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Introduction
This article will take an in-depth look at vibratory conveyors.
You will understand more about topics such as:
What are vibratory conveyors?
How vibratory conveyors work
Considerations when choosing vibratory conveyors
Characteristics of vibratory conveyors
Types of vibratory conveyors
Advantages and disadvantages of vibratory conveyors
Applications of vibratory conveyors
Maintenance tips for vibratory conveyors
And much more.....
Chapter 1: What are Vibratory Conveyors? How do They Work? What to Consider When Choosing Them
Vibratory conveyors are material-handling equipment used to transport fine to coarse-grained bulk materials. These vibratory conveyors are strong conveying equipment utilized for bulk commodities with fine to coarse graininess. If the materials are transported horizontally, they are easily and efficiently transported. The suspension design is the only constraint. High conveyance rates are especially evident when directly contrasted with conveyor belts, which, when utilized in silos, block with the same material pressure or degrade too soon. Vibrating conveyors are resistant to congestion or blockages in the conveyor channel. In most cases, they resume working freely and unhindered. When organizing the design, it is important to remember that they operate most effectively in horizontal or incline orientation.
A vibratory conveyor's accumulation track, which can be linear or gravity-based, helps with directional movement and reduces conveyor vibrations. Pneumatic, electromagnetic, or piezoelectric motors can be used as drive units to generate the required rotation, force, and vibrations.
A transport trough, or platform, is the first component of a vibratory conveyor's architecture. Materials are transported using carefully controlled linear vibrations that cause the materials to leap, hop, and toss. Depending on design features, travel speeds are controlled by frequency, amplitude, and slope angle and range from a few feet per minute to over 100 feet (30 m) per minute.
Similar to how orifices or valves control fluid flow, various vibratory conveyors can be used to regulate material flow. With a frame that contains soft springs to limit vibrations, they can be configured to feed bulk materials at a fixed pace with capacities ranging from a few pounds per hour to over several tons per hour. Vibratory feeders have the benefit of being able to eliminate bridging, which slows down processes and assemblies and obstructs effective material flow. A vibratory feeder's free flow reduces the potential for bridging brought on by friction. Direct force, which sends force directly to the deck, and indirect force, which is a resonant or natural frequency, generate a smooth and uniform flow.
Working Principle of Vibratory Conveyors
As its name suggests, a vibratory conveyor is a mechanical tool that uses vibration to feed and position material in production lines. Electromagnets are used to produce vibrations. The device transforms vibrations caused by electromagnetic fields into mechanical vibrations. These mechanical vibrations are then harnessed to move components down the production line. There is a fixed magnetic coil under the spring-mounted conveyor. An external power source is then used to magnetize the coil to produce an electromagnetic actuation or vibration. The conveyor is restricted to vertical movement once the actuation starts due to the springs mounted to it. Typically, 1 to 6 electromagnets are positioned under the feeder base. The components and pieces in the bowl feeder are moved onto the bowl conveying rails for production after the electromagnetic vibrations are translated to mechanical ones by the vibrations.
Considerations When Choosing Vibratory Conveyors
Establish the span the aggregate must cross, the ideal width, and the required vibration to move the material. For instance, a broader trough and a larger drive are needed to transport rocks long distances. These concepts help one decide what vibrating conveyor will work best for their project and the appropriate drive and power requirements.
To describe the appropriate load capacity and pieces per minute, the user must understand what the conveyor will move, how much must be transported, and at what pace. Using these numbers, the supplier can determine the ideal conveyor's approximate size, shape, and duty rating. If the user needs clarification of these numbers, the supplier can assist in figuring out the appropriate capacity and speed for that particular application.
Control and special considerations: These conveyors are normally low-maintenance and passive, but can incorporate control if they are a part of a larger control system. Numerous passive options are effective if control is not required. Determine any additional specifications, such as those for foundational damping, containment/sterile components, or hazard protection. The supplier should share these factors with the provider and any other significant party to guide the client towards the best solutions.
Characteristics of a Vibratory Conveyor
It is simple to regulate the discharge capacity. For example, using an inverter, the user may regulate the discharge capacity (in tons/hour).
Vibratory conveyors are useful for moving various materials, including powder, granules, blocks, and other types.
A vibration feeder has low maintenance costs and minimal wear-related characteristics.
A vibratory conveyor can be utilized in unique circumstances. The vibrating feeder can be fitted with a dust cover, liner plate, sealing portion, etc., depending on the applicable operating conditions.
Vibratory conveyors provide dependable operation and smooth vibration.
A vibratory conveyor’s unique grid layout can avoid material blockage and the spacing between grids can be altered.
Frequency converter motors are optional; you can alter the capacity by changing the frequency of the motor, making it simple to regulate the feeding rate without often starting the motor.
Chapter 2: Types of Vibratory Conveyors
Standard-Duty Vibratory Conveyors
Standard-duty vibrating conveyors are designed for medium-to-light-density material, such as plastics, wood, porous rock, and the like. Depending on requirements, they can be portable and modular, with capacities ranging from 1 to 40 tons per hour at up to 60 feet per minute. These conveyors are a dependable and secure solution for moving aggregate. They also normally have a long lifespan and encounter little to no wear. They are used in manufacturing polymers, processing chemicals and food, among many other things.
Base-Balanced Vibratory Conveyors
Base-balanced vibrating conveyors have a heavier frame isolated from the customer's primary support structure and operate close to resonant frequencies. Unlike the unbalanced design, this enables the conveyor to be put on less durable structures. In addition, the heavier frame reduces the reaction forces generated by the dynamic motion of the conveyor trough. The conveyor frame's reduced motion is subsequently isolated from the nearby building.
The conveyor trough is connected to the frame using an eccentric drive connection installed on a shaft and driven by a belt. The springs used to fasten the trough to the frame are commonly made of fiberglass or coil. Conveyors are set to run at a particular speed using a number of springs, and the eccentric drive connection regulates the amount of throw. In addition, the conveyor's power requirements are decreased thanks to an elastomeric coupling between the eccentric (an electrically-mounted wheel or disk) and the trough, shielding the connection between the two from severe loads that could lead to failure.
Base-balanced vibratory conveyors can often be as short as 40 feet long since longer lengths cause the frame to resonate at higher frequencies. However, these gadgets are helpful for fluidizing, dewatering, classifying, and screening.
This conveyor requires periodic bearing lubrication, belt inspection, and overall unit inspection. Base-balanced vibratory conveyors are employed in both industrial and sanitary settings.
Unbalanced Vibratory Conveyors
Unbalanced vibratory conveyors are categorized as being earth-grounded and are used near sources of resonant frequency. As a result of this vibration, the conveyor must be firmly mounted to a sturdy structure, often a concrete slab provided by the customer that is thick enough to withstand the reaction forces generated by the conveyor trough's dynamic motion.
Several springs, normally made of fiberglass or coil, mount the trough to the anchored frame. A belt-driven, shaft-mounted eccentric drive connection then operates the conveyor trough. Conveyors are set to run at a particular speed based on the number of springs, and the eccentric drive connection regulates the amount of throw. In addition, the conveyor's power requirements are decreased thanks to an elastomeric coupling between the eccentric and the trough, shielding the connection between the two from severe loads that could lead to failure.
Unbalanced vibratory conveyors can extend beyond 100 feet in length if a suitable mounting structure is provided. These gadgets are helpful for fluidizing, dewatering, classifying, and screening. This conveyor requires periodic bearing lubrication, belt inspection, and overall unit inspection. Industrial applications often employ unbalanced vibratory conveyors.
Dynamically-Balanced Vibratory Conveyors
Dynamically balanced vibrating conveyors are a type of conveyor with an equal mass running close to the resonant frequency. Unlike the unbalanced design, this enables the conveyor to be put on less durable structures. In addition, their heavier frame reduces the reaction forces generated by the dynamic motion of the conveyor trough. The conveyor frame's reduced motion is subsequently isolated from a nearby building.
The conveyor trough is connected to the frame using an eccentric drive connection installed on a shaft and driven by a belt. The springs used to fasten the trough to the frame are commonly made of fiberglass or coil. Conveyors are set to run at a particular speed using the number of springs, and the eccentric drive connection regulates the amount of throw. In addition, the conveyor's power requirements are decreased thanks to an elastomeric coupling between the eccentric and the trough, shielding the connection between the two from severe loads that could lead to failure.
Base-balanced vibratory conveyors can often be as little as 40 feet long since longer lengths cause the frame to resonate at higher frequencies. Nevertheless, these gadgets are helpful for fluidizing, dewatering, classifying, and screening.
This conveyor requires periodic bearing lubrication, belt inspection, and overall unit inspection.
Base-balanced vibratory conveyors are employed in both industrial and sanitary settings.
Feeder Vibratory Conveyors
The feeder-style vibrating conveyor is the most basic type of vibrating conveyor. It is a brute-force conveyor that doesn't need to be tuned and has almost no exterior working components. A series of brute force-style vibratory feeders are available for sanitary and commercial applications. Trough lengths are typically 12 feet or fewer, and the general uses are for regulated feeding from a storage vessel situated above the unit. The width of a trough can vary from 4 inches to several feet. Sizes are chosen for each application.
Dual eccentric motors that are connected to a conveying trough power this style of a vibratory conveyor. To only allow trough motion in the conveying direction, these motors are parallel mounted and coupled to the trough at a specific pitch angle. In addition, coil spring isolators are used to support the troughs to lessen vibration transfer into the supports for the conveyor.
The velocity of the product flowing down the conveyor trough can be adjusted using a variable-frequency drive to regulate the speed of the eccentric motors, metering the amount of product supplied to the next location. Setting the eccentric weight force on the motors allows users to change the conveyor's maximum throw to whatever they want. In addition, the user now has the option to regulate the rate at which materials are fed into their process line via hoppers or overhead bins. Manual or automated motor control can change flow rates from 0 feet to 60 feet per minute.
These conveyors are exceptionally sanitary, safe, trustworthy, and affordable, thanks to their straightforward design and use. Fewer cracks and crevices that could trap dirt and open building techniques make cleaning easier. Standard sealed exciter motors are permanently lubricated. Units need to be inspected occasionally to ensure they run under design requirements. Finally, this conveyor type can also be set up as a shaking table configuration for leveling products in containers before sealing.
Coil spring isolators support these brute-force feeder-style conveyors to lessen any residual vibration that may enter the nearby support structure. Coil spring isolators can be hung above or below based on customer needs.
Centrifugal Vibratory Conveyors
Centrifugal vibratory conveyors, also called rotary feeders, feature a revolving bowl that propels pieces outward. They have bowl-shaped walls enclosing a conical, centrally powered rotor. Rotational force separates parts and components as the feeder spins. The rotating components are pushed and dragged toward the bowl's outside rim as they rotate quickly.
Centrifugal feeder systems are used in industries including food processing, pharmaceuticals, and medical supply that deal with small, oddly-shaped parts that need to be handled quickly. Regardless of the size and shape of the components, centrifugal bowl feeders can sort and appropriately orient them at a pace of 3,000 per minute.
Natural-Frequency Vibratory Conveyors
Two or more spring-connected masses are used in natural-frequency vibratory feeders, commonly referred to as “tuned” or “resonant” feeders. The two-mass, spring-connected vibratory system is the most popular. The response or excitation mass has a separate mass from the trough mass. The natural frequency feeder uses the oscillations' inherent magnification, which happens when the system is run at speed close to its natural frequency or resonance state. As a result, only a minimal force is needed to produce the appropriate vibratory forces. In addition, rotating electromagnets or eccentric weights help produce vibratory force.
The bulk's damping capability must be considered more than the weight of the material or load. The material's ability to absorb energy produces the damping effect (a decrease in the amplitude of an oscillation). For example, when vibrating, granular and powdered materials lose energy through intergranular friction and deformation.
Vibratory feeders are divided into several categories according to how they respond to the supporting structures and foundations. The structure's rigidity and permissible stresses must be considered when choosing a vibratory feeder.
Oscillating Conveyors
Conveyor manufacturers like to categorize some of their products as oscillating conveyors. Oscillating conveyors are sometimes referred to as a particular kind of vibrating conveyor that uses a lower operating frequency and a bigger motion amplitude than is generally used with other vibrating conveyors. As a result, oscillating conveyors transport bulk items in sectors including waste management, recycling, and the timber industry. For instance, these conveyors could be used to move the wood waste from an upstream system to a point where it would be discharged. The motion or movement of the material is gentler with a vibrating conveyor than with an oscillating conveyor, which operates at higher frequencies and lower amplitudes. Oscillating conveyors are also called jump conveyors in quarrying applications and grasshopper conveyors in hard rock mining applications.
Heavy-Duty Vibratory Conveyors
Heavy-duty vibratory conveyors are often utilized for rock, metal, and bulk quantities of heavy products since they are designed to move bigger, more awkward commodities that need tremendous power and speed. They are commonly installed units with capacities surpassing 500 tons per hour and speeds up to 90 feet per minute. These foundation supports include dampers, dashpots, and stands. Motors frequently control heavy-duty vibratory conveyors; more power is needed for heavy-duty vibrating conveyors than for normal-duty vibrating conveyors. Therefore, they are utilized in large-scale industries such as foundries, industrial manufacturing, lumber, rubber, etc.
Brute-Force Vibratory Feeders
Because the vibratory drive is coupled directly to the trough assembly, a brute-force vibratory feeder is called a single-mass system. Typically, they are employed in heavy-duty applications. Although an electromagnetic drive system is an option, electromechanical drives are the most common. Brute-force feeders rotate a large centrifugal counterweight to produce oscillating forces. Brute-force feeders have the most straightforward design of all vibratory feeders. However, their feed-rate regulation and range are constrained because they are intended to be constant-rate feeders. The feed rate can be affected by altering the trough slope, aperture, quantity of counterweight, and stroke length. Since the trough stroke is only marginally dependent on the motor's operating speed, variable-speed drives are rarely fitted. For brute-force feeders, tuning the motor speed is not necessary.
Leading Manufacturers and Suppliers
Chapter 3: Advantages, Disadvantages, Applications, and Maintenance of Vibratory Conveyors
Advantages of Vibratory Conveyors
Regulating the flow of material for spreading across inspection belts or filling containers: The same time-saving benefits of easy cleanup and reduced wear is also present in a vibratory conveyor, which also uses an electromagnetic drive to control material flow. This flow control is very helpful in recycling when trying to control flow or fill a container to a specific weight. Instantaneous stop/start control and the flexibility to slow down or speed up product flow enable adaptability in feeding various materials, as is frequently the case with recycling processes. In addition, these features enable accuracy in precision-filling applications.
Dewatering and size-based material separation are typically required to distinguish between waste and recyclable materials. A linear vibratory screen effectively separates material by size while feeding it into the conveyor. To police the material and separate the useful product from anything that needs further processing, this is frequently used to separate dust from useful materials or eliminate large parts from the bulk product. In addition, a dewatering screen is used to tackle the issue of liquid residue in bottle cases, especially glass or plastic cases. Vibrating machinery can separate the liquid from the material by running the glass or plastic over a screen. The liquid drains out to a designated area, and the material flows onward for additional processing or into a container. This approach is practical and efficient, and attention has been paid to the vibrating screens' design to make cleanup simple.
One of the most frequent requirements in the recycling sector is the effective movement of materials and transportation of those resources between two places. A vibratory conveyor is powered by dual vibrator motor drives and is an effective high-volume conveying solution with little power usage. Since there are no spots where material could become stranded, and the conveying trough does not rapidly wear out, vibrating conveyors do not need routine maintenance as belt conveyors do. Additionally, cleaning up is simple, cutting down on wasted time in this field that values efficiency.
Compressing materials to smooth out peaks and fill can be challenging when filling bulk bags or IBC (intermediate bulk containers) containers with recycled plastic, glass, or metal materials. The uneven portions can start to "cone" and form a peak at the top and frequently stack on top of one another rather than spreading out to the container's corners. A vibrating table can compact the material, promoting a movement towards the container's corners and leveling out the peaked material at the top of the bag. This vibration will ensure filling capacity and bag stability. In addition, low-level vibratory tables are close to the ground. Therefore, they can be made to fit already-existing filling setups because container-filling problems are typically discovered before hopper additions.
Vibratory containers have no moving parts and are simple to clean. Due to their lack of moving parts, vibratory conveyors are easier to clean and require less maintenance than other mechanical conveyors.
Vibratory conveyors feature horsepower requirements that are energy efficient. Vibrating conveyors only need a little horsepower to transport goods. Lower horsepower results in improved energy efficiency and lower running expenses.
Super-quiet operation: A further advantage of the low horsepower is the operation's resulting low noise level, which frequently ranges between 60 and 75 A-weighted decibels (dBA).
Vibratory conveyors feature a strong and maintenance-free design. The robust design enables continuous operation while guarding against spills and leaks that would otherwise need repair and downtime.
There is less need for spare components with vibratory conveyors than with other conveyors.
Vibratory conveyors usually require little energy use (as low as 14p per hour).
Vibratory conveyors’ efficiency leads to increased productivity.
Vibratory conveyors include gentle-start possibilities.
Vibratory conveyors are programmable with a PLC interface.
Vibratory conveyors offer choices for variable speeds that provide complete control of processing rates.
Disadvantages of Vibratory Conveyors
Vibratory conveyors are an expensive investment.
Vibratory conveyors can create “excessive” noise; sound-reduction devices are available at an additional expense.
One must carefully study which vibratory conveyor is most suitable for their specific application.
Industries Where Vibratory Conveyors are Utilized
There are several applications for vibratory conveyors in the agriculture sector. First, they are employed in procedures that prepare vegetables, fruits, and other agricultural products for packaging and shipment to retailers or other processing facilities. In addition, these conveyors are successfully utilized to load large parcels of agricultural products into vehicles so they can be delivered to their intended location. Additionally, vibratory conveyors help process, dry, and store agricultural products very effectively. Vibratory conveyors are used for feeding livestock and moving and processing sugar, tobacco, fertilizer, and fruits. These conveyor belts reduce an agricultural-based facility’s workforce and help decrease operating costs.
These belts make it simple to synchronize agricultural procedures. They handle the methodical materials expertly and produce great turnaround time. These agricultural conveyor belts are created specifically to meet the demands of the industry. As a result, they are both efficient and cost-effective. In addition, they are capable of adapting to any temperature. As a result, various conveyor belts are employed in agricultural applications.
Mining Industry: Through various phases of the mining cycle, ores, concentrates, and tailings are transported using vibratory conveyors. Vibratory conveyors move commodities to stockpiles and ore to feed processing facilities. Depending on the type of mine, conveyors can run for short distances or long distances, such as those used for deep mines or underground activities. The material to be carried and the needed capacity, among other things, affect the vibratory conveyor belts' width. Carry-back and spillage of material, noise, and vibration are a few issues associated with vibratory conveyor systems in mining applications. One must maintain these conveyor systems for mining operations to be highly efficient, effective, and productive.
Chemical Industry: Vibratory conveyors transport fertilizers and chemical powders to make different products like detergents.
Food Industry: The use of vibratory conveyors in the food sector is always significant since they impact how quickly items are transported for cooking. Different conveyor belts are needed for different foods, such as confectionery, baking, dough processing, meat, poultry processing, etc., to transport them from one location to another more effectively and efficiently. In addition, conveyor belts need to be cleaned and sterilized since they come into direct contact with the food that needs to be conveyed. Therefore, always keep a vibratory conveyor’s ability to be easily cleaned in mind when selecting the appropriate conveyor belt within the food industry to ensure that the food's quality is maintained and that there are no losses from contamination. The food industry has always been known for its high standards of quality. Thus, it is important to take great care and precaution when selecting any equipment used in producing or near food.
Maintenance Tips for Vibratory Conveyors
Constant vibration can occasionally cause bolts to become loose in places where they clearly shouldn't be, which could mean they need to be held to the proper tolerances.
Valuable energy is being wasted on making rattling noises rather than driving parts when vibrations occur.
Vibrations cause bowl components that would otherwise be fixed together to rub against each other, causing premature wear and tear.Ensure the system is secure on the surface: A vibratory feeder is designed to function on a level surface, most frequently a heavy weldment or floor. Therefore, ensure the system is level and evenly secured to the floor/weldment. In addition, check that each leveling foot on the feed system support structure is firmly and evenly contacting the ground, if it has any contact. To get the best performance, leveling feet should be adjusted to bring the system as close to level as feasible.
Check the tightness of each bolt on the vibratory feeder: Test each bolt for tightness; start at the feeder bowls and vibratory inline drive units to ensure that the feed system is locked together as intended.
The vibratory conveyor should be equipped with electrical protection measures.
Check the anchor bolts at least once daily during the equipment's initial operation to prevent loosening.
Replace the lithium-based grease and oil the motor thoroughly every two weeks. Add the required amount of lithium-based grease through the oil cup while refueling. An oil cup is not included on the motor when employing sealed bearings.
Grease nipples are present on the running parts, such as the bearing seat and tie rod bearing seat. Therefore, each operating shift should include the injection of lithium- or calcium-based grease to ensure lubrication and normal operation of the moving parts.
The vibration conveyor should have its bearings checked after 1500 hours of operation, and if there is substantial damage, it should be changed immediately.
When an operator notices an anomaly in their work, they should check and stop as soon as possible to fix the problem.
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