AN idea by Leverlink founder Richard Sharp early in 1991 led to the production of the first “dynamic” impact bed for troughed conveyor belts in Australia, forming the foundation for Leverlink’s current leading-edge technology.
Mr Sharp had the idea to develop a better and more reliable product; one that would dissipate kinetic energy and provide the benefits of long service life, as well as assisting in reducing maintenance costs in terms of consumables and labour.
The design for the dynamic impact bed – using rubber torsion springs as suspension – was radically different from the static impact beds that were dominating the Australian marketplace at the time.
Load zones and transfer points
Most belt damage occurs at conveyor load zones (e.g. under crushers) and transfer points. The reasons for this are many and varied.
Impact bed or belt support cradle?
Many so-called impact beds are nothing more than belt support cradles with limited design capacity to dissipate impact energy and provide belt damage protection.
Design and engineering
Leverlink’s experience, engineering skills, and continuous improvement program through research and development and infield monitoring has made the company leaders in the design and application of dynamic impact beds in Australia.
All Leverlink dynamic impact beds are custom-built to suit the application, and in areas where installation space and access are restricted, the design can be such that the individual parts can be broken down and reassembled on the conveyor frame in manageable parts with minimum effort.
- No rollers to replace
- Reduced downtime
- Reduced maintenance costs
- Protects conveyor structure from impact damage
- Supports belt profile at load zone
- Long service life
- Cost effective
- Cost saving
- Easy to retrofit
Rubber torsion springs – impact/vibration attenuation
Leverlink has developed rubber torsion springs that provide a unique method of absorbing impact with the added benefit of vibration attenuation.
Rubber torsion springs are used extensively in its designs for various applications.
Leverlink is the largest manufacturer of rubber torsion springs in Australia, and also manufactures some of the biggest rubber torsion springs in the world.
With a proven track record, the company uses in-house engineering and design combined with extensive infield representation and has years of experience in mining, quarrying, and material handling problems.
Load zone design
The design of an effective conveyor load zone can often be a complex issue.
Functional specifications such as belt speed, width, type of belt, product size, free fall heights, and product moisture content are all major design considerations.
Spillage control
Spillage can be controlled by effective skirting and inner wear plate design and the added use of belt support systems.
Case study one
Leverlink was contacted by a large mining operation who were continually experiencing failure of its impact roller frames.
The conveyor belt was 2000mm wide with a 45-degree trough angle, and the belt was running at 1.5 m/sec, the feed material was -500mm with a free fall height of 2500mm, and the production rate was 1800 tph.
With the functional specifications supplied, Leverlink then visited the site to determine what additional information could be gained that would assist in the engineering and design of a Dynamic Impact Bed to minimise the damage to the conveyor belt and supporting structure.
The Dynamic Impact Bed was built and installed.
The goal was achieved, and the client completely satisfied, they then purchased a second unit for an identical load zone.
This was 26 years ago. In this time the slider bars have been replaced three times and the impact mounts twice, but it is expected the Dynamic Impact Beds will last another 10 years.
Case study two
An offshore copper mine commissioned Leverlink to provide a solution for extremely high costs due to belt damage at a conveyor load zone.
The conveyor belt was 2400mm wide, 23 degrees trough angle, and running at 3.35m/sec. The material was hard rock/copper ore at -250mm with a free fall height of 6000mm. The peak capacity was 10,000 tph.
Engineering calculations determined a multi-trough Dynamic Impact Bed was required for the application.
This was designed, manufactured and exported to the client. When installed and commissioned it resolved the belt damage problem to the customer’s satisfaction.
One year later the mine ordered a second unit for a similar conveyor belt.
Leverlink has been at the cutting edge of rubber torsion springs and dynamic impact beds for about 30 years, and can provide fully customised impact beds, and many more products and services.
More information:
Call: Eastern States (07) 3737 2400
Western States (08) 6165 8892
Email: [email protected]
Website: www.leverlink.com.au
