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Pulley Set
Precision-balanced, rubber-lagged drive and tail pulleys for aggregate conveyor belts in the AVL-DMP cold-feed and reclaim systems.
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At a glance
| Shell diameter | 250–630 mm (10"–25") |
|---|---|
| Face width | 400–1,200 mm (16"–48") |
| Shaft diameter | 60–120 mm |
| Shell material | S355 structural steel, minimum 10 mm wall |
| Drive lagging | 10–12 mm bonded rubber, Shore A 60–65, diamond/herringbone |
| Dynamic balance grade | ISO 1940 G6.3 |
| Bearing housing | Cast-iron pillow-block, labyrinth-sealed |
| Maximum belt speed | Up to 2.5 m/s |
Overview
The pulley set comprises the drive (head) pulley and tail (return) pulley that define the two ends of each conveyor belt in the AVL-DMP — including the cold-aggregate feed conveyors, the reclaimed asphalt pavement (RAP) feed belt, and the fines return conveyor. Drive pulleys transmit motor torque through lagging to the belt surface; tail pulleys maintain take-up tension and guide the return strand cleanly back to the feed end.
Pulley geometry, dynamic balance, and lagging condition directly affect belt tracking, throughput consistency, and the service life of the conveyor belt itself — which is typically the single most expensive wear item on the conveyor system. A full pulley set replacement, when completed at the correct maintenance interval, protects belt investment and eliminates the belt-wander and spillage that reduce aggregate accuracy.
Function
The drive pulley converts rotary torque from the conveyor gearmotor into linear belt motion; the tail pulley maintains the belt loop geometry and allows controlled take-up tensioning. Correct lagging on the drive pulley maximises the coefficient of friction between pulley shell and belt backing, preventing slip under wet or dusty conditions typical of aggregate handling. An unbalanced pulley induces cyclical belt tension variation that causes splice fatigue, edge cracking, and erratic weigh-feeder readings. The tail pulley must rotate freely and true; a seized or eccentrically worn tail pulley causes the belt to track to one side, leading to edge damage and material spillage onto the plant structure.
Construction & quality
Shells are fabricated from S355 structural steel tube (minimum wall thickness 10 mm for widths up to 800 mm; 12 mm for wider belts) with full-penetration-welded end discs and stub-shaft assemblies. Shafts are machined from C45 steel, ground to h6 tolerance on bearing seating diameters, and inspected for straightness to within 0.05 mm TIR. Drive pulley shells are fitted with 10–12 mm bonded natural-rubber or SBR lagging, Shore A 60–65 hardness, in diamond-groove or herringbone pattern to expel trapped material and maintain grip. Tail pulleys are supplied plain or with spiral-groove lagging for self-cleaning in muddy aggregate environments. All completed assemblies are dynamically balanced to ISO 1940 G6.3 or better. Bearing housings are cast-iron pillow-block (SNL or equivalent) with labyrinth seals pre-packed with NLGI 2 lithium-complex grease.
When to replace
- Lagging delamination, grooving, or chunks missing from the drive pulley shell surface
- Belt tracking persistently to one side despite full take-up and tracking-roller adjustment
- Audible rumble, roughness, or intermittent knocking from pulley bearing housings
- Visible shell denting, out-of-round deformation, or weld cracking on the pulley rim
- Repeated belt slippage under normal load even after correct take-up tension is applied
Compatibility & fitment
Pulley sets are sized for belt widths of 400 mm to 1,200 mm across AVL-DMP plant capacities from 40 TPH to 160 TPH; Avelta matches shell diameter, face width, shaft dimensions, lagging type, and bearing housing specification to each customer's conveyor configuration.
Why buy from Avelta
Every Avelta pulley leaves the factory dynamically balanced, with weld integrity confirmed by ultrasonic inspection and lagging adhesion verified before despatch — eliminating the field vibration and belt-wander problems common with generic replacement pulleys. Matched bearing housings and grease are included in the supply, making the assembly a single-source, ready-to-install unit.
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