What are Traditional Design Wing Pulleys?
Also known as self-cleaning pulleys, wing pulleys are primarily used on the tail end of bulk handling systems where loose materials have a tendency to reside on the underside of the conveyor belt, causing damage to one or both components. Wing pulleys incorporate a non-continuous contact surface comprised of individual wings or fins. This construction results in the creation of open voids that allow loose material to fall away from the contact surface. In applications where continuous contact is desired, spiral wing pulleys can be utilized. The difference between wing pulley configurations is component thickness and the use of supplemental reinforcing agents. The thicker the components used, the greater the series name (heavy, mine, etc.). Furthermore, to brace the components under the heavier loads, wing pulleys utilize stiffening agents such as gussets and reinforcing rings between wing members. Because diameter plays a role in pulley capacity, not all configurations are available in all diameters.
Product Offering
The Dominator Heavy Duty Wing Pulley
The patented design of the Dominator 8-12” diameter Heavy Duty (HD) Wing Pulley maximizes the material cleanout rate by incorporating the proven design features of The Eradicator® Wing. Self-gusseted angled wings provide reinforcement to prevent wing fold over better than a non-gusseted design.
For bulk handling applications where material removal is desired and moderate to heavy impact or extreme loading is likely. Available in four hub styles and features double wing supports to reinforce the tips to prevent wing fold over.
Diameters Available: 8″ thru 12″
HUB TYPES:
Hub style availability will vary based on pulley construction.
Patent# 8,857,606
The Deflector® Wing Pulley
The Deflector 14-52” diameter Heavy Duty (HD) Wing Pulley increases the performance of a traditional wing pulley with the addition of PCI’s proven and patented ports coupled with angled deflectors to continuously direct material to the outer edges of the pulley. The combination of these features enables the Deflector to cleanout 5 times faster than a traditional wing pulley.
For bulk handling applications where material removal is desired and moderate to heavy impact or extreme loading is likely. Available in four hub styles and features gussets to reinforce the wing members.
Diameters Available: 14″ thru 52″
HUB TYPES:
Hub style availability will vary based on pulley construction.
Patent# 8,857,606
Patent# 10,442,631
How Does it Work?
Traditional wing pulleys feature straight wings that contact the belt intermittently, entrapping and recirculating material rather than displacing it, often leading to belt damage and pulley failure. The Deflector wing pulley utilizes the same straight wing members as a traditional wing pulley but drastically improves cleanout efficiency from its cleanout ports and patent pending deflectors. The accelerated cleanout produced by the deflectors and ports will provide longer component life for the pulley and the belt.
Because the Deflector wing pulley improves on the performance of a traditional wing pulley, any bulk material application where a traditional wing pulley is being used will benefit from the Deflector. However, if maximum cleanout efficiency is desired, no other conveyor pulley will perform as well as the Eradicator.
Mine Duty Wing Pulleys
Mine Duty wings are designed for more demanding bulk handling applications where material removal is desired and extreme loading is highly likely. Available in three hub styles and feature gussets and reinforcing rings to stabilize wing members.
Diameters Available: 12″ thru 52″
HUB TYPES:
Welded Compression Hubs with Bushings
Keyless Locking Devices
Dead Shaft Assembly
Hub style availability will vary based on pulley construction.
Standard Duty Wing Pulleys
Standard Duty wings are designed for light to medium duty bulk handling applications where material removal is desired but impact or extreme loading is unlikely. Available in several hub styles and utilize flat tips to maximize contact and rigidity.
Diameters Available: 6″ thru 12″
HUB TYPES:
Hub style availability will vary based on pulley construction.
Squirrel Cage
Squirrel cage pulleys are comprised of solid steel round bars welded to a series of disks which serve as the pulleys core. The open body construction provides for added clean-out over round bar or standard wing pulley designs.
Round / Beater Bar
Beater bar (round bar) designs feature a series of solid steel round bars welded to a tube or pipe core. The robust construction provides an increased safety factor in harsh environments.
7-Shaped
7-Shaped wing pulleys feature steel wing members formed to a bent shape resembling the number seven. The profile of the wing member reduces belt wear while providing an economical construction for light duty applications.
Solid Core
Solid core pulleys offer self-cleaning benefits in the smallest of pulley diameters. Wing members can be designed using profiles including fins with flat tips, round bar or custom profiles.
For the Optimum in Cleaning Solutions – See the patented PCI® Eradicator® Wing Pulley Products
The Eradicator®
The Eradicator wing pulley retains the belt cleaning benefits of a traditional wing while providing continuous belt contact and improved cleanout efficiency.
The Eradicator®-MAX
The Eradicator-MAX wing pulley combines the unmatched cleanout rates of the Eradicator with maximum wear- life and strength at all diameters.
The Ice Eradicator®
PCI’s Ice Eradicator is the world’s first proven solution to temper the costly effects of frozen conveyor belts. The Ice Eradicator wing pulley’s elevated temperature prevents snow and ice build-up between the wings during continuous operation or during shutdown. PCI’s innovative technology can also be adapted to an Eradicator drum pulley.
Frequently Asked Questions (FAQs)
Does a pulley’s load capacity increase by increasing pulley material thicknesses?
While component thicknesses do contribute to overall pulley capacity, shaft diameter plays the primary role in achieving a desired load capacity. In other words, selecting a pulley with thicker components (Mine Duty over Heavy Duty, MC Series over FC Series) won’t necessarily achieve a greater load capacity if the axle is not sized to accommodate the application loads.
What is the longest length of conveyor pulley that PCI can offer?
PCI can manufacture pulleys with face lengths greater than 14 feet. Pulleys of this length require special consideration to account for shaft deflection. Small diameter pulleys of increased face length commonly utilize fixed stub shafts in place of traditional through shaft designs. Fixed stub shafts decrease the likelihood of end disk fatigue, as a result of shaft deflection. (For additional information, please see PCI Pulley Selection Guide)
When is a hub keyway needed in a conveyor pulley?
The purpose of a hub keyway is to help the transmission of torque from a shaft to the pulley in a drive application. Hub keyways are utilized on pulleys that are driving a belt. Most often, the pulley and belt are being turned by the shaft which is being powered by a motor, gearbox, or sprocket. The hub keyways provide the bushing another point of contact to help drive the torque from the motor or gearbox.
When is a hub keyway NOT needed in a conveyor pulley?
The pulley that is in a non-drive position, is driven by the belt and not the shaft. When utilizing compression hubs and bushings there is sufficient grip on the shaft from the bushings themselves. A hub keyway is not needed for pulleys that operate in driven (non-drive) positions.
Wing: What applications benefit from using a Wing Style conveyor pulley?
Also known as self-cleaning pulleys, wing pulleys are primarily used on the tail end of bulk handling systems where loose materials tend to reside on the underside of the conveyor belt, causing damage to one or both components. Wing pulleys incorporate a non-continuous contact surface comprised of individual wings or fins. This construction results in the creation of open voids that allow loose material to fall away from the contact surface. In applications where continuous contact is desired, a spiral style or Eradicator® Wing pulley can be utilized.
Wing: How do I specify additional reinforcing agents such as gussets and reinforcing rings?
While we welcome your custom designs, PCI has designed our Wing Pulleys with standard options for construction choices like gussets and reinforcing rings. PCI Heavy Duty Wing pulleys feature the use of gussets while PCI Mine Duty Wing pulleys feature gussets and reinforcing rings as a standard design detail.
Product Specific Resources
PCI Wing Pulleys – Traditional Styles
PCI Wing Pulleys – All Self Cleaning
Downloads
The Eradicator®
Pulley Assemblies
Dead Shaft Assemblies
Spiral Designs Also Available
Lagging & Tip Options
