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The BJ Magnets’ Magnetic Head Roller (also known as Magnetic Pulley) is the perfect magnetic product to be used as head pulley when imbedded in a conveyor belt and positioned at the “head” of a conveyor belt – at the discharge end, to continuously extract tramp metal contamination from the product running on conveyor belt systems. This is a type of magnetic separator used to remove ferrous metals and other magnetic materials from a conveyor belt or material during the production stream. The magnetic field of the pulley attracts the iron particles which are stuck to the belt until it reaches the underside. As the belt leaves the roller, the impact of magnetic flux of the roller on the belt eventually decreases and dissipates; urging the unwanted contamination to fall from under the belt into a separate repository. Hence, the separated iron particles pass out of the magnetic field and are collected separately into a bin. The cleaned non-ferrous material is discharged normally over the pulley in a vertical drop.
The BJ Magnets’ Magnetic pulley offers a very great efficiency in terms of removal of iron contaminants like nails, spikes, nuts, bolts, cans, and wire from material flowing on conveyor with maintenance-free operation. Regardless of the application, this type of magnet is a low-cost way to remove unwanted ferrous metal from a conveyor belt during the production stream.
The BJ Magnets’ magnetic head roller can be designed not only in a way to fit an existing conveying system, but also can be built to customer’s specification with end shafts supplied to desired requirements. In which case details such as a “crowned” face can be implemented in the design (if necessaire). Even though it being newly built with fitted components, it can alternatively be part of an overall original plant machinery design, in whatever circumstance it will be installed.
PRODUCTS
The BJ Magnets’ Head Pulley Magnet may come either in conical or cylindrical shape, wrapped with stainless steel shell construction, ceramic or rubber lagging which can be produced in different models including but not limited to:
Pulley Lagging: is the covering of the outer surface of the magnetic head pulley to increase the coefficient of friction between the pulley and conveyor belt. Lagging is usually needed when a head pulley is used as a drive pulley on a long conveyor belt. Rubber lagging is the most popular type and it’s primarily used on the larger diameter pulleys.
Several benefits are gained by using pulley lagging as it is manufactured with high quality materials of which design is intended to ensure maximum protection in tough applications – In which case the conveyor belt last longer since they can operate at lower tension; and the pulley shell life is extended due to the protection against abrasion from metal belt fasteners.
Vulcanized Lagging: is the curing of the rubber which results in increased rigidity and durability, as it is less vulnerable to deformation. The vulcanized lagging has increased tensile strength which reduces the risk of physical damage – and this type of lagging can withstand severe temperatures while working continuously.
Herringbone Grid: which offers superior traction and is mainly used on drive pulleys. It displaces water and other liquids between the pulley face and the belt, in which instance the direction of the grooves is very important. The centre point always goes toward the direction of belt travel, as the groove lagging is smooth and very robust.
Chevron Groove: offers superior traction and is mainly used on drive pulleys. It displaces water and other liquids between the pulley face and the belt. Unlike the herringbone, the grooves meet at the pulley centre so the liquid escapes in either direction.
Diamond Groove: is sometimes referred to as a double herringbone and is primarily used for reversing conveyor drive pulleys. The diamond groove has bi-directional pulley rotation, so that it can be used in either direction.
Rough Top Lagging: gives excellent traction without cutting grooves. It is a 2-ply stretch duck fabric that has an irregular surface. The surface is comprised of a nubby rubber strip that is applied to the entire pulley surface to prevent slippage between the pulley and belt. It is used for wet, icy or dirty low-tension applications.
Tape (Safety Walk) Lagging: is an abrasive tape that is adhered to the entire pulley surface to prevent slippage between the pulley and belt. This option provides traction when applied to slippery surfaces and is a reduced cost alternative to other lagging options.
Taper Lock Hubs & Bushings: is a style/brand of bushing for fastening the shaft to the pulley.
XT Hubs & Bushings: is a style/brand of bushing for fastening the shaft to the pulley.
APPLICABLE REQUIREMENTS
The BJ Magnets’ Head Pulley Magnet forces protect your capital plant-equipment while reducing maintenance costs in ensuring highest product purity, not to forget increase up in production time. With the permanent magnet being embedded within the head pulley, it creates a strong magnetic field as the head pulley with a cylindrical or conical shape being wrapped with a rubber or ceramic lagging efficiently separates all ferrous related metals. The magnetic field adheres ferrous contaminants to the belt as clean product passes over the head pulley; in which case tramp metals from the underflow are safely captured in a bin to be discarded. This type of self-cleaning magnet is efficient for use in industries like recycling facilities, aggregate, mining and quarrying, food processing, plastic and wood production, waste management (to name a few) as it thoroughly removes foreign tramp metals from bulk materials on a belt conveyor.
As ferrous metals are attracted to the magnet when the conveyor belt moves, the attracted metals are lifted and separated from the material stream while cleaned material continues along the conveyor belt. This results in efficient separation of ferrous metals at low maintenance cost since no electricity is required; inasmuch as our compact design is energy efficient and easy to install.
The BJ Magnets’ magnetic head roller is designed and manufactured to not only remove unwanted iron from belted materials, but to also prevent machines such as crushers or eddy current separators from getting damaged during downstream processes. Clients who acquired the BJ Magnets’ Head Pulley Magnet have improved their products quality and processes, such as sand, gravel, limestone, recyclables, wood products, food, chemicals, mining, rock products, ceramics, paper, plastics, and rubber.
Fabrication of custom design assemblies involves multiple processes in which case it is critical to have a well-documented quality control procedures as quality control plays a critical role in all aspects.
The BJ Magnets’ Head Pulley Magnet can be produced in varied sizes to meet the requirements of most conveyor system applications with magnetic field strength reaching up to 10,000 Gauss. The eccentric magnet rotor can be adjusted at various angles compared to the external casing. This influences the moment of discharge of the non-ferrous metals. Since the magnet rotor is placed eccentrically in respect of the external casing, the iron particles cannot become attached to the external casing which would cause burn-in problems. The pole system can be adjustable in a way that the application of force can be optimally adjusted for maximum ejection efficiency. In comparison to concentric pole systems, the eccentric pole system increases the metal yield by 50% in which case the service life of the belt and drum shell is considerably lengthened. The shaft supports the head pulley, while the bearings enable smooth rotation of the Pulley Magnet during the production stream.
With more than 15 years of expertise in this industry, BJ Magnets will customise your Magnet Head Pulleys design to meet your specific application needs, which can be manufactured either in Ceramic, Neodymium (NdFeB) or Ferrite. Diameter can also be adapted as per your need, ranging from 150 mm to 1,500 mm. Not to forget the width which can also be designed in dimensions for 300 mm to 2,400 mm – with ability to withstand a temperature that ranges between -20°C to 200°C; of which the conveyor belt speed can reach up to 5 m/s.
As part of the construction, the magnetic pulley is made up of ring magnets fitted on a shaft inside a Stainless Steel 304/316 drum shell. The shaft is made up of steel which is carefully machined from oversize stock to required finished dimensions, and is expected to support the required load. The magnets forming the head pulley are totally well enclosed inside the stainless-steel drum, with features for easy installation in the belt conveyors. Which installation is very simple as it only requires to loosen the conveyor belt, remove the old pulley and install the new magnetized pulley which comes with four bolts on a set of the pillows to block bearings that normally hold the pulley in place.
Hence, before considering acquiring a magnetic pulley, it is crucial to take in consideration the width of the conveyor belt as well as the diameter of the pulley shaft which must match with the diameter of the equipment; such that the selected pulley must fit into the intended conveyor system. With 15 years of experience in design and development of Permanent Magnets and Magnetic Systems, BJ Magnets will assist you in supplying an effective Head Pulley Magnet that is easy to clean and has no maintenance cost as it will help prevent expensive shutdown and delays equipment process line.
The self-cleaning of the magnetic pulley is very effective in terms of separating large as well as fine particles from non-ferrous material. Moreso saying, installing the BJ Magnets’ customized Head Pulley Magnet tailored to your plant will improve your product quality and ultimately enhance your product value.
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Key Components & Roles
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The BJ Magnets’ Head Pulley Magnet – simple but yet effective is a unique combination of design, construction, and operational benefits that makes it an ideal solution for efficient ferrous metals separation in various industries in terms of relevant specialised applications such as wet or dry material processing, high-temperature environments as well as explosive or hazardous environments. Its operating main principles lay on the effectiveness of the magnetic attraction, in consideration of the gravity which depend on the products flow rate, as well as the centrifugal force which is the resultant of the preceded mentioned.
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The BJ Magnets’ Head Pulley Magnet has a permanent magnet embedded within the head pulley which creates a strong magnetic field that extends across the conveyor belt width; which ferrous metals like iron and steel on the conveyor belt are attracted to the magnetic field. The attracted metals are thereafter lifted from the conveyor belt – in which case lifted ferrous metals are separated from the non-magnetic materials. Hence, separated metals are carried by the magnetic field to the pulley’s edge, and are discharged into a collection area; which results in cleaned material being carried further along the conveyor belt. |
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BJ Magnets is ISO 9001:2015 certified company by SABS for Quality Management System. All our Magnetic Separator Equipment are designed, manufactured and supplied under observation of the principles of the HACCP International Food Safety Standard 0909MAGSEP 1-2010. Moreso, to the bargain of their effectiveness, the internal and external aspect of the magnetic equipment is produced according to the food health and safety standard in terms of the building materials; which is austenitic stainless steel of grade 304 or 316. Thereof upon completion, a certificate of Factory Acceptance Test (FAT) which is valid for 12 months is issued; in which case the equipment shall not be subjected to the anual validation.
