C OM P O N EN T S

An Effective Approach to Pulley Design

& Manufacturing
Five Differentiators and One Big Reason They’re So Important

A Superior Industries White Paper

Superior Industries, Inc. | 315 E State Highway 28, Morris MN 56267 | +1 (320) 589-2406 | info@superior-ind.com | www.superior-ind.com
 CONTENTS
Abstract. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
One Big Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pulley Design Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Elite Welding Expertise & Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pulley-Specific Engineers & Proper Application. . . . . . . . . . . . . . . . . 6
Pulley Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
In-House Testing Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Machined-Steel Vs. Cast Iron XT Bushings. . . . . . . . . . . . . . . . . . . . . . 7
Broad Product Range & Expedited Deliveries. . . . . . . . . . . . . . . . . . . 8
Proper Pulley Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2 Superior Industries, Inc. | 315 E State Highway 28, Morris MN 56267

 ABSTRACT

Pulleys are “the heart” of any conveying system – and maximum pulley
life is essential to cost-efficient material handling and high-capacity
production. Importantly, a manufacturer’s approach to pulley design,
manufacturing, and proper application has a direct effect upon pulley
reliability or potential pulley failure. Why is this so? What are the major
differentiators in the design and manufacturing process? And, why are end
users often confused when specifying heavier-class pulleys?

ONE BIG REASON

Look closely at a pulley and conveyor component manufacturer,

particularly when quoting heavier-class pulleys. Why? Above that of the
standard CEMA-duty pulley, there are no standards that govern the load
ratings or material thicknesses of heavier-class pulleys.

“Heavier-class pulleys are not governed by an association, but rather by

“Superior has long been an active and
contributing member of CEMA, playing key
roles in education and the establishment
of quality standards in the industry.”
~Brent Burdette
manufacturers trying to address an emerging market,” says Brent Burdette,
resident sales engineer for Superior Industries. As a result, he says that each
manufacturer has “its own take” on design and manufacturing methods
regarding larger-class pulleys. Component designations vary too – from the
common term of Mine Duty, to Super Duty, Quarry Duty, and more.

“All these varying approaches to design and manufacturing, may lead to

variations in quality and service life, costly misapplications, and confusion
among end users,” says Burdette, who has worked for several major pulley
manufacturers before joining the Superior Industries team. “I always point to
the fact that Superior has long been an active and contributing member of the
Conveyor Equipment Manufacturers Association (CEMA), playing key roles in
education and in establishment of quality standards in the industry,” he says.

RIM In addition, ask your pulley manufacturer to supply you with product
END DISC weights. In most cases, a heavier pulley is a longer-lasting pulley. When
comparing weights, look specifically at the pulleys rim thickness and end
disc thickness. Just like conveyor idlers, belting will wear down the rim over
time. Stronger, thicker rims will last longer. Since it’s the point of connection
to the shaft, the end disc supports all of the weight of the pulley. It takes a
SHAFT
lot of pressure. Comparing end disc thickness is a simple way to determine
which pulley is stronger. Beware of extra, ineffective weight added to the
center disc. This additional weight serves no structural purpose.

+1 (320) 589-2406 | info@superior-ind.com | www.superior-ind.com 3

PULLEY DESIGN CLASSES

CEMA Duty Mine Duty 1.5 Mine Duty 2.0 Super Duty Core Systems® Design

Wing Pulleys – –

Drum Pulleys

Chevron® Pulley – –

Load, dimensions and crown Roughly 1.5X service factor Roughly 2.0X service factor Exceeds 2.0X service factor Custom
Design Standards
defined by ANSI B105.1 of CEMA standard of CEMA standard of CEMA standard Engineered Class

Conveyor Type Light duty, portable Medium duty Heavy duty Extra heavy duty High tonnage

Belt Style Fabric Fabric Fabric Fabric Steel cable or fabric

Belt Burden Not started under load Started under moderate load Started under full load Started under full load Started under full load

Starts and Stops Infrequent Moderate Frequent Frequent Frequent

Feed Characteristics Uniformly loaded Uniformly loaded Non-uniformly loaded Non-uniformly loaded Non-uniformly loaded

4 Superior Industries, Inc. | 315 E State Highway 28, Morris MN 56267

 FIVE TOP DIFFERENTIATORS AT SUPERIOR

1. ELITE WELDING EXPERTISE & TRAINING

Superior Industries operates a state-of-the-art, in-house welding training
center to train its labor force in welding technologies such as shielded metal
arc, gas metal arc, flux-cored arc, gas tungsten arc, and submerged arc, which
creates deeper-penetration welds that are stronger and more precise.

Students also learn numerous weld testing methods. Upon completion

At its on campus weld training center,
Superior welding instructors train and certify
using content approved by the American
Welding Society (AWS) and American Society
of Mechanical Engineering (ASME).
of the intensive program, students can earn certifications from the
American Welding Society (AWS) and the American Society of Mechanical
Engineering (ASME).
“Many are certified to the level of AWS D1.1, a standard that is not often
seen at other pulley manufacturing companies,” says Burdette, who
also points to the relationship between Superior and its sister company,
Westmor Industries, a manufacturer of pressure vessels for the propane
industry. “The propane storage and transport equipment industry demands
top-notch welding technologies and extensive product testing; and this is
the technological knowhow and elite welding expertise that is developed
and shared between our companies,” he adds.

While a majority of conveyor pulley manufacturers practice Metal Insert Gas

(MIG) welding to bond a pulley hub to the end disc and then the end disc
to the rim, Superior utilizes an automated Submerged Arc Welding (SAW).
SAW is a high-efficiency, high-productivity, wire-fed process that is often
used in demanding heavy industrial applications.
GRANULAR FLUX CONSUMABLE
ELECTRODE VACUUM SYSTEM
FROM HOPPER
FOR RECOVERY OF
GRANULAR FLUX
“The weld is encapsulated in a flux, which is a strong benefit for our
BLANKET OF
DIRECTION OF TRAVEL
GRANULAR FLUX
employees,” says Dave Dybdahl, an instructor at Superior’s in-house weld
SLAG
training center. “You don’t have any bright, ultraviolet infrared light and
there is no smoke plume. From a safety standpoint, it creates a much
MOLTEN FLUX MOLTEN
healthier environment for factory employees.
WELD METAL

BASE METAL SOLIDIFIED WELD METAL

In a submerged arc weld, the blanket of
granular flux submerges the welding operation,
preventing sparks, spatter, and radiation.
Since the weld is produced within the flux, SAW maintains extremely
high heat inputs, which means the robotic technology can weld faster
and distortion or warpage is much less. In addition, these automated
welds possess better uniformity, ductility, corrosion resistance and impact
strength. The process is also splatter-free.

+1 (320) 589-2406 | info@superior-ind.com | www.superior-ind.com 5


Superior is equipped with its own group of
employees and equipment for testing pulley
craftsmanship after design and manufacturing.
Finite element analysis (FEA) is a computerized
method for predicting how a product reacts
to real-world forces, vibration, heat, fluid flow,
and other physical effects. Finite element
analysis shows whether a product will break,
wear out, or work the way it was designed.
6 Superior Industries, Inc. | 315 E State Highway 28, Morris MN 56267
2. PULLEY-SPECIFIC ENGINEERS & PROPER APPLICATION
During the quoting and specification process, pulley-specific engineers
work closely with customers on current equipment analysis, application
sizing, and future recommendations.
“It’s a frustration to some end users that manufacturers apply pulleys
differently, and that all mine-duty pulleys are not the same. To address this
situation, we use ‘the service factor’ of the pulley as the quantifiable factor,”
says Burdette. For example, he says, CEMA-duty pulleys are rated as a 1.0
service factor baseline, with mine-duty units being 1.5- to 2.0 times greater
than CEMA-duty, and super-duty units exceeding a 2.0 service factor.
Specifying the right pulley for an application begins by qualifying the
customer’s requirements. Is the operation looking for a component
that addresses additional safety, service, or stress factors? Or, are they
simply seeking the most economical solution? “We have to identify those
interested in the most uptime and service life of a product versus those
looking for the lowest capital costs to get running,” says Burdette.
Another qualifier, says Burdette, is addressing the true purpose of the mine
duty pulley in a given application. Is it to allow the use of a smaller pulley?
Or, is it to increase the service factor of the same-size pulley? “Depending
upon the circumstances, we look at it both ways – meeting both the size
requirements as well as the desired service factor,” he says.
Burdette encourages end users to get at least three quotes when specifying
heavier class pulleys. “Always compare weights. Superior pulleys are likely to
be heavier in weight over that of competitive models; and measurements
of rims and end discs on Superior pulleys exceed those of competitive
models,” he says.
Superior also employs the latest Finite Element Analysis (FEA) design
methods to predict potential failures and allow the engineers to adjust
designs accordingly by translating specs and recommendations into
life-like visualizations. Versus traditional analytical solutions, FEA design
geometry is more complex and far more accurate in predicting the
performance and/or weakness of the design, identifying its safety margins
and determining the optimal design with confidence.
SUPERIOR PULLEY SPECIFICATIONS

CONVEYOR PULLEYS
Pulley Diameter Integral Hub Diameter Face Width Contact Bar Thickness
Pulley Types
inch (mm) inch (mm) inch (mm) inch (mm)

CEMA Duty Drum Pulley 4”- 60” (101 - 1,524) 12” (304) and under 12”- 78” (304 - 1,981) –

CEMA Duty Wing Pulley 6”- 60” (152 - 1,524) – 12”- 78” (304 - 1,981) 1/4” x 1-1/2” min., 3/8” x 1-1/2”, 5/8” x 1-1/2”

Mine Duty 1.5 Drum Pulley 8”- 60” (203 - 1,524) 12” (304) and under 12”- 78” (304 - 1,981) –

Mine Duty 2.0 Drum Pulley 8”- 60” (203 - 1,524) 12” (304) and under 12”- 102” (304 - 2,590) –

Mine Duty 2.0 Wing Pulley 8”- 60” (203 - 1,524) – 12”- 78” (304 - 1,981) 5/8” x 1-1/2” min. (15 x 38)

Super Duty Drum Pulley 10”- 60” (254 - 1,524) 12” (304) and under 12”- 102” (304 - 2,590) –

Super Duty Wing Pulley 10”- 60” (254 - 1,524) – 12”- 78” (304 - 1,981) 3/4” x 2” min. (19 x 50)

CEMA Duty Chevron® Pulley 8”- 36” (203 - 914) All CEMA 12”- 78” (304 - 1,981) 1” x 1/2” half round bar (38)

Mine Duty Chevron® Pulley 12”- 48” (304 - 1,219) Varies 12”- 78” (304 - 1,981) 1” round bar (25)

Super Duty Chevron® Pulley 12”- 48” (304 - 1,219) Varies 12”- 78” (304 - 1,981) 1-1/2” round bar (38)

3. IN-HOUSE TESTING TECHNOLOGIES

Compared to more common cast iron
bushings, Superior utilizes its own machined
steel. Cast iron can turn brittle over time.
While manufacturers often outsource critical testing, Superior Industries
conducts its testing in-house. “For example, we can X-ray test our welds,
and we can complete Nondestructive Testing (NDT) in-house. This plays
an important role in assuring that structural and mechanical components
perform their function in a safe, reliable, and cost-effective manner,” says
Burdette. He explains that NDT allows for careful and thorough materials
evaluation without the need for deconstruction or damage. NDT can be
used prior to the use of a component for quality control purposes, or it
can be employed while components are in use to detect service-related
conditions caused by wear, fatigue, corrosion, or stress. Maintaining
in-house NDT technicians strengthens quality control standards, while
streamlining manufacturing processes and contributing to faster lead times.
4. MACHINED-STEEL VS. CAST IRON XT BUSHINGS
“Versus a cast iron bushing, our XT bushings are machined steel, which
gives added strength. As a standard bushing, most manufacturers
offer a cast iron bushing, which is not as maintenance-friendly and
tends to get quite brittle over time,” says Burdette. “The operations
and maintenance crews really love steel bushings. If they ever take
out a shaft for some reason, or re-lag the pulley, they don’t have to
buy a new set of bushings, or damage the pulley,” he explains.

+1 (320) 589-2406 | info@superior-ind.com | www.superior-ind.com 7

 While proven to reduce pulley failure, XT bushings are designed
specifically for applications with two hubs versus a single hub; and bushing
PROPER PULLEY SELECTION applications such as drive sheaves and sprockets. The XT design yields
1. New or replacement? more calculable and consistent variables, allowing the specification of
2. If replacement, any issues or failures the right pulley for the application – and ensuring maximum pulley life.
with current?
3. Construction and size dependent on: 5. BROAD PRODUCT RANGE & EXPEDITED DELIVERIES
Tensions/Loading Superior Industries offers a broad range of conveyor pulley styles, sizes, and
• Motor classes from CEMA-duty to Mine Duty, Super Duty, and Engineered Class.
• Belt Speed
• Wrap Angle Engineered Class pulleys are specifically designed to meet the load
• Belt Specifications conditions of a specific conveyor in applications such as overland
conveyors, high-tonnage mining conveyors, large coal power plants, gold
Drive mines, and large capital projects. “There are pulley manufacturers who
• Reducer do not offer engineered class, as they do not have the in-house analysis
• Coupling expertise to tackle these applications with a certain level of confidence,”
• Sprocket says Burdette.
• Backstop
Importantly, adds Burdette, “We offer the industry’s fastest lead times on
Material both standard and custom-designed orders.” He attributes that to the
• Tons Per Hour in-stock availability of standard products from primary distributors; and
• Lump Size to all the in-house skill and expertise from pulley-specific engineers to
• Material Type elite welders, critical testing methods, and advantages such as in-house
vulcanization, which speeds lead times and improves quality.
Location/Function
• Tunnel Superior Industries maintains three pulley manufacturing plants,
• Power Plant strategically-located in the Midwest, Southwest and Southeast United
• Ship States, plus three plants in South America.
• Primary Conveyor
• Plant Feed With a vast history as a single-source supplier of material handling systems
and conveyor components, today’s Superior Industries offers material
processing solutions from the Rock Face to Load Out® – everything from the
feed point to crushing, screening, conveying, and loading/unloading systems.

SPWP1218ENPR-01

8 Superior Industries, Inc. | 315 E State Highway 28, Morris MN 56267