DURAFLEX Product Guide · SPROCKET CHART 3/8" (36 CNT) PITCH DURA FLEX™ SPROCKET CHART # of TEETH O.D. MAX. BORE (with key) # of TEETH ... The diameter of the shaft the sprocket

DURAFLEX™ Product Guide

Section i: Cheat Sheet Advantages:

Can be spliced in as little as 30 seconds

Truly hinges

Longer belt life then Flat Flex

Easy to Clean

Belt openings can be varied depending on product support required

Tight transfers

Less Stretch

Specifications: Belt Pitch: 1/2” (12.7mm); 3/8” Nominal (36 Count) (8.5mm) Actual

Flat Strip: .162” x .035” (4.11mm x .89mm) “Kwik Connect” Rod: .050” (1.27mm) Edge Construction: Clinched Edge Belt Width Range: 4” to 144” (101.6mm to 3,658mm) Materials: Strip = ½ hard T-302

Rod = ¾ hard T-302 Belt weight: 1/2” Pitch ** 1.01 lbs/sq. ft. 3/8” Pitch ** 1.54 lbs/sq. ft. **Weight depended on number of sprocket lanes

Standard Sprocket Sizes: Available in UHMW-PE and T-303 s/s

1/2" PITCH DURA FLEX™ SPROCKET CHART

3/8" (36 CNT) PITCH DURA FLEX™

SPROCKET CHART

# of TEETH O.D.

MAX. BORE (with key)

# of TEETH O.D.


9 1.54 5/8 13 1.51 5/8

13 2.19 1 1/8 19 2.16 1 1/8

15 2.51 1 3/8 23 2.58 1 3/8

19 3.16 1 3/4 27 3.01 1 3/4

25 4.12 2 1/2 37 4.07 2 1/2

Nose Bar Size: 1/2” PITCH = 3/4” minimum diameter 3/8” PITCH = 3/8” minimum diameter

Tension Limits for Dura Flex™ Belts: Straight Running Applications: 1/2” pitch 22 lbs per bend 3/8” pitch 22 lbs per bend Maximum Load per sprocket: S/S = 44 lbs Acetal = 52 lbs Current Standards: Breaders: 1/2” Pitch: 40” wide 10 sprocket Main and Hopper Belts 34” wide 8 sprocket Main and Hopper Belts

Information Required to Quote Dura Flex™: Belt width (inches): _________ Belt Pitch (1/2” or 3/8”): _________ Number of Sprocket Lanes: __________ Belt Length (feet): __________

Information Required to perform Dura Flex™ Application Evaluation: Belt Width (inches): ____________ Belt Pitch (1/2” or 3/8”): ____________ Belt Length (feet): ____________ Application: ____________ Max. Temperature: ____________ Nose Bar Diameter: ____________ Nose Bar Configuration: ____________ Product size (inches): ____________ Product Weight (lbs/sq. ft.): ____________ Support bed (top): ____________ Support bed (bottom): ____________ Conveyor Length (ft): ____________ Belt Speed (ft per minute): ____________ Drive Sprocket Diameter (inches): ____________ Drive Shaft Diameter (inches): ____________ Tail Shaft Diameter (inches): ____________ Distance between bearings: (inches): ____________

Replacement Belts: Number of Sprocket lanes: ____________ Number of Actual Sprockets: ____________

Section 1: General Information

Terms:

Belt Width (BW): Overall measurement from the outside of “Kwik Connect” rod to outside of rod. Length (BL): Overall Length of belt. Number of Sprockets (SL): Number sprocket lanes across the width of the belt. Belt Pitch (BP): Measurement from centerline of rod to centerline of rod. Ex. 1/2” or 3/8” Sprocket Centers (SC): Measurement from centerline of sprocket to centerline of sprocket. Minimum - 2 ½” Maximum - 8 ½” Average Spacing 6”

Intermediate Spaces: The openings in between the sprocket lanes. Wicket / Picket: 0.035” x 0.162” ½ hard T-302 Stainless Steel strip. “Kwik Connect” Rod: 0.050” Ø ¾ hard T-302 Stainless Steel wire. Outside Diameter: Overall dimension of sprocket. Pitch Diameter: Theoretical line where the rod of the belt engages the tooth of the sprocket. Root Diameter: The diameter tangent to the bottoms of the tooth spaces, also known as bottom diameter. Bore: The diameter of the shaft the sprocket is going to be used in combination with. Keyway: A keyway is used in conjunction with a key to ensure the sprocket teeth are aligned properly. Keyway size is based on specific standards for shaft diameters.

Section 2: Product Specifications Belt (1/2” and 3/8” Pitch):

Strip Dimensions and Tolerances: Thickness: 0.035” ± 0.001” Width: 0.162” ± 0.003” Finish: 2B Edge: #4 rolled

Chemical composition may only be type T-304, T-302 or T-301 Stainless Steel Tensile Strength: 165-230 ksi Rod Dimensions and Tolerances: Diameter: 0.050” Ø ± 0.001” Finish: smooth bright finish Chemical composition may only be T-302 Stainless Steel Tensile Strength: 220-250 ksi

Sprockets: Acetal: Natural (USDA/FDA Approved) Stainless Steel: T-303

1/2" PITCH DURA FLEX™ SPROCKET CHART

3/8" (36 CNT) PITCH DURA FLEX™

SPROCKET CHART

# of TEETH O.D.


# of TEETH O.D.


9 1.54 5/8 13 1.51 5/8

13 2.19 1 1/8 19 2.16 1 1/8

15 2.51 1 3/8 23 2.58 1 3/8

19 3.16 1 3/4 27 3.01 1 3/4

25 4.12 2 1/2 37 4.07 2 1/2

Custom sizes can be made at an additional cost and lead time. Flights and Flight Clips: A variety of flights can and have been designed for Dura Flex™. Attachment hole placement in the flight is the most critical dimension. Holes should line up with non-drive sprocket lanes.

For flight clips see drawing 26499-01 Rev. A (1/2” pitch only) Drawing file location: S:\ENGINEERING\New Eng Drawings 25000 +

Note: Can be made at an additional cost and lead time.

Section 3: Applications Dura Flex™ can be used as a drop in replacement for virtually all applications that currently use Flat Flex, Flexx Flow and DuraHinge. The exceptions would be 1/8” , 1/4” belts or a nose roller smaller then 3/8” diameter for 3/8” pitch and 3/4” diameter for 1/2” pitch.

Section 4: Maintenance

Sprocket Location:

picture 1

Helpful hints prior to beginning installation and start up

Dura Flex™ works with existing slider pans, slider beds and support rails.

There is no top or bottom to the belt. Try and make sure unit is as square as possible.

Belt path should be free of any obstructions. Ensure sprockets are properly engaged in openings as explained in

picture 1 and that they are engaged in the same openings across the full width of belt.

Make sure edges of belt are not rubbing on anything. Run the system with minimum tension. (allowed by process)

Installing Sprockets & Nosebars Installing drive sprockets

Use the belt as a template to set up drive sprockets.

Dual tooth sprockets engage in drive (smaller) openings of belt across width.

Make sure sprocket teeth are engaged in same openings

across full width of belt. Ensure sprocket teeth are driving against the connecting rods

(not the strip). The degree of wrap on sprockets should be no more than 180

degrees. Key sprockets down on the shaft – or dimple shaft.

picture 2

Bend or remove pan “tabs” as needed to correctly install sprockets

*IF USING NOSEBARS- for 1/2” pitch belt 3/4" (.75) Minimum Diameter and for 3/8” pitch belt 3/8” (.375) Minimum Diameter.

** SEE DRAWING 3 INDICATING NOSE ROLLER SUPPORT MODIFICATIONS FOR FINGERS

picture 3

Nose Roller Stock sizes: 3/4",1”,1 1/4" and 1 1/2" Diameters

Cut flanged nose rollers to required length

*** If using beater blocks (Vibratory Blocks) SEE DRAWING 4 indicating

beater block placement – they need to be located underneath of Drive openings (Small Openings) in order to clear out material build up and

decrease wear on beater block.

picture 4

B) Installing idle sprockets

To set up idle sprockets use belt as template to determine sprocket placement.

Place idle sprockets in one opening over from smaller openings so that 1 tooth is engaged in smaller opening and 1 tooth is engaged

in longer opening. Ensure sprocket teeth are engaging against the connecting rods

(not the strip), keep in mind that the belt engages the sprocket on

idler shafts therefore the openings will be different than the drive. Key all idle sprockets down onto shaft.

picture 5

Rod Orientation

Making the Belt Endless If take-up on the conveyor is adjustable, set to minimum for installation.

Orient belt for proper direction of travel, see picture 6. If installation under tension is required, pull ends so they mesh together

and use wire ties to secure belt ends for rod insertion. Locate hooked end Kwik Connect rods supplied with belting and orient as

shown in picture 6.

Take hooked Kwik Connect rod supplied with the belt and insert, being

certain to engage all openings. Refer to pictures 7 & 8.

When rod is approximately 1/2” from being fully inserted, orient it so the hook fits over the tab on insertion side.

Lock hooked edge of rod around tab on opposite belt edge. Apply minimum amount of tension required.

Incorrect Correct

picture 6

picture 7 picture 8

When starting up the unit for the first time, run slowly to ensure

smooth operation of belting and proper sprocket placement

Removing the Belt Should you need to remove belt from the unit simply cut the Kwik

connect rod. BE CAREFUL NOT TO CUT THE STRIP!

No! Yes!

Cut rod only

Section 5: Market Competitors: Wire Belt of America: Flat-Flex, XT and Flat-Flex Metric, CompactGrid Advantages:

Cheap

Well established (OEM’s design equipment around their product)

Flexible Belt with large open area Disadvantages:

Short Life (more down time)

Does not truly hinge

Requires large back bends

Hard to splice

Special tools required

Knuckles in belt prevents changing to other styles unless unit is modified

Many variations makes a lot of stock

Can snag easily

Stretch

Edge curl

Lumsden: Flexx Flow

Advantages:

Cheap

“Me Too” Product

Flexible Belt with large open area

Disadvantages:




Hard to splice



Can snag easily

Stretch

Edge curl

Maertens: Rod Network Belts, ELT (extended life time)

Advantages:

Cheap


Chain Edge construction (different then others)


Disadvantages:



Hard to splice



Can snag easily

Stretch

Edge curl

Maryland Wire Belts: Dura-Hinge

Advantages:

Z-Bends hinge

Stronger then Competition



Disadvantages:



Hard to splice



Can snag easily

Stretch

Edge curl

OEM’s: JBT FoodTech: (John Bean Technologies) formerly– Stein, FMC (food technology)

Freezing Equipment : Meat, Seafood, Poultry and Vegetables

Cooking Equipment: Meat, Seafood, Poultry, Vegetables and Bakeries

Breading Equipment: Seafood, Poultry

Canning Equipment:

Forming – Cutting, Slicing HEAT and CONTROL:

Meat, Poultry and Seafood Processing Equipment: Fryers, Ovens, Branding, Battering and Breading

MP Equipment:

Meat, Poultry and Seafood Processing Equipment: LAWRANCE EQUIPMENT:

Tortilla Processing Equipment: Coolers

JC Ford

Casa Herrera

END USERS: Poultry:

Tyson’s

Pilgrim’s Pride

Perdue

Mountaire

Criders

Simmons

Maple Leaf Poultry (Canada) Potatoes:

Lamb Weston/ConAgra

JR Simplot

Ore Ida Appetizer Plants:

Rich Sea Pack

ConAgra

Section 6: Required Customer Information Information Required to Quote Dura Flex™: Belt width (inches): _________ Belt Pitch (1/2” or 3/8”): _________ Number of Sprocket Lanes: __________ Belt Length (feet): __________

Information Required to perform Dura Flex™ Application Evaluation: Belt Width (inches): ____________ Belt Pitch (1/2” or 3/8”): ____________ Belt Length (feet): ____________ Application: ____________

Max. Temperature: ____________ Nose Bar Diameter: ____________ Nose Bar Configuration: ____________ Product size (inches): ____________ Product Weight (lbs/sq. ft.): ____________ Support bed (top): ____________ Support bed (bottom): ____________ Conveyor Length (ft): ____________ Belt Speed (ft per minute): ____________ Drive Sprocket Diameter (inches): ____________ Drive Shaft Diameter (inches): ____________ Tail Shaft Diameter (inches): ____________ Distance between bearings: (inches): ____________

Replacement Belts: Number of Sprocket lanes: ____________ Number of Actual Sprockets: ____________

Section 7: Troubleshooting

Problem Suggestion

One edge of the belt is leading

the other.

Check to make sure belt has not

jumped sprockets.

You see a pronounced gap in

belt openings.

Check to make sure belt is spliced

properly and that connecting rod passes through all openings.

You notice edge damage on the belt.

Check to make sure the belt path is free and clear of obstruction.

You notice deflection across

the width of the belt.

Check to make sure the sprockets are

properly aligned across the width of the belt or if using nose bar check to make

sure diameter is sufficient.

You notice the rods ends are

turned so they are not parallel

with the surface of the belt (one or both edges).

Check to make sure nothing his hitting

the edge(s) of the belt.

You notice the belt is loose on one side of the belt and tight

on the other side.

Check to make sure the drive and tail shafts are square.

You notice the belt tracks to one side.

Check to make sure the belt supports have not moved and the take-up is

adjusted even on both sides.

You notice the belt is cupped

inward in between the nose

rollers.

Check to make sure the nose rollers are

located inline with the sprocket lanes

(small openings).

You notice rod breaks. (Within

the belt and at the hook) Check to make sure sprockets are

engaged properly with the belt. Nose bar and drive shaft are square. Nothing

is hitting the edge of the belt.

You notice sprocket wear. Check to make sure belt is engaged properly with the sprockets. Make sure

sprocket teeth are engaging the belt rods. Check the load per sprocket.

Section 8: Engineering Product / Application Specifications:

Dura Flex™ Application Guidelines

Same sprockets used on Drive and tail shafts. Both should be keyed

Support Bed: Longitudinal rails, Herringbone support bed and solid pan support bed. Typical Longitudinal rail spacing is 6”- 8” and Herringbone spacing 10”- 12” (For heavy loads consult Cambridge International Engineering)

Maximum bed speed: 75 fpm (belt can be run at higher speeds…product load, support bed, unit length and customer’s expectations should be taken into consideration)

Nose Rolls: 1/2” Pitch (24 count) 3/4”Ø min.; 3/8” Pitch (36 count) 3/8” Ø min.

Splicing is accomplished with the “Kwik Connect” and side access. Internal splicing can be accommodated with 3 piece connecting rod system. (Available upon request)

Dura Flex™ belt weight is calculated from the following formulas: Variables:

Belt Width: (BW)

Belt Pitch: (BP) 1/2” = 24 count ; 3/8” = 36 count

Sprocket Lanes: (SL)

Sprocket Centers: (SC): (minimum spacing 2 1/2” maximum 8 1/2”) SC = (BW- 1.5”) / (SL-1) Rod Weight: (RW) per lineal foot: RW = (BW+.375”)* BP * 0.000569 NOTE: 0.000569 is derived from volume of a cylinder in cubic inches using length as a variable multiplied by .29 pounds per cubic inch density. Ex. (3.1416*(.050/2) ^2*.29 lbs/in^3) Strip Weight: (SW) per lineal foot:

SW = (BW+.25”+ (((SC-1)*6+4)*IF (BP=24 then .585”); IF (BP=36 then .46”)))*BP*0.00147 – (BP*.00026*((SC-1)*6+4))

NOTES: The length of the vertical legs (bends) is calculated using (1 pitch + 1 rod Ø + 1 strip thickness) for 1/2” pitch (24 count) ex. .500”+.050”+.035”=.585”, for 3/8” pitch (36 count) ex. .375”+.050”+.035”=.46”, 0.00147 is derived from the volume of a rectangular extrusion using length as a variable multiplied by .29 pounds cubic inch density and assumes no angle for the wicket legs. Ex. .035”*.162”*.29*.894 = 0.00147 (.894 compensates for geometry fudge factor) (BP*.00026*((SC-1)*6+4)) = this equation removes the slug weight from the strip. .00026 is derived from the volume of slug (.035” x .068 x .1884”) multiplied by .29 pounds cubic inch density then multiplied by 2 slugs per bend. Belt Weight per lineal foot: Belt Weight = RW + SW

Section 9: Evaluation Calculations

NOTES:

Drive tension is calculated by using standard formulas in Cambridge Intl. Engineering handbook (Ref. pages 77-78).

At 75% of the belt and sprocket capacity a message will appear stating the belt is over tensioned. This was done to alert user to take a closer look at application parameters.

Belt Strength is calculated using the following formula: ((SL-1)*6+4)*22/1.5= Working Tension

Section 10: Manual Estimating

Dura Flex™ Estimating Formulas

Enter Variables

Width in inches, W = 25 = BELT WIDTH IN INCHES (BW)

Belt Pitch (3/8"=36 or 1/2"=24) 24 = NUMBER OF RODS PER FOOT (BP)

Length in Feet, L = 100 = BELT LENGTH IN FEET (BL)

Number Of Sprocket, S = 5 = NUMBER OF SPROCKET LANES (SL) (across the width of the belt)

Sprockets C-C, SS = 5.875 = THE CENTER TO CENTER MEASUREMENT BETWEEN SPROCKET LANES (SS)

Machine Speed = 193 = BENDS PER MINUTE (MS)

(98.831)*(NB/SS)^0.43 **This equation derates the machine speed based on openness of the belt

Number of Bends = 28 = NUMBER OF BENDS PER WICKET (NB)

Calculations

(SL-1)*6+4

Labor

2310 Rod Straightening (hrs) 1.80 = TIME REQUIRED TO STRAIGHTEN RODS FOR COMPLETE JOB

=((BP/9*0.000192)*(BW+0.375)*BL)+0.5

Clinching (hrs)

2344 Inspection (hrs) 0.30 = AT PRESENT NO EXTRA TIME IS ADDED FOR

CLINCHING. THE CLINCHING PROCESS IS PERFORMED IN LINE WITH FORMING AND ASSEMBLY

Form and Assemble (2 hr setup) 10.93 = TIME REQUIRED TO FORM WICKETS AND ASSEMBLE BELTING (including setup)

(((((SL*4)+(SL-1)*2)*BL*(BP/45))/MS)+2)

* 45 = machine up time per hour

2334 Form, Assemble and Clinch (hrs) 11.23

Total Labor (hrs) 13.03 = TOTAL HOURS INCLUDING SETUP TO COMPLETE JOB

2310 ROD STRAIGHTEN + 2344 INSPECTION + FORM AND ASSEMBLE

Material

Rod Material (lbs) 43.32 = POUNDS OF ROD MATERIAL NEEDED TO MAKE COMPLETE JOB (including scrap)

BL*(BW+0.375)*(BP*0.000569)*1.25

Strip Material (lbs) 172.17 = POUNDS OF STRIP MATERIAL NEEDED TO MAKE COMPLETE JOB (including scrap)

((SL+0.25+(SL*4*IF(BP=24,0.585,0.46))+(SL-1)*2 *IF(BP=24,0.585,0.46))*(BP*0.00147)*BL) *1.038

Rod Information

# of Rods Required: (this includes 15 splice) 2485 =

NUMBER OF RODS REQUIRED FOR COMPLETE JOB. THIS INCLUDES EXTRA RODS

Rod Length (in) 25.38 ROD RUN LENGTH

ROUNDUP(C7*24+25+(C7/50*30),0)

NOTE: 0.000569 is derived from volume of a cylinder in cubic inches using length as a variable multiplied by .29 pounds per cubic inch density. Ex. (3.1416*(.050/2) ^2*.29 lbs/in^3) If statements were used to determine vertical leg length based on belt pitch (i.e. 24 count =.585” and 36 count = .46”) 0.00147 = The rectangular area of the strip multiplied by .29 density of the material. (Ex. .035*.162*.29 *.894 = .00147 (.894 compensates for geometry fudge factor) *** 1.038 Accounts for the scrap rate of strip. 1.038 is the typical scrap rate for flat wire based products.

Documents

DURAFLEX Product Guide · SPROCKET CHART 3/8" (36 CNT) PITCH DURA FLEX™ SPROCKET CHART # of TEETH O.D. MAX. BORE (with key) # of TEETH ... The diameter of the shaft the sprocket