VULCANIZED SPLICING FOR STEEL CORD CONVEYOR BELTS ONE-STEP METHOD TWO-STEP METHOD

VULCANIZING SPLICING FOR STEEL CORD CONVEYOR BELTS

CONTENTS

INTRODUCTION 2 STANDARD PATTERN 2 SPLICING MATERIALS 4 SPLICING PROCEDURE A. B. C. D. E. Preparation Forming Vulcanizing Finishing Precautions 5 6 13 15 15

INTRODUCTION
A vulcanized splice has many advantages over mechanical splices such as freedom from: 1. 2. 3. Tear hazard Tight joint to hold material Greater strength in the joint

This manual giving step by step of vulcanized splice for steel cord belt. Following is the cross section for the steel cord conveyor belt with conventional construction.

Figure 1: Cross section of steel cord belt

STANDARD PATTERN OF ONE-STEP METHOD & TWO-STEP METHOD

Detailed drawings of specific belt specifications are available upon request. (1) ONE-STEP METHOD
Belt Travel 4d+15 Unit: mm

CL

22.5o or 17o

25

S 50 L: S+15d+150 S+15d+75 15d+50 25

25

S+75 25

Belt Width

(2)

TWO-STEP METHOD
Belt 4d+15 Unit: mm

CL

22.5o o or 17

25 15d+5 0

S L:2S+34d+165 2S+19d+65

S 15d+5 25

25

2S+19d+65 25 Cover Gum (W10)

Steel Cord

Tie Gum (W25) Cement (W90)

Cover Gum (W10)

Step Length (S) Except heat resistant rubber

Steel cord construction 3+9+15 d Steel cord dia. (mm) 2.3-2.5 2.6-3.0 3.1-3.4 3.5-3.6 3.7-3.9 4.0-4.3 4.4-4.7 4.8-4.9 5.0 S Step length (mm) 300 350 400 450 500 550 600 650 700 Steel cord construction 7x7 d Steel cord dia. (mm) 2.5 2.6-3.1 3.2-3.4 3.5-3.8 3.9-4.1 4.2-4.6 4.7-5.2 S Step length (mm) 250 300 350 400 450 500 550

Belt Width

Steel cord construction 7 x 19 (Sew)

d Steel cord dia. (mm) 5.0-5.2 5.3-5.7 5.8 5.9-6.3 6.4-6.6 6.7-6.9 7.0-7.2 7.3-7.7 7.8 7.9-8.3 8.4-8.8 8.9-9.2 9.3-9.6 9.7-10.0 10.1-10.6 10.7

S Step length (mm) 650 700 750 800 850 900 950 1000 1050 1100 1150 1200 1250 1300 1400 *

Steel cord construction 7 x 19 (Open)

d Steel cord dia. (mm) 5.5 5.9 6.2 6.6 7.5 8.0 8.5 9.0 9.6 10.3 10.8 11.5 12.5

S Step length (mm) 650 700 750 800 950 1000 1100 1150 1200 1300 1400 1500 1650

Note: *Please consults Bridgestone.

SPLICING MATERIALS
Cover Rubber Materials Heat Resistant Rubber General F110 W10 W25 E41 W90 6 mths H12 H20 N/A H90 SF150 T: H15 B: 12 T: H25 B: N/A N/A SF180 A2000 Q11 Q23 N/A A10 Q23 N/A Q93 Abrasion Impact & Cut AS-A Y10 W25 E41 W90 FX-S X10 W25 E41 W90 6 months Flame Oil JIS, DIN, Oil Ace MSHA H, L, G F10 L13 W25 E41 W90 W25 E41 W90

Cover Gum Coating Gum Nylon Cloth Rubber Cement Shelf Life

T: H95 Q93 B: H90 4 months

Note: (1) The above shelf life is subject to the materials stored at the condition below: Away from sunshine and heat In a dark and cool place with the temperature of less than 30oC, preferably in a refrigerator.! When the materials are taken out from refrigerator, remove moisture on the surface completely. (2) (3) The shelf life period is shown on a label attached to the splicing materials. Please consult the details of the material code and the dimensions of the material with Bridgestone.

SPLICING PROCEDURE
A. (1) PREPARATION Set a worktable on the frame of the conveyor.
Work Table

Lower Heat Plate

Lower Frame

Hydraulic Pressure Plate

Note:

1. 2.

Set the worktable and lower heat plate of vulcanizing press on the same level. A single pressing should make the vulcanization. In case the splice area is too wide to be vulcanized by one press, use two or three vulcanizes with a overspread
Vulcanizing Press

steel and single

plate apply

Work Table

Work Table

2m l

L+Min.0.3m l1 l1 B Belt width + 0.2m * = B x 0.414 2m

pressing.

3.

Dimensions of the work table are shown below:

Minimum l = 2m + l1 50mm

If a vulcanized press is used other than 22.5o, then should be determined according to the angle of the vulcanizing press.

(2)

Overlap both sides of belt on the vulcanizing press.

Work Table Vulcanizing Press Work Table

Belt Travel
Belt

B. (1)

FORMING Determination of center line.

B/2 B/2 B/2 B/2 B/2 B/2 Belt Width B/2 B/2 B/2 B/2 B/2 B/2

1m

1m

0.5m

0.5m

1m

1m

Figure 2: Determine the center line

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(2)

Determination of cut-off line and base line.

(3)

Cut belt along the cut-off line with bolt clipper. It is advisable to lift up one side of the belt, so that cutting becomes easier.

(4)

Peel off top and bottom rubber covers using Tirfor (tugging tool) and knife.

(5)

Draw lines on the exposed area for both belt ends using the measured dimensions as specified below.
One-step method Two-step method

50

S 15d+50 S+15d+125

25 50

2S+4d+15 15d+50 2S+19d+140

25

(6)

Cut the rubber between steel cords by inserting knife. Remove the rubber around steel cord by knife.

In case of partial replacement or re-splicing, it is advisable to remove the aged rubber around steel cord as much as possible with wire wheels grinder. Take care not to damage steel cords.

Buff the Corner Rubber

(7)

Buff a 25mm wide strip area and the surface of the covers approx. 50mm with the wire wheel grinder.
8

(8)

Cut steel cords to the specified length.

One-step method Two-step method

S 15d+50 S+15d+75

25

2S+4d+15 15d+50 2S+19d+90

25

Mark three center points at intervals of 500mm on both sides. Then, line up the sides provisionally, measuring the distance l1 and l2 which must be the same.

(9)

After buffing, lay a polyethylene sheet underneath splicing area and clean the splice area with toluene. Apply a sufficient amount of rubber cement to the steel cords. Allow it to dry thoroughly. It is recommendable to use a hot air-blower in order to accelerate drying.

(10) Prepare bottom cover gum sheet and tie gum sheet. Lay tie rubber on cover rubber. Roll on the rubber with roller. Poke tie rubber with an awl on entire surface to discharge air. Total thickness of gum sheets is thicker than the actual bottom cover of the belt by 0.5mm.
Cut this portion Cover Gum (W-10) Tie rubber (W-25) Cut this portion

L L+100

Steel Cord

Bottom Cover

(11) Mark three center points on each side of belting, and line up both sides so that all points are in a straight line. After lining up, lay prepared bottom and tie gum on work table. Then fix belt to the work table.

2.5m

2.5m

L+Min. 0.3m Fix belt to the worktable

10

(12) Lay steel cords located at the center of the belt with the butted ends meeting. Next lay alternating cables down and continue alternating to the edges of the belt. Fills tie gum between cords, starting at the center and continue to the belt edges. Every 5-10 cords check alignment by using string.
A - A Tie Gum

Tie Gum

Edge Rubber = Cover Gum

Put edge rubber on both sides of the

(13) Put tie gum and cover gum in order.

Cover Gum Tie Gum

Carefully roll out each material so that air pockets will not occur between the overlapped layers.

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(14) Cut off the surplus edge portion. Poke small holes on the entire splice surface to discharge air by using an awl.

(15) Check the finish thickness of the formed area. Make sure that the thickness of the formed area is thicker than the belt by 1.0mm to 1.5mm. If not, add sufficient tie gum in step (13).

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(16) Mark the joint number on the top cover with white rubber. The joint numbers should be provided consecutively in the direction of the running belt.

(17) Place a releasing fabric on both top and bottom covers. Make sure that the fabric is set without wrinkles.

C. (1)

VULCANIZING Set edge former next to the belt edges. Edge formers must be made of steel and 0.5 to 1.0mm thinner than the thickness of the belt.

Edge Former

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(2)

After spreading out the releasing fabric on the entire splice area, assemble upper heat plate and upper frame. Hand tighten the stay-bolts. Clamp the entire equipment by tightening stay-bolts located at the both sides of the press. (Make sure the upper heat plate and frame align exactly with the lower plates and frame)

(3)

Connect the hose with the hydraulic pressure plate and the electric wire with the heat plate, respectively. Apply water pressure between 10 and 12kg/cm2. When the pressure exceeds 12kg/cm2, adjust it by using an air exhaust valve located in the water pressure pump.

(4)

Switch on the electricity and vulcanize the belt for a predetermined time at a temperature of 145oC 5 oC.
General Belt

Belt Thickness (mm) vs Curing Time (min) <=15mm 50 min <=25mm 60 min <=30mm 70 min

Temperature ( oC ) <=35mm 80 min 145 +/- 5

Pressure ( kg/cm2 ) 8~ 10 (0.8~1.0 MPa)

Cooling Temperature ( oC ) <80

Heat Resistant Belt Type Belt Thickness (mm) vs Curing Time (min) <=15mm <=21mm <=25mm 25 25 25 60 NA 40 40 35 35 35 65 NA 60 60 45 45 45 70 NA 60 60 145+/- 5 <120 165(<=20), 175(>20) +10/ -5 165(<=20), 175(>20) +10/ -5 (0.8~1.0 MPa) 8~10 Temperature ( oC ) Cooling Pressure Temperature ( kg/cm2 ) ( oC )

F-110 F110STF A-110 SF-150 WF-100 SF-180 A-2000

* The vulcanizing time for a thicker belt, which is not specified above should be determined on all such occasions. (5) After vulcanization, cool down the belt below 120 oC without loosing the pressure.

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D.

FINISHING

When the vulcanization is finished, disassemble the press and check the appearance of the splice area. The protruded portion at the edges of rubber cover should be cut off by scissors or knife, and finish with a disk sander.

E. (1) (2) (3) (4) (5) (6) (7)

PRECAUTIONS The worktable and the lower side of the vulcanizing press should be installed respectively before working and maintained at the same level. Lining up of the formed ends should be made with special care. Lapping of the materials should be made after cleaning the surface with solvent in any case. Arranging of the steel cords should always be made straight. The thickness of materials to be used must be adjusted so that the thickness of the splice area before vulcanizing may not exceed more than 1.1mm compared with the belt. To measure thickness, use such device as slide calipers or dial thickness gauge. Inspection of vulcanizing press Inspection of vulcanizing press is recommendable periodically at least once a year especially on temperature and pressure distribution. Manuals on how to inspect the press are available upon request.

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