Conveyor System Notes
1) Types of Conveyors
Belt Conveyor (Logistics and normal use)
Roller Conveyor (MDR tote movement)
Grip Conveyor (Overhead, incline, and decline use)
Chain Conveyor (Used in mining sites)
Bucket Conveyor (Heavy weight handling)
2) Types of Belts Used in Conveyor Systems
PU-PVC Belt (High speed and low volume use)
Grip-PU Belt (Short line endless belt)
Grip-PVC Belt (Incline and decline use)
Anthracite Belt (Low speed with high volume use)
Rubber Belt (Used in mining and coal sites)
Plastic Tooth Type Belt (No need for belt alignment)
3) Types of Gears Used in Conveyor Systems
Helical Gears (Efficient, high speed, minimum vibration, and quiet operation)
Worm Gears (Low efficiency with high temperature)
Bevel Gears (Heavy material handling and airport baggage handling)
4) How to Align a Conveyor Belt
Tracking Roller (Most important)
ETU Roller (Only used in Vanderlande conveyors)
Head Roller
Tail Roller
5) Types of Rollers Used in Conveyors
Drive Roller
Tension Roller
Snubber Roller
Support and Return Rollers
Side Roller
Head and Tail Roller (ETU)
6) Belt Joint Types
Finger Belt Joint (Uses belt types logistics operation)
Zip types belt joint (only for emergence)
Chemical agents heat (high weight, minimum finish long).
7) Types of Motors Used
AC Induction Motor – Commonly used in industries,
Servo Motor (Closed loop system)
Stepper Motor – Provides high torque at low speed with accurate positioning.
MDR (Motor Driven Roller) working in DC voltage with low speed control.
8) Types of motor connection to drive roller conveyor:
Plug type
V-belt type
Shaft-mounted motor type
Timing belt type
9) Types of Sensors Used in Conveyors
Proximity Sensor
Photoelectric Sensor
Flow Sensor
Magnetic Sensor
10) Conveyor electrical components:
LMS (Local
Manual
Switch)
Encoder
VFD
(Variable
Frequency
Drive)
Sensors
Relays /
Relay
module
11) Conveyor divert components:
MDR motor
Loop V-belt and timing belt
Left and right piston
Air suction pieces
Drive chain rollers
12) Reasons for Conveyor Breakdown
Motor failure
Brake coil issue
Sensor misalignment
PLC communication issue
Roller damage
13) How to Find Conveyor Faults
PLC HMI
SCADA alarm and indicator lights
Conveyor indicator lamp
* Orange light indicates jam detection
* Blue light shows conveyor fault condition
* Red light indicates emergency affected conveyor
* Green light shows conveyor running status
14) Types Emergency of Conveyor Safety Devices
Emergency Pull Cord
Emergency Stop Button
15)How to vulcanize a conveyor belt
Measure the belt first
Cut the belt finger
Route the conveyor belt correctly
Start the vulcanizing process
Set the temperature according to belt specification
Top side temperature: 185°C to 190°C
Bottom side temperature: 185°C to 190°C
Apply pressure as required (approximately 2 bar)
16) What is the use of a pneumatic system:
It is used for movement and basic control purposes
It is used to move parts in right and left directions using air pressure
17) Safety procedure for conveyor breakdown
Check the conveyor carefully and identify the issue
Inform the supervisor immediately
Ensure motor power is disconnected
Apply LOTO (Lock Out Tag Out)
Verify CRPI / LOTO tags are properly applied
Start maintenance work only after safety confirmation
18) Pneumatic System Uses
Used in automation and pneumatic systems
Works quickly and efficiently
19) Basic Components of Pneumatic Systems
Air regulator
Control valve
Pressure control valve
Pneumatic cylinders
Solenoid valve
Vacuum suction system
Flow control valve
What is PLC?
PLC (Programmable Logic Controller) is an industrial digital controller used to automate machines and industrial processes.
20. Definition
PLC is used in industrial automation.
It controls machines and processes automatically.
It works based on programmed logic.
21. Main Function
PLC receives input signals.
It processes the logic.
It gives output signals to operate devices.
Input → Process → Output
22. How PLC Works
Sensors and switches send signals to the PLC.
The PLC processes the program logic.
Output devices operate according to the command.
23. Input Devices
Examples of PLC input devices:
Push Button
Limit Switch
Proximity Sensor
Temperature Sensor
24. Output Devices
Examples of PLC output devices:
Motor
Relay / Contactor
Solenoid Valve
Indicator Lamp
25. Main Components of PLC
CPU (Brain of PLC)
Input Module
Output Module
Power Supply
Programming Device
26. PLC Programming Languages
Ladder Logic (Most Common)
Function Block Diagram (FBD)
Structured Text (ST)
27. Advantages of PLC
Reliable and fast operation
Easy troubleshooting
Flexible programming
Less wiring required
High durability
Easy to expand
28. Applications of PLC
Industrial automation
Conveyor systems
Packaging machines
Water treatment plants
Material handling systems
29. Example of PLC Operation
Press the Start Button.
PLC receives the input signal.
PLC processes the program logic.
Motor starts automatically.
30. PLC Basic Block Diagram
Input Devices → Input Module → CPU → Output Module → Output Devices
31. Quick Facts About PLC
PLC works in real-time.
It is easy to maintain.
It reduces downtime.
It increases productivity.
[Link] is LOTO?
LOTO means Lock Out Tag Out.
It is a safety procedure used to isolate hazardous energy before maintenance work.
[Link] are the types of LOTO?
Electrical LOTO
Mechanical LOTO
Hydraulic LOTO
Pneumatic LOTO
Thermal LOTO
Chemical LOTO
strial processes.