Super-sized production

When it comes to manufacturing conveyor belts, orders come in all shapes and sizes. From the minute to the massive, Habasit is committed to meeting customer demands of every proportion.

This commitment was recently expanded when Habasit Sweden took on the production of perhaps the world`s widest conveyor belts for a Nordic customer. With widths of up to 12,2 m by 10 m long, the project presented particular challenges which required outsized originality.

More than 100 sprockets on each shaft. At the first installations normal sprocket design is used but latterly split sprockets are used.

The bulk challenge

The customer needed two types of the M2520 modular belts, including the POM GripTop and the antistatic FlatTop POM/Black PC. The initial task was to work with the customer to find a suitable shaft deflection, as well as square shaft torsion where the drive would be positioned at the end. A shaft length of more than 12 m would mean that it could wind much more than allowed at full load.

The belts were to be assembled on-site at Habasit AB in Hindås, Sweden, but the challenge was to find enough space for production, since there were no assembling tables with a length of 12,2 meters. Instead, the team developed a method to build two meters of belt at a time and then assemble them together at the end. This was also necessary because the full-length belt would otherwise be too heavy to carry and could collapse during transportation. For this unusual size, additional full-length PA Rods had to be developed in cooperation with a Danish company.

How to transport a giant

When it was time to ship the belts, the process required the strength of 15 Habasit employees just to transport them to the 13 m long wooden packing boxes. Although it was an impressive feat of teamwork, the packages were an unprecedented size and suddenly a new issue arose. What truck would be large enough to carry them? They soon realized that the only solution was to take the belts back out of the boxes and bend them so that they fit against the inside walls of the truck. The products could later be returned to the boxes and finally shipped to the end user. Even with the help of the entire shipping and fabrication department, it was a day`s worth of work just to send the colossal belts on their way.

A new size of solution

When the belts finally arrived to their destination, engineers faced the new challenge of how to align the belt with over 100 sprockets per shaft in order to get the correct grip and axial position?

It was a riddle of epic proportions and the answer they discovered is a secret just as big. After all, constructing and transporting supersize belts is a process of experimentation and surprising invention, but one thing is clear, this recent success has once again broadened the boundaries of what Habasit customers can come to expect when it comes to all-sized customized solutions. (ST)

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