in the belt conveyor drum, as the drum keeps rotating, the oil scraper on the drum continuously pours the oil onto the motor and gear.
Cooling oil takes away the heat generated by the motor and gear in motion, and transfer the heat onto the drum wall, the heat dissipation is accelerated and the gear is lubricated.
Oil-cooled drum motor is not allowed to enter any oil.
Oil-steeped belt conveyor drums are also called direct oil-cooled belt conveyor drums.
Such belt conveyor drum allows oil to enter the motor, and the oil directly contacts the rotor and stator.
When the rotor and stator work, the heat generated is transferred to the rotating drum’s inner wall.
This structure has a better heat dissipation effect, but the lubricating oil and electric motors’s quality requirements are relatively high.
- Reducer Type
Many types of reducers are produced all over the world, no more than 3 types can be mass-produced for motorised pulleys.
1. Gear train
The most commonly used reducer for motorised pulleys is the gear train.
This kind of transmission has the advantages of simple structure, reliable performance, easy production, convenient installation and maintenance, at the same time, its efficiency is high and noise is low.
Two-stage deceleration is commonly used, and a few are three-stage deceleration.
2. Planetary gears
Compared with gear train transmission, this type of transmission has the advantages of small size, lightweight, large carrying capacity, and stable operation, but it is not convenient for maintenance.
3. Cycloidal pinwheel reducer
This type of structure can be described as “Chinese characteristics”.
Except for Japan, other countries rarely use this type of reducer for motorized head pulleys.
The conveyor head drum with such reducer can realize small linear speed and large power.
- Working Environment
There are 3 common working environments for motorized head pulleys:
If subdivided, there are high temperature, humid tropical zone, and some special use occasions, but rare motorized head pulleys are used in these scenarios.
When you buy motorized head pulleys, mainly consider the following points:
- Internal/external motor
The motorised pulley with internal motor is more suitable for harsh environments, the motorised pulley with external motor is more convenient to maintain, but it has requirements for the working environment.
- Explosion-proof and flameproof function
If your belt conveyor is in a flammable and explosive environment, you need to use a conveyor head drum with flameproof and explosion-proof function.
- Motor cooling mode: oil-cooled/oil-steeped
If your belt conveyor is in a high-temperature environment and the motor must dissipate heat quickly, you must use an oil-steeped motorized head pulley.
We are the source factory specializing in the production of motorized head pulleys.
With our own factory and various kinds of advanced production equipment, we SiroSilo is able to customize your dreamy drive pulley according to your actual requirements.
Some foreign customers visit our factory, they enjoyed a pleasant visit and communication with us, and finally placed an order for our motorized head pulley.
You are welcome to visit our factory at any time, or you can video call with us through WhatsApp, we can lively broadcast our factory to you.
If you are interested in purchasing motorized head pulleys recently, please send us an inquiry on this website and leave your requirements for motorized head pulleys, we will reply to you within 1h.
Motorized Pulley for Conveyor Belt Ultimate FAQ Guide
Types of pulley in conveyor belt
In order to understand the types of pulley in conveyor belt, you must first understand the belt conveyor’s composition.
The components of the belt conveyor are:
- Head (including motor, transmission, pulley, etc.)
- Body (including frame, idler roller)
- Attachments (including tensioning device, cleaning device, braking device)
The figure below displays the structure of a common belt conveyor in the Chinese market, according to this diagram, the common types of pulley in conveyor belts include drive pulley and tail pulley.
The belt conveyors in foreign markets also equip with bend pulley, takeup pulley, and snub pulley.
Conveyor pulley diameter calculation
The conveyor pulley diameter calculation follows the below principles:
When the circular conveyor belt’s tensile stress is large, the additional bending stress should be smaller, and the pulley diameter should be larger;
On the contrary, when the tensile stress is small, bending stress should be larger, and the pulley diameter can be smaller.
There are many websites that can provide pulley calculator programs, which can be converted between pulley centers, diameter, angular velocity, drive torque, belt length, belt velocity, and belt tension.
For example, the website shown in the figure below:
Conveyor pulley components
The picture below lists the conveyor pulley components in detail.
This type of belt conveyor is very common in China, but it is somewhat different from the belt conveyor in foreign markets.
What is a motorized pulley?
The motorized pulley is a kind of equipment commonly used to drive fixed belt conveyors or mobile belt conveyors, this equipment installs the motor and reducer into the round drum, which is well sealed and convenient to use and maintain, saves installation space.
How does a motorized pulley work?
Motorized pulleys are divided into internal motor type and external motor type.
Due to the different motor positions, these two types of motorized pulleys have different basis.
- The basis of drive pulley conveyor with internal motor
Both the motor and the reducer are placed in the cylindrical drum, and the power is transmitted from the motor to the drum body through the reducer, the power generated in this way can drive the conveyor belt to run.
- The basis of drive pulley conveyor with external motor
The motor is installed outside the drum, but the reducer is installed inside the drum.
The power generated by the motor is transmitted to the drum through the coupling transmission.
The coupling drives the drum to rotate under the reducer’s control, then the drum drives the conveyor belt to run.
Drum pulley drawing
We all know that the motorized pulley has a reasonable structure, high operating efficiency, and it is convenient to use, this is all because the motorized pulley’s structure is very reasonable.
Look at the following cross-sectional view of a motorized pulley with external motor, let us analyze its structure in detail:
- 1. Motor
It is the main component of the motorized pulley, which is as important as the heart of the human body.
- 2. Coupling
As a safety device, it can prevent the motorized pulley from being subjected to excessive load, it plays an overload protection role.
- 3. Left cover
Fix and seal the bearing, prevent the motorized pulley from entering impurities.
- 4. Left support
Support and fix the drum.
- 5. Left bearing seat
It is located on the left side and can bear the comprehensive load, where there is a bearing, there must be a support point.
- 6. Left flange shaft
Realize the mutual connection between shafts.
- 7. Drum body
Cylindrical, it will rotate quickly when the motorized pulley is working.
- 8. Reducer
It can control the speed, match the speed and transmit torque.
- 9. Right cover
Seal the drum, prevent the motorized pulley from entering impurities.
- 10. Right bearing seat
Located on the right side, it has the same function as the left bearing seat.
- 11. Right support
Its function is the same as that of the left support.
How to make a motorized pulley system?
The production process of drive pulley conveyor is mainly divided into the following steps:
- Drum processing
- Flange shaft processing
- Motor drilling
- Making a junction box
- Parts processing and procurement
- Nail nameplate
If you want to learn more about the production process of the drive pulley conveyor, you can directly add my WhatsApp +8617312124727 to make a video call, and I can show you the production process of the drive pulley conveyor.
Head pulley specification
In the process of head pulley selection, the supplier often provides the head pulley specification form for the customer to view.
The customer selects the appropriate diameter, power, belt width, belt speed, and load according to their own production requirements.
The specification of SiroSilo head pulley is shown in the table below, you can refer to the table below to select your favorite head pulley.
Conveyor belt drum calculation
For the choice of conveyor belt drum, the most important thing is to determine its power. According to the following guide, you can understand how to determine the conveyor belt drum’s power.
- Determine your motorized head pulley’s power according to your requirements.
How to determine your motorized head pulley’s power?
First, calculate the motorized head pulley’s shaft power PA (Kw).
In the formula for calculating shaft power:
|L||Horizontal projection of the center distance between the drive pulley and the tail pulley (m)|
|B||Belt width (mm)|
|H||Material lifting height (m)|
|V||Linear speed of drum surface (m/s)|
|Q||Belt conveying capacity (t/h)|
If belt width is less than 400mm, conveying upwards:
If belt width is less than 400mm, conveying downwards:
If belt width is greater than 400mm, conveying upwards:
If belt width is greater than 400mm, conveying downwards:
Then, calculate the motor power.
P=PA/η, in this formula:
|P||Motor power (Kw)|
|PA||Motor shaft power (Kw)|
|η||Total transmission efficiency of motorized pulley (%)|
When a smooth pulley is used, η=87%;
When the rubber-lagged pulley is used, η=89%.
In the following cases, the motorized head pulley’s power must be increased:
- Work continuously for more than 8 hours a day.
- Rubber-lagged pulley.
- Frequent startup.
Conveyor drive pulley lagging
The conveyor drive pulley lagging is usually divided into 2 types: hot vulcanization injection and cold-adhesive lagging.
When the conveyor drive pulley is used in the food processing industry, it will be lagged with food-grade silicone according to customer requirements.
The food-grade silicone’s main component is ammonium silica, which is an environmentally friendly silicone, non-toxic, odorless, good elasticity, non-cracking, long service life, cold and high temperature resistance, and it also has excellent electrical properties.
When the conveyor drive pulley needs to be used in special industries, it can be lagged with nitrile rubber according to customer requirements.
Nitrile rubber is a synthetic rubber made by copolymerization of butadiene and acrylonitrile, it is a synthetic rubber with good oil resistance, high abrasion resistance, good heat resistance, strong adhesion, and good aging resistance.
On-site cold-adhesive lagging of conveyor drive pulley is a commonly used method, and the lagging can be carried out on site.
The whole process does not need to disassemble the pulley, does not need the heating and pressurization of the vulcanizer, and only relies on the glue’s adhesive force to complete a pulley lagging.
Compared with the traditional thermal vulcanization, it saves time, it can also save manpower and material resources, and avoid long-distance transportation, this is undoubtedly an advanced lagging method.
Since glue plays a critical role in cold-adhesive lagging, the choice of glue needs to be more cautious.
First and foremost, excellent glue bonding performance is essential, cold vulcanized glue SK313 is just the right choice.
Original imported two-component, high-strength cold-adhesive glue SK313 is composed of 1kg glue and 40g curing agent.
Compared with ordinary glues on the market, the curing speed can be increased by 3-4 times, and the lagging time can be multiply saved.
The product has passed the strict DIN industrial standard, and the bonding performance is comparable to that of thermal vulcanization.
In addition to suitable bonding performance, this glue also has acid and alkali resistance, water resistance, oil resistance, corrosion resistance, and is safe and flame retardant, it can be used with confidence even in coal mines or in harsh environments.
Next, let me introduce the steps of cold-adhesive lagging on site.
Use a glue shoveling machine to remove the residual glue on the pulley surface;
Install the tungsten steel grinding disc on the angle grinder, and then use the angle grinder to polish the entire drum, remove the stains and rust on the surface;
Clean the drum, apply cleaning agent SK353, and clean the whole drum in depth;
Brush the metal treatment agent on the pulley surface, it will be helpful for exerting the glue’s adhesive force;
Use a glue brush to apply a layer of cold vulcanized glue on the pulley surface, then apply a layer more after drying, and apply a layer of cold vulcanized glue to the RIT wear-resistant rubber sheet’s bonding surface;
After it dries a little, stick the rubber sheet to the pulley surface and use a rubber hammer to harden it, then use a rubber repair agent to fill the rubber sheet’s joints with a “V-shape” seal;
Finally, use a rubber knife to beautify and adjust the lagging edge.
Motorized pulley manufacturers
The motorized pulley manufacturers listed below are the main players in this niche, if your bulk handling and food processing need to introduce high-quality motorized pulleys, you can contact the below manufacturers.
China’s drive pulley manufacturers are also gradually improving their manufacturing level, the quality of drive pulleys made in China is getting higher and higher, if you want to purchase affordable drive pulleys, please contact us.
Belt conveyor drum pulley manufacturers in China
China’s belt conveyor drum pully manufacturers are mainly concentrated in Zibo City, Shandong Province, which is the industrial belt of reducers, motors, crushers, and water pumps.
All large and small belt conveyor drum pully manufacturers can be found here.
We SiroSilo is a professional belt conveyor drum pulley manufacturer in China, welcome you to video call with us through WhatsApp, we can lively showcase our factory to you.
Drum motor with pulleys
The motorized pulley is a driving device in which all components are installed in a circular drum, this kind of device is mainly used to drive a belt conveyor.
Because all parts are installed in the drum, this drive device can work normally in harsh environments, and can effectively save installation space and protect the operator’s safety.
In industries and fields such as food, packaging, warehousing, mining, aggregates, and aviation baggage systems, because belt conveyors are used frequently, these industries have a relatively large demand for motorized pulleys.
Drum motor working principle
A drum motor is a driving unit with a motor and a reducer placed inside the drum body, the torque transmitted by the motor and the reducer drives the drum body to rotate, and the friction generated between the drum body and the conveyor belt drives the belt to move.
It is mainly used as a power source for belt conveyors.
The drum motor’s characteristic is long-time continuous operation, so the motor must operate continuously.
Once the conveyor stops, the drum motor must be able to start under load, so the motor should have a larger starting torque and the starting current should not be too large.
How to correctly confirm the motor’s rated power?
Under the premise that the motor can meet the mechanical load requirement, determine the motor’s rated power in the most economical and reasonable manner.
When determining the motor power, it is necessary to consider the motor’s heating, overload capability, and starting performance.
Heavy duty drum motor
Heavy duty drum motors generally refer to drum motors with high power, large diameter, and high torque.
Such heavy duty drum motor can load a wider belt and load heavier materials on the belt.
How to disassemble a drum motor
The belt conveyor drum is used in conjunction with the belt conveyor, it is a new type of drive device with good performance.
When the belt conveyor drum needs maintenance, it has to be disassembled.
Please refer to the following video, then you can better understand the disassembly process:
Drum motor price
The drum motor price varies from market to market.
In the Indian market, the conveyor head drum’s price is shown in the following figure:
In the Chinese market, the price of drum motors is shown in the photo below:
Drum motor VS. gear motor
Compared with the conveyor head drum, the gear motor’s only advantage is cost-effectiveness.
As the belt conveyor’s new generation drive device, conveyor head drum is far superior to gear motor in the following aspects.
- Compact structure, small footprint;
- Fully enclosed design, suitable for harsh production environment;
- Easy to clean, maintain, saving the operator’s time and energy;
- Low power consumption, easy for centralized control;
- It can meet all kinds of the backstop, brake, lag, and other needs.
Please speed up your action to send us an inquiry, we will send our SiroSilo conveyor head drum’s specs and quotation sheet to you for comparison.
SiroSilo could also supply the following products, if you are also interested in any type, please feel free to send us an inquiry: