Conveyor Covers: An In - Depth Introduction
1. Definition and Function
A conveyor cover is an essential component installed on a conveyor system. Its primary function is to safeguard other components of the conveyor and the materials being transported from various external factors. These external factors can include elements such as rain, wind, dust, and even potential impacts.
Outdoor conveyor systems that operate over long paths are particularly in need of conveyor covers. However, they are also installed in indoor settings when the materials require protection from moisture or other contaminants. Additionally, conveyor covers play a crucial role in protecting workers or other machinery from the contents being transported. This is especially common when there is a risk of materials being ejected from the conveyor belt at any point during the transportation process.
2. Materials Used
2.1 Metal Materials
Steel: In most cases, steel is a popular choice for manufacturing conveyor covers. Its durability ensures that the cover will not be easily dented or damaged. However, regular steel may be susceptible to rust, which can compromise its integrity over time.
Galvanized Steel: To address the rust issue, many conveyor covers are made from galvanized steel. This type of steel has a zinc coating, which makes it highly resistant to rust and corrosion. As a result, it can maintain its structural integrity and appearance for a longer period, even in harsh environmental conditions.
Aluminum: Aluminum conveyor covers are also available. While they are lighter - duty compared to steel covers and more prone to damage, they have the advantage of being highly resistant to rust and corrosion. In some cases, aluminum covers can also be more cost - effective, especially for applications where weight is a concern.
2.2 Plastic Materials
Although not as common as metal covers, plastic conveyor covers are used for lighter - duty applications. They are lightweight, which can be beneficial in certain setups, and may offer some resistance to moisture and certain chemicals. However, they are generally not as durable as metal covers and may not be suitable for applications where there is a high risk of impact or exposure to extreme environmental conditions.
3. Design and Structure
3.1 Sealed vs. Ventilated Designs
Sealed Systems: In many cases, the conveyor cover is designed to create a sealed system. It attaches to the conveyor frame with no gap between the frame and the cover. This design is highly effective in protecting the conveyed materials and the conveyor components from external elements. For example, in a food - processing plant, a sealed conveyor cover can prevent dust and contaminants from entering and spoiling the food products being transported.
Ventilated Designs: Some covers, however, are mounted on legs that create a gap between the conveyor frame and the cover itself. This design may be implemented to ensure proper ventilation of the transported items. For instance, when conveying items that produce heat or need to be aired out during transportation, such as freshly baked goods or certain chemicals, a ventilated cover allows for air circulation. It can also facilitate the monitoring of the transport process, as workers can more easily observe the materials moving through the conveyor. Although a raised cover is not as effective as a sealed one in fully protecting the contents of the conveyor system, it still offers a certain level of protection to the components and materials.
3.2 Partial vs. Full - Length Covers
Partial Covers: Sometimes, the cover only runs over part of the conveyor system. This is often done to facilitate the loading and unloading of the conveyor system. For example, in a mining operation, the loading area of the conveyor may be left uncovered to allow for easy dumping of mined materials, while the middle section, where the materials are transported over a long distance, is covered to protect against dust and weather.
Full - Length Covers: While not always the case, in some applications, a full - length cover may be used. This is common when the materials being transported are extremely sensitive to external factors or when strict environmental regulations need to be adhered to. However, even with full - length covers, there are usually provisions at the ends of the conveyor system to allow for loading and unloading. If the transported materials need to be monitored or inspected midway through the system, the cover can be designed with breakable sections or access points.
4. Types of Conveyor Covers
4.1 Based on Shape and Profile
Full Low - Profile Covers: These covers have a low - lying profile, which can be beneficial in applications where space is limited. They still provide full coverage of the conveyor, protecting the materials and components from above. In a factory with low - ceilinged areas, full low - profile covers can be installed on conveyors without interfering with the overall layout.
Full Covers: As the name implies, full covers provide complete coverage of the conveyor system. They are suitable for applications where maximum protection is required, such as in pharmaceutical or electronics manufacturing, where any contamination can have serious consequences.
Full with Window Covers: These covers are designed with windows, usually made of a clear, durable material such as polycarbonate. The windows allow workers to visually inspect the materials being transported without having to open the cover. This is useful in quality - control processes, where continuous monitoring of the product is necessary.
3/4 Covers: These covers cover three - quarters of the conveyor system. They are a compromise between full coverage and the need for easy access or ventilation in some parts of the conveyor. For example, in a recycling plant, a 3/4 cover may be used to protect the conveyor from the majority of dust and debris, while still allowing for easy access to the conveyor for maintenance or to remove any large objects that may get stuck.
1/2 Covers: Covering half of the conveyor system, 1/2 covers are used in situations where partial protection is sufficient. This could be in an indoor warehouse where the main concern is protecting the conveyor from occasional spills or minor dust, and where access to the conveyor for quick adjustments or maintenance is frequently required.
5. Installation and Maintenance
5.1 Installation
The installation of a conveyor cover depends on its design and the type of conveyor system. For covers that attach directly to the conveyor frame to form a sealed system, proper alignment and secure fastening are crucial. This may involve using bolts, screws, or specialized clips. In the case of covers mounted on legs, the legs need to be firmly anchored to the ground or the supporting structure to ensure stability. Some conveyor covers, like those from Superior Industries, are designed for easy installation and do not depend on any idlers, which simplifies the installation process.
5.2 Maintenance
Regular maintenance of conveyor covers is essential to ensure their continued effectiveness. For metal covers, inspection for signs of rust, corrosion, or damage is necessary. Galvanized steel covers may require less maintenance in terms of rust prevention, but any signs of wear or damage to the zinc coating should be addressed promptly. If the cover has a painted or protective coating, it should be checked for chipping or peeling, and the coating should be reapplied as needed. For plastic covers, inspection for cracks, warping, or signs of degradation due to UV exposure (if used outdoors) is important. Additionally, all covers should be checked periodically for proper alignment and secure attachment to the conveyor system.
