OSENC Magnetic Separation
Custom Magnetic Head Pulley for Conveyor Replacement
Continuous Ferrous Separation at Conveyor Discharge
A magnetic head pulley replaces the conveyor’s standard head pulley. Ferrous material remains attracted around the belt and pulley for longer, while non-magnetic material follows its normal discharge trajectory. Selection starts with the existing pulley interface, belt, speed, feed layer, target iron, magnetic arc, and splitter—not a generic drum diameter.
Best Application Conditions
- Dry or suitably controlled material distributed across the conveyor
- Exposed strongly magnetic pieces or particles
- Enough room below the head to create separate trajectories
- An existing conveyor suitable for pulley replacement
- Maintenance access for belt, bearings, splitter, and collected metal
Replacement Interface Data
| Required dimension | Reason |
|---|---|
| Pulley diameter and face length | Matches belt and separation geometry |
| Shaft diameter, steps, keyways, and extensions | Matches drive and bearing interfaces |
| Bearing-center distance and housings | Matches conveyor structure |
| Belt width, thickness, and construction | Defines coverage and magnetic working gap |
| Speed and drive arrangement | Controls mechanical load and trajectories |
| Lagging or shell surface | Affects traction, wear, and magnetic distance |
Magnetic Arc and Discharge
The stationary or designed magnetic zone must hold ferrous material beyond the non-magnetic discharge, then release it into the metal stream. The required arc depends on feed position, pulley rotation, belt wrap, speed, particle behavior, and splitter. “Half magnetic” or “full magnetic” must be replaced by an approved pole/arc drawing.
Feed Layer and Belt Thickness
The magnetic field must act through the conveyor belt and any lagging before reaching the target. A thick belt, repair patch, wear layer, or deep feed increases distance. Spread material into a stable layer and avoid center surges that bury small iron.
Mechanical Review
Confirm shaft load, torque, speed, runout, bearing fit, balance/operation, lifting, and belt tension. Do not use a magnetic pulley drawing that matches magnetic dimensions but ignores conveyor mechanics. The final responsibilities for shaft, bearings, drive, and installation must be clear.
Head Pulley vs Housed Drum
| Magnetic head pulley | Housed drum |
|---|---|
| Part of the customer’s belt conveyor | Separate enclosed separator |
| Material passes over the conveyor belt | Material contacts or approaches rotating drum shell |
| Usually driven by conveyor system | Usually has its own drive |
| Requires pulley replacement dimensions | Requires inlet/outlet and support interfaces |
Testing
Define magnetic measurement positions on the final pulley, including belt/lagging effect where relevant. Mechanical checks may include dimensions, shaft fit, runout, rotation, and surface condition. Material tests must record feed, speed, depth, splitter, and collected fractions.
Request a Custom Pulley Review
Send the existing pulley and conveyor drawing, belt data, speed, drive, material, layer, target iron, bearing arrangement, lagging, available space, and desired discharge.
Magnetic Head-Pulley Replacement Data
The quotation should describe material discharged from an existing conveyor and connect each proposed feature to an operating or acceptance requirement.
| Selection logic | Select a head pulley when continuous separation at belt discharge fits the trajectory and smaller liberated ferrous material can reach the pulley field. |
|---|---|
| Application inputs | Material, size distribution, bulk density, moisture, layer depth, target size, normal and peak rate and belt speed |
| Mechanical interface | Provide original pulley diameter, face width, shaft ends, bearings, lagging, wrap angle, drive torque, splitter and guarding dimensions. |
| Cleaning and service | Confirm access for belt release, bearing service, pulley lifting and removal of wrapped wire or accumulated magnetic material. |
| Acceptance method | Agree shaft and interface dimensions, runout, balance, magnetic arc or coverage and a trajectory-based separation test. |
Project Scope and Supply Boundary
Boundary for Custom Magnetic Head Pulley for Conveyor Replacement
- This is a configurable project page, not a released standard model with universal published performance.
- We confirm the manufacturing route, approved drawing and belt width and speed, burden depth, rated suspension height, largest tramp-iron size, cleaning arrangement and structural interface for the inquiry.
- Dimensions, magnetic values, pull force, capacity, separation result, materials, certification, lead time and warranty become project facts only in traceable quotation, drawing, inspection or order documents.
Engineering Conditions Behind the Recommendation
- Do not select from a surface Gauss value alone.
- Review field strength and gradient at the rated working distance, including the conveyor belt, burden depth and any protective plate.
- Belt speed, feed uniformity, target size, shape and magnetic response determine how much time and force are available for capture.
- Mechanical passage capacity is not the same as effective separation capacity.
- Quote or test conditions must identify material, size distribution, moisture, bulk density, normal and peak rate, feed distribution, speed, layer or flow geometry, contamination loading and cleaning interval.
What We Need to Configure This Project
Input set for Custom Magnetic Head Pulley for Conveyor Replacement
- How we use your data: We compare your material, contamination risk, production target and line interface before we configure a proposal or rule out an unsuitable option.
- Material: name and composition; dry or wet; powder, granule, lump, fibre or slurry; minimum, maximum and typical particle distribution; moisture, stickiness, tendency to cake or bridge, abrasiveness, corrosiveness, bulk density, normal temperature and maximum temperature.
- Production and target: normal and peak throughput, continuous or batch feed, feed uniformity, contaminant or recovery target, magnetic response if known, typical and maximum target size, initial concentration, acceptable residual and whether product loss is permitted.
- Installation: belt width and speed, normal and maximum burden depth, magnet position and rated working distance, available suspension and maintenance space, support and lifting arrangement; cleaning method, permitted shutdown, contact-material, wear and corrosion requirements; indoor, outdoor, washdown, high-humidity, dusty or hazardous-area conditions.
- Supporting project files: drive voltage, frequency and phase where a self-cleaning unit is considered; control interface and any site air requirement; destination country; current drawings, site photographs, running video and a representative material/contaminant sample when testing is needed.
- What you receive next: We use the confirmed inputs to prepare a project-specific drawing and inspection plan. We do not treat performance as confirmed until the agreed design and any required representative test or site acceptance establish the result.
Project Support
Send your drawing, material data or installation photo
We will review the product structure, magnetic circuit direction, cleaning method, material contact requirements and inspection items before preparing a quotation.
Frequently Asked Questions
Why is “Magnetic Arc and Discharge” important for this decision?
The stationary or designed magnetic zone must hold ferrous material beyond the non-magnetic discharge, then release it into the metal stream.
Why is “Feed Layer and Belt Thickness” important for this decision?
The magnetic field must act through the conveyor belt and any lagging before reaching the target.
Why is “Mechanical Review” important for this decision?
Confirm shaft load, torque, speed, runout, bearing fit, balance/operation, lifting, and belt tension. Do not use a magnetic pulley drawing that matches magnetic dimensions but ignores conveyor mechanics.