Full definition
A mechanical splice is a non-vulcanized method used for joining the ends of conveyor belts through the application of metal fasteners. This technique involves the use of clips, staples, or hinged plates that penetrate both overlapping belt ends, securing them together with a hinge pin or an integral interlock. Mechanical splicing is particularly advantageous in scenarios where quick repairs are necessary, allowing for a faster return to operation compared to traditional vulcanized splicing methods. The primary types of mechanical splices include wire staples, hinged plates, and solid plates, each offering varying degrees of strength and installation efficiency.
Wire staples, which are U-shaped and driven through the belting, are suitable for lighter duties and provide around 50-60% of the original belt strength. Hinged plates, such as those offered by Flexco and MLT, utilize bolt-on metal plates with a hinge pin, delivering strength in the range of 60-70% and allowing for quick installations that can typically be completed within 30-60 minutes. Solid plates, which are either riveted or bolted without a hinge, can provide up to 70% strength, but require more effort to install and are often less versatile in field repairs.
While mechanical splices can be completed with minimal tools and do not require a heat source, they also have their drawbacks. The reduced strength (50-70%) compared to vulcanized joints means that these splices may not be suitable for all applications, especially those involving tight-radius pulleys or cleaners where a smooth surface is necessary. Additionally, the presence of a splice can create a bump that may affect the belt's operation. It is crucial to select the appropriate splice type based on the belt's thickness, width, and tension specifications. For maximum durability and life, the mechanical splice should be replaced with a hot vulcanized splice during the next scheduled maintenance shutdown.