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A steel belt is a type of conveyor belt used in many industries such as food, chemical, wood processing, and transportation. [1]
Steel belts are generally made from carbon steel or stainless steel which has been alloyed or treated depending on the application.[ citation needed ]
Compared to plastic belts, steel belts are generally more expensive upfront, but it can offer better durability. Over time, a steel belt may develop deformations or curvature due to wear and tear. These deformations can be rectified through various methods such as shot peening to flatten out the cross curvature of deformed steel belts. This process can be performed on-site without interrupting production.[ citation needed ]
The two main systems using steel belts are single-belt and double-belt systems. Single-belt systems are appropriate for manufacturing single-sided products such as pastilles, flakes, strips, and sheets. The double-belt system can manufacture the top and bottom of a product simultaneously, such as in chemical, rubber, laminate, and composite material processing operations.[ citation needed ]
Ground stainless steel belts are normally produced with surface roughness ranging from 0.4 μm down to 0.1 μm, with well-rounded edges, and developed for level and straight contour. Such belts are supplied in open lengths, with the ends prepared for welding on site, or in endless condition with a welded joint.
Perforated steel belts enable the drying media, for example hot air, to be transferred 'through' the belt, so that the air is in contact with all parts of the product on the belt. Normally, manufacturers offer perforated belts with five standard perforation patterns[ clarification needed ] which cover most requirements. Other patterns, with a minimum hole diameter of 0.8 mm (0.03 in.) and different spacing, can be provided to suit specific applications.[ citation needed ]
Mirror polished stainless-steel belts to produce several types of thin film and ceramic sheets. The belts are available in thickness from 0.60 to 2.00 mm (0.02362 to 0.0787 in.) with thickness variation less than or equal to 80 μm. Polished steel belts are produced endlessly or as open-length belts.[ citation needed ]
Seamless steel belts are suitable for the production of high-quality plastic foils and films, such as optical and packaging films. The thickness of these belts typically ranges from 0.03 to 0.60 mm (or 0.012 to 0.23 in.). They are particularly useful for machines with narrow drum diameters that require the use of wide belts.[ citation needed ]
Solid stainless-steel belts are, as standard, delivered in cold-rolled condition with a mill finish of Ra < 0.4 μm and have rounded edges. Carbon steel belts are, as standard, delivered in a hardened and tempered condition with a mill finish of Ra < 0.4 μm and have rounded edges. Solid steel belts are leveled and straightened to obtain flatness and straightness and are supplied in open lengths, with the ends prepared for welding on site, or in endless condition with a welded joint.[ citation needed ]
Steel belts used in the food business are made to be sanitary, simple to clean, dependable, and flexible in their use. They are employed in the cooking process as well as the drying and steaming of perishables, the freeze-drying of instant coffee, the casting of caramel and other candies, and the formation of chocolate droplets.
Stainless-steel belts are part of continuous production processes. Unlike conveyor belts used purely for transportation purposes, steel belts used in this industry serve as media for transferring heat and/or pressure. Applications for steel belts in the chemical industry include casting, polymerizing of resins, waxes, paraffins and many other substances.
Steel belts may be used to move the finished product or raw material or in parcel sorting systems, transporting of bottles, bulk loads, bricks, machinery parts and the like. Straight tracking, high abrasion resistance, and dynamic fatigue strength are crucial when transporting bulky material or unit load. Extremely high operating speeds cause a high number of load cycles and create severe operating conditions. Steel belts can be made to suit these extreme requirements.
Steel belts play an essential role in modern, continuous production processes for wood-based panels (WBP) such as particle boards, OSB- and MDF boards, where they serve as heat and pressure transfer media at the same time. As the steel belt surface has a direct influence on the final panel surface quality, this application imposes high demands on steel belts regarding thickness uniformity and surface finish.
Stainless steel, also known as inox, corrosion-resistant steel (CRES) and rustless steel, is an alloy of iron that is resistant to rusting and corrosion. It contains iron with chromium and other elements such as molybdenum, carbon, nickel and nitrogen depending on its specific use and cost. Stainless steel's resistance to corrosion results from the 10.5%, or more, chromium content which forms a passive film that can protect the material and self-heal in the presence of oxygen.
A conveyor belt is the carrying medium of a belt conveyor system. A belt conveyor system is one of many types of conveyor systems. A belt conveyor system consists of two or more pulleys, with a closed loop of carrying medium—the conveyor belt—that rotates about them. One or both of the pulleys are powered, moving the belt and the material on the belt forward. The powered pulley is called the drive pulley while the unpowered pulley is called the idler pulley. There are two main industrial classes of belt conveyors; Those in general material handling such as those moving boxes along inside a factory and bulk material handling such as those used to transport large volumes of resources and agricultural materials, such as grain, salt, coal, ore, sand, overburden and more.
Corrosion is a natural process that converts a refined metal into a more chemically stable oxide. It is the gradual deterioration of materials by chemical or electrochemical reaction with their environment. Corrosion engineering is the field dedicated to controlling and preventing corrosion.
In physical chemistry and engineering, passivation is coating a material so that it becomes "passive", that is, less readily affected or corroded by the environment. Passivation involves creation of an outer layer of shield material that is applied as a microcoating, created by chemical reaction with the base material, or allowed to build by spontaneous oxidation in the air. As a technique, passivation is the use of a light coat of a protective material, such as metal oxide, to create a shield against corrosion. Passivation of silicon is used during fabrication of microelectronic devices. Undesired passivation of electrodes, called "fouling", increases the circuit resistance so it interferes with some electrochemical applications such as electrocoagulation for wastewater treatment, amperometric chemical sensing, and electrochemical synthesis.
Hot-dip galvanization is a form of galvanization. It is the process of coating iron and steel with zinc, which alloys with the surface of the base metal when immersing the metal in a bath of molten zinc at a temperature of around 450 °C (842 °F). When exposed to the atmosphere, the pure zinc (Zn) reacts with oxygen (O2) to form zinc oxide (ZnO), which further reacts with carbon dioxide (CO2) to form zinc carbonate (ZnCO3), a usually dull grey, fairly strong material that protects the steel underneath from further corrosion in many circumstances. Galvanized steel is widely used in applications where corrosion resistance is needed without the cost of stainless steel, and is considered superior in terms of cost and life-cycle. It can be identified by the crystallization patterning on the surface (often called a "spangle").
Anodizing is an electrolytic passivation process used to increase the thickness of the natural oxide layer on the surface of metal parts.
Extrusion is a process used to create objects of a fixed cross-sectional profile by pushing material through a die of the desired cross-section. Its two main advantages over other manufacturing processes are its ability to create very complex cross-sections; and to work materials that are brittle, because the material encounters only compressive and shear stresses. It also creates excellent surface finish and gives considerable freedom of form in the design process.
Ultra-high vacuum is the vacuum regime characterised by pressures lower than about 1×10−6 pascals. UHV conditions are created by pumping the gas out of a UHV chamber. At these low pressures the mean free path of a gas molecule is greater than approximately 40 km, so the gas is in free molecular flow, and gas molecules will collide with the chamber walls many times before colliding with each other. Almost all molecular interactions therefore take place on various surfaces in the chamber.
A belt is a loop of flexible material used to link two or more rotating shafts mechanically, most often parallel. Belts may be used as a source of motion, to transmit power efficiently or to track relative movement. Belts are looped over pulleys and may have a twist between the pulleys, and the shafts need not be parallel.
Galling is a form of wear caused by adhesion between sliding surfaces. When a material galls, some of it is pulled with the contacting surface, especially if there is a large amount of force compressing the surfaces together. Galling is caused by a combination of friction and adhesion between the surfaces, followed by slipping and tearing of crystal structure beneath the surface. This will generally leave some material stuck or even friction welded to the adjacent surface, whereas the galled material may appear gouged with balled-up or torn lumps of material stuck to its surface.
Sheet metal is metal formed into thin, flat pieces, usually by an industrial process.
Strapping, also known as bundling and banding, is the process of applying a strap to an item to combine, stabilize, hold, reinforce, or fasten it. A strap may also be referred to as strapping. Strapping is most commonly used in the packaging industry.
Fusion bonded epoxy coating, also known as fusion-bond epoxy powder coating and commonly referred to as FBE coating, is an epoxy-based powder coating that is widely used to protect steel pipe used in pipeline construction from corrosion. It is also commonly used to protect reinforcing bars and on a wide variety of piping connections, valves etc. FBE coatings are thermoset polymer coatings. They come under the category of protective coatings in paints and coating nomenclature. The name fusion-bond epoxy is due to resigning cross-link and the application method, which is different from a conventional paint. In 2020 the market size was quoted at 12 billion dollars.
Rustproofing is the prevention or delay of rusting of iron and steel objects, or the permanent protection against corrosion. Typically, the protection is achieved by a process of surface finishing or treatment. Depending on mechanical wear or environmental conditions, the degradation may not be stopped completely, unless the process is periodically repeated. The term is particularly used in the automobile industry.
An air knife is a tool used to blow off liquid or debris from products as they travel on conveyors. Air knives are normally used in manufacturing or as the first step in a recursive recycling process to separate lighter or smaller particles from other components for use in later or subsequent steps, post manufacturing parts drying and conveyor cleaning, part of component cleaning. The knife consists of a high-intensity, uniform sheet of laminar airflow sometimes known as streamline flow.
A conveyor system is a common piece of mechanical handling equipment that moves materials from one location to another. Conveyors are especially useful in applications involving the transport of heavy or bulky materials. Conveyor systems allow quick and efficient transport for a wide variety of materials, which make them very popular in the material handling and packaging industries. They also have popular consumer applications, as they are often found in supermarkets and airports, constituting the final leg of item/ bag delivery to customers. Many kinds of conveying systems are available and are used according to the various needs of different industries. There are chain conveyors as well. Chain conveyors consist of enclosed tracks, I-Beam, towline, power & free, and hand pushed trolleys.
A checkweigher is an automatic or manual machine for checking the weight of packaged commodities. It is normally found at the offgoing end of a production process and is used to ensure that the weight of a pack of the commodity is within specified limits. Any packs that are outside the tolerance are taken out of line automatically.
A drum motor is a geared motor drive enclosed within a steel shell providing a single component driving pulley for conveyor belts.
The belt filter is an industrial machine, used for solid/liquid separation processes, particularly the dewatering of sludges in the chemical industry, mining and water treatment. Belt filter presses are also used in the production of apple juice, cider and winemaking. The process of filtration is primarily obtained by passing a pair of filtering cloths and belts through a system of rollers. The system takes a sludge or slurry as a feed, and separates it into a filtrate and a solid cake.
Shot peening can be used to recondition distorted steel conveyor belts. The shot peening process is quick and cost-effective compared with other methods and does not interrupt daily production. A deformed steel belt has the following disadvantages:
