Causes and Treatment of Damage to Steel Wire Rope Core Conveyor Belt

With the development of coal mines in China, especially the increasing development of long-distance, large capacity, and high-speed transportation lines, the application of steel wire rope core belt conveyors has been promoted. Steel wire rope core tape is made of steel wire rope as the core, covered with rubber on the outside, which improves the tensile strength of the steel wire rope core tape, allows for high speed and load-bearing operation, increases transportation capacity, and has a long service life. Its position is becoming increasingly important in the coal mining system. Its disadvantage is that there are no horizontal wires overall, the horizontal strength is low, and it is easy to cause longitudinal scratches and low expansion and contraction force. When hard objects such as coal are caught between the drum and the tape, or when they fall into large pointed objects, it is easy to cause the steel wire rope to be scratched. Therefore, it is necessary to eliminate or minimize abnormal damage and scratches, extend the service life of the belt, and ensure the normal operation of the system. In the coal transportation system, besides normal wear and tear, it is often believed that various objective or human factors may cause abnormal damage or even breakage of the tape, which requires repair. With the development of vulcanization and cold repair technology, this problem has been solved.

1、 Reasons for tape damage

1. Reasons for longitudinal tearing of conveyor belts

1) Vibration and impact can cause loosening and detachment of fasteners, resulting in the fall of baffles or chute side panels.

2) Foreign objects are mixed in the material, which are hard and have sharp edges. The coal chute is blocked and squeezed tightly.

3) Lack of rollers, damage or ineffective rotation.

4) The tape deviated severely and scraped onto the frame.

2. The reason for tape cracking.

1) Due to spatial limitations, the tape has multiple bends.

2) During joint vulcanization, multiple vulcanizations were carried out due to various reasons.

3. Reasons for tearing of vulcanized joints

1) The diameter of the reversing drum is small, and the tape bears large bending stress.

2) The quality of vulcanized joints is poor, especially if there are bubbles or cracked overlapping edges during vulcanization, the strength of the joints is significantly reduced.

3) The tape has a short working cycle, frequent starts, and high instantaneous tension.

4. Reasons for damage to the covered adhesive surface

1) The gap between the lining plate of the material guide groove and the tape is not appropriate, causing abnormal wear or foreign objects embedded in the gap, resulting in abnormal wear or scratches.

2) The material flow rate at the guide groove is inconsistent with the tape speed, resulting in a large drop and accelerating the wear of the adhesive surface.

3) The roller is damaged, causing abnormal wear or scratches on the tape.

4) Scratches on the cleaner.

5) Slippery tape can also cause abnormal wear of the tape

2、 Repair treatment of adhesive tape

1. Repair of wear or detachment of cover adhesive and edge adhesive

Method 1: Cut off the damaged part, with the incision edge at a 45 ° angle; Polish the cut surface and its surroundings, remove adhesive debris, and wipe clean with gasoline; Apply and cover the adhesive paste twice, then dry it and fill it back with the covering adhesive film; Use a vulcanizing machine for vulcanization.

Method 2: Cut off the damaged part with the incision edge at a 45 ° angle; Polish the cut surface and its surroundings, remove adhesive debris, and use an FA glue gun for repair. Preheat the glue gun after connecting it to electricity for 10-15 minutes, and use composite glue A and B in a 1:1 ratio to evenly coat the damaged parts in the glue gun. When filling, the surface of the filler should be raised by 1.5mm as the shrinkage after curing; Use a compaction roller to compact the adhesive, and after the new adhesive layer becomes hard, use an angle grinder to smooth the repaired area. A. B composite adhesive does not contain solvents and can quickly meet the working strength requirements after repair, which is quick and efficient. Stable performance and good wear resistance after repair.

2. Repair treatment of exposed steel wire rope

Expose the steel wire rope on the surface or edges, and repair it separately according to the methods of covering adhesive damage and edge adhesive damage. However, the steel wire rope should be wiped with core adhesive paste, and a 1.5mm thick core adhesive film should be filled back near the steel wire rope before covering with adhesive.

3. Repair treatment of longitudinal scratches and tears

Tearing or scratching the tape along the wire rope will not cut the wire rope.

Method 1: Mark along the crack with a distance of 60mm-100mm on each side. First, cut off the upper and lower covering glue, with the cutting edge at a 45 ° angle. Cut off the rubber between the steel wire ropes at the cut point (keep 1mm of rubber on the steel wire rope surface), and carefully polish the cutting surface; Apply gasoline to the polished surface, dry it, and apply core adhesive paste twice. After the adhesive paste is dry, use core adhesive film to connect the cut parts, and then apply upper and lower covering adhesive. The covering adhesive should be 1mm to 1.5mm behind the working surface and 10mm to 20mm wider than the polished area. Finally, vulcanize it.

Method 2: Small scratches or tears can be repaired with diamond patches. Long distance scratches or tears can be repaired with repair strips. The operation process is as follows: polish the damaged area and diamond patch, clean the polished surface with cleaning agent, and air dry; Brush the adhesive twice, after the first coat is completely dry, apply the second coat and let it air for 10 minutes if it seems to be dry but not dry; When pasting patches and tape, pay attention to pressing them in the same direction without any bubbles in the middle; Use a compaction roller to press. After processing, wait for 1 hour to achieve the required strength.

4. Repair of broken wire rope

Method 1: Cut off the damaged part of the covering rubber and steel wire rope, prepare a new steel wire rope of the same diameter, carefully polish the rubber covered by the original steel wire rope, and apply the core rubber paste twice with the new steel wire rope. Insert the new steel wire rope, fill the core rubber, apply the covering rubber film, and vulcanize it.

Method 2: When the wire breakage does not exceed 5%, a glue gun and a patch can be used to repair it. A V-shaped groove is opened at the break, polished and cleaned, and composite glue A and B are evenly applied to the V-shaped groove with a glue gun in a 1:1 ratio, and ground flat. Then diamond patches can be used for repair, but both the top and bottom must be repaired with diamond patches. Since this process cannot achieve the original strength of the steel wire rope, it is prohibited to use diamond patches when the wire breakage exceeds 5%.

Conclusion: In recent years, bonding technology has been increasingly developed, bringing great convenience to on-site work. Compared with traditional hot vulcanization, cold bonding technology is more convenient and fast in construction, with simple operation, low cost, and can be used immediately. Especially the process of using glue gun in combination with A and B composite glue has a wide range of applications, and can quickly reach working strength after repair. Through on-site practice, the application effect is excellent and the value is promoted for use