10/1/2014

Tensioning Devices

Conveyor Belt Installations and Related Components

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TENSIONING DEVICES.
In order to drive a conveyor belt with a full load, the belt must be under optimum
tension to prevent it from slipping on the drive pulley. A slack belt is also difficult to
train. Two types of tensioning devices are used, namely:
(1) Screw take-up tensioning.
(2) Automatic take-up tensioning.
The ideal tensioning device should possess the following features:
(1) It should be capable of applying equal tension across the width of the belting.
(2) It should apply tension gradually
(3) In the event of the load on the belt varying, the applied tension should be
capable of correspondingly increasing or decreasing
(4) The actual value of the applied tension should be known, thus preventing
overstressing of the belting.
(5) It should automatically take up any slack or stretch in the belting.
The screw take-up has the advantage of simplicity and is located at the base of the
conveyor. The two bearings of the tail pulley shaft are mounted on rails. Each
bearing can be adjusted individually forward or backwards by means of long bolts
usually termed "take-up screw". The screw-type take-up is limited to very short
belts.
Figure 1 Screw Take-Up

The automatic gravity take-up tensioning device is the only tensioning device which
has all the desirable features as mentioned previously. This device consists of a
weighted loose pulley introduced into the return strand of the conveyor belt at some
point. The best position for this device is immediately behind the driving drum. The
counterweight is made in sections so allowing for adjustment should the duty of the
conveyor vary. The counterweight is fitted loosely on vertical tubes on which it can
slide.
Figure 2 Vertical Gravity Take-Up

This type of automatic tensioning is introduced at the tail pulley. The tail pulley
bearings are fitted between rails to facilitate a sliding action in the event of any
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change in the workload of the belt.

Figure 3 Horizontal Gravity Take-Up

1. General conditions
The type of take-up provided, and suggested application, are based on the following:
Type 1: Screw and manual winches
For conveyors not having room for gravity take-ups and having centre distances less
than:
i. For synthetic carcass belts:
40 m for inclined belts and 100 m for horizontal belts.
ii. For steelcord belts:
80 m for inclined belts and 200 m for horizontal belts.
Type 2: Gravity systems
For all conveyors if technically and economically feasible.
Type 3: Motor driven winches with constant pre-tension
For all conveyors requiring motor driven winches but where variable pre-tensions are
not essential.
Type 4: Motor driven winches with variable pre-tension
For all conveyors where equivalent Type 2 take-up systems will have:
i. Take-up masses which are excessive for economical designs and/or
ii. Specified take-up pulley travel distances which cannot be made available.
a. The gravity take-up is the preferred type. An alternative method should only be
provided if:
i. A gravity take-up cannot be installed for sound technical reasons
b. All take-up components will be fully protected against environmental conditions
and spillage.
c. The design of all conveyor structures and components shall be based on the
greatest take-up force required during normal running, acceleration or
deceleration with either full load or no load.
Typically this is what the gravity take up looks like :
Figure 4 vertical carriage travel take-ups

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Figure 5 for horizontal carriage travel take-ups.

Skewing of the take-up carriage shall be reduced to a minimum by providing one

guide rollers at each corner of the carriage. Refer to Figure 6.

Figure 6: Take-Up Carriage Arrangement

Fig 7: Travel Wheel Guide Roll Arrangement

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