Magnetic Head Pulley Design & Operation
Magnetic pulleys are non-electric, self-cleaning, magnetic separators that operate as head pulleys on conveyors. Dings pulleys are constructed of a Ceramic VIII magnetic core encased in a protective non-magnetic stainless-steel shell. Dings magnetic head pulleys are shipped ready to install making them easy to use.
Magnetic head pulleys are designed to separate and collect ferrous and other magnetic materials from conveyed material. As the product is discharged from the conveyor, non-magnetic material follows its normal trajectory off the belt while ferrous clings to the magnetic head pulley until it is released under the conveyor as the belt moves the ferrous metal past the pulley’s magnetic field.
Magnetic Head Pulley Advantages Over Overhead Magnetic Separators
Under certain situations, using a magnetic head pulley for your application can have advantages when compared to an overhead magnetic separator. An overhead magnetic separator has to pull ferrous material out of a burden up through the air to the suspended magnets face. The suspension height puts a greater distance between the face of the magnet and the material being separated, necessitating the use of a larger more expensive magnet. A magnetic head pulley however, has the advantage of pulling ferrous material down to the belt at the magnet’s surface where its field strength is greatest. A magnetic head pulley is most often used when burden depth in your process is shallow.
Magnetic Head Pulley Used with an Overhead Magnetic Separator
However, if your process results in a substantial burden depth, it may be useful to use both types of separators. An upstream overhead crossbelt separator to remove metal from the top of the material stream along with a head pulley to catch and separate any ferrous lying on the bottom of the belt. This method ensures that tramp metal missed by one will be caught by the other, providing further protection for your downstream equipment.
In What Type of Applications are Magnetic Head Pulleys a Good Option?
- In applications where the burden depth on the belt is shallow.
- For deeper burden depths when used in conjunction with an upstream crossbelt overhead magnet.
- This arrangement ensures that if a heavy burden depth causes ferrous metal to be missed by one magnet, it will be caught by the other. One magnetic separator working on the bottom of the load and the other at the top.
Different Pulley Strength Series for Different Applications
Since every application has its own specific needs regarding the magnetic depth of field required, Dings Company offers you three different magnetic strengths. As we mentioned earlier, magnetic head pulleys are constructed of an internal ceramic magnet assembly enclosed within a welded nonmagnetic stainless-steel shell. The amount and arrangement of the magnetic material depends on the model. The standard and heavy-duty model have much the same arrangement. However, the heavy-duty version has more magnetic material than the standard model for a deeper magnetic field. The Dings DFC model has the strongest, deepest and most uniform magnetic field of the three. These performance enhancements are due to the Dings Flux Control (DFC) Circuit.
What is Dings DFC Circuit Design?
Dings Flux Control (DFC) Circuit design eliminates internal leakage between magnetic poles and improves separating performance. Other ‘conventional’ magnetic circuits contain air or filler material between the magnetic poles; this allows flux (magnetism) to escape (leak out) and be wasted. In Dings DFC design – blocking magnets are strategically positioned in the spaces between the magnetic poles. These redirect the flux outward, into your product, converting the wasted flux into working force – making the magnet more efficient.
Dings DFC Design improves the overall performance of the magnet in 3 ways
- The magnetic field is stronger
- The magnetic field extends deeper
- The magnetic field pattern is more uniform
Magnetic Head Pulley Lagging
If your process involves wet/outdoor environments, heavy belt loads, or other problematic conditions that cause your head pulley to slip while moving your belt. Dings offers three different types of optional lagging to increase your pulleys traction, 3M Safety Walk grip tape, Rough Top and Vulcanized Lagging.
Vulcanized Lagging Pattern Options
- Herringbone
- Diamond
- Chevron
Dings Company Magnetic Group Helps You Find the Right Magnetic Separation Solution for Your Application
Dings Company Magnetic Group engineering and sales staff work together from our Milwaukee, WI factory to provide outstanding customer service from experts in magnetic separation. We listen to our customers to gain an understanding of their needs and apply our experience in their trade to provide magnetic separation equipment that is sized and positioned for the best possible performance in their specific application. Contact Us at magsales@dingsco.com or call us at (414)672-7830 for help finding the right magnetic separation solution for your application.