Intro
As you may know, a belt splice, which joins the two ends of the conveyor belt, has been the weakest part of a conveyor belt, comprising only up to 90% of the belt’s total strength.
And the data also shows that improper splicing is accountable for almost 80% of conveyor belt failures. This highlights the crucial role that belt splicing plays in the conveyor belt’s overall performance and reliability.
In this article by Bsbeltfactory, we will discuss the importance of conveyor belt splices and their impact on overall performance and reliability, and go over the 3 main types of conveyor belt splices as well as tips to avoid failures in the conveyor belt splicing procedure. We believe your little reading time will pay back quickly.
Why Conveyor Belt Splices Matters
Before we go through the different types of belt splices, let’s discuss a bit about why belt splicer matters and what factors affect them.
As you might expect, the joint is the point at which the two ends meet and are attached.
On the conveyor belt, the connection can be made in a variety of ways, each with its own advantages and disadvantages depending on the application, and each will affect the conveyor belt’s performance and results in different ways.
The reason it’s important to consider the style of the joint on your conveyor belts is that, no matter how well the belt is made, the joint can sometimes contribute to issues in the sanding process, such as chatter, loading, tracking, belt breakage, and overall abrasive performance.
In addition, when choosing the belt splice type that’s right for you, it’s important to consider the material and application condition of your conveyor belts.
3 Types of Conveyor Belt Splices
Now that we understand a bit about the impact of belt splicing, we will dive into the benefits and defects of common methods of splicing a conveyor belt, including mechanical splicing, Hot vulcanization splice, and cold vulcanization splice.
1.Mechanical splicing:
Mechanical splicing is formed by joining the two ends of the belt together with mechanical connectors. This involves utilizing mechanical connectors like steel buckles including wolf tooth and butterfly buckles. Specialized mechanical tools are employed to clamp the belt ends onto the connectors, creating a sturdy joint that is tightly secured.
Mechanical splicing offers a range of benefits, including its simplicity of operation, low cost, and ease of maintenance. It is also fast and efficient, helping to reduce downtime and enhance overall equipment maintenance efficiency. Moreover, mechanical splicing is versatile and suitable for connecting most types of conveyor belts, making it a reliable and practical solution for belt jointing.
Despite the numerous advantages of mechanical splicing, it is important to be aware of some of its limitations. One such limitation is that the mechanical interface can be challenging to clean and may be prone to bacteria growth. Additionally, the joint may weaken over time and become vulnerable to damage, which could ultimately impact the longevity of the conveyor belt product.
Nevertheless, mechanical splicing remains a highly effective and efficient method for connecting conveyor belts when the machine is challenged to disassemble. For example, this common method is generally used for splicing PVC and PVG whole-core flame retardant and antistatic conveyor belts below grade 8.
2、Hot Vulcanizing of Conveyor Belt
Hot vulcanization splicing has been the most widely used conveyor belt joining method as well as the most ideal belt splicing for its exceptional strength and durability.
This technique requires bonding the two ends of the belt together using a special joint material, and then using a heat press to vulcanize the joint at a specific temperature, resulting in a strong and long-lasting connection.
Hot vulcanized splices are particularly well-suited for heavy and highly abrasive conveyor belts, providing superior strength and abrasion resistance. Although the cost of this method is relatively higher compared to other joint methods, the reliability and durability of the connection more than justifies the expense.
It is suitable for conveyor belts with good wear resistance, low tension, smooth joints, and not easy to bend, such as PU conveyor belts and PVC conveyor belts.
3、Conveyor Belt Cold Splicing
Cold vulcanization splicing is an effective method for bonding the ends of conveyor belts together. This technique involves using a cold-bonding adhesive to connect the two ends of the belt, creating a strong and durable bond.
To achieve this type of belt splicing, the belt ends need to be ground, cleaned, and then glued together with a cold-bonding adhesive carefully at the butts and tightly pressed together, ensuring maximum contact between the adhesive and the belt. Finally, the adhesive is allowed to cure at room temperature, resulting in a strong and long-lasting connection.
Compared with mechanical splicing, it boasts higher efficiency and lower cost and offers better connection strength. Meanwhile, it relies less on facilities than the hot vulcanization splicing in operation. This way, it has been an ideal belt splicing type for lightweight conveyor belts and on-site splicing operations.
However, the performance of cold vulcanization splicing largely depend on the technique craft and adhesives. So it always works as an option for emergencies but not for long-term operations.
Tips to Avoid Belt Splice Failure
As mentioned above, the conveyor belt splices are the weakest parts of the belt body. In general, mechanical splicing can only reach 40-50% of the strength of the belt body, conveyor belt cold splicing can reach 60-70%, and the hot vulcanized joint can reach 80-90%.
Then, if a belt splicing has not been connected properly, its strength will be lower than expected. There are varied factors that will affect the splicing performance, for example, the temperature of the hot-melt machine presses the joint, too high or too low, or it may be time.
There are also some operational errors, such as excessive grinding of belt ends, excessive lap length, and insufficient bonding performance.
Therefore, in addition to choosing the appropriate conveyor belt splicing method, we should also pay attention to the belt splicing process. The following are tips based on our experience to help you make it flat, firm, and durable to avoid joint failure.
- Make sure the bonding interface at both belt ends is clean and dry. A drier and cleaner interface will allow the glue to infiltrate the fabric more fully and solidify the bonding.
- After the bonding interface overlaps, apply uniform pressure, and a more uniform pressure will enhance the strength of adhesion.
- Keep the tighter the bonding between the overlapping surfaces, the stronger the bonding force.
Conclusion:
In summary, the different types of conveyor belt splicing or joining include hot splicing (hot vulcanizing splice), cold splicing (using cold adhesive), and mechanical fasteners. Each method has its advantages and is suitable for different applications depending on factors such as belt material, strength requirements, operating conditions, and convenience.
Overall, hot vulcanized joints are a preferred method for connecting conveyor belts that require high performance and durability.
Bsbeltfactory offers high-quality conveyor belts that employ hot-vulcanized splicing. The belt splicing is flat, the correctness is strictly controlled within plus or minus 0.2mm, and the joint fastness is 80-90% of the original belt.
The belt splice coordinated with the conveyor belt as a whole, which can make the conveyor belt joint completely sealed, not affected by moisture, has a long service life and exceptional strength, and can withstand even the most challenging industrial applications.
For assistance in making your selections, our engineers are ready for your support.
