No matter how cautious you are, errors can occur, and machinery eventually wears out over time. Conveyor belts in industrial settings like chemical plants carry various solids. These belts have numerous parts that need to work in harmony. If your conveyor belt malfunctions, it can disrupt your entire system, leading to financial losses and reduced productivity. This blog provides useful tips on how to track a conveyor belt and addresses the potential issues that may arise.
Let’s get started.
What Is A Conveyor Belt System?
A conveyor belt system is a handy machine that swiftly moves stuff from one spot to another. There are different types, but they usually have a frame with wheels, rollers, or a belt to support and transport materials.
You put your items on top, and off they go!
These systems can be powered by hand, gravity, or a motor. And because there are lots of variations, each conveyor belt system is designed for a particular job.
Whether it’s motorized rollers or vertical conveyors, each of these options provides a different way to meet your specific needs.
However, it’s important to note that every type of conveyor system can run into problems, causing interruptions in the flow of materials and potentially affecting your profits.
Let’s quickly delve into the next section to find out what these conveyor belt problems might be.
Common Conveyor Belt Snags
It’s unrealistic to list every possible problem you might encounter with your conveyor belt. However, here are some common snags you’re likely to deal with, along with their expected consequences.
1. Mistracking Of The Conveyor Belt
Conveyor Belt Mistracking happens when the belt veers off its intended path.
Tracking, which is all about keeping the belt aligned properly, is crucial for smooth operations. Mistracking occurs when something disrupts this alignment, often causing the belt to slip to one side and throwing the whole system off balance.
Mistracking can have serious consequences.
- It can end up disrupting the entire system’s intended operation.
- It could result in uneven wear on the belt, triggering various other issues.
- If the belt completely slips off track, the system could malfunction and stop working altogether.
It’s essential to watch for subtle signs of mistracking, even if they don’t initially seem harmful.
Conveyor belt tracking troubleshooting
When your belt starts shifting side to side and showing signs of wear, it’s time to troubleshoot its alignment. Conveyor tracking issues can stem from different parts of your system. Here’s what to check when your belt begins mistracking:
- Conveyor frame: Ensure the frame is level and square to prevent belt misguidance.
- Snub rollers: Align these rollers with the frame and apply adequate tension to the belt for proper tracking.
- Belt cutting: A crooked belt due to improper cutting can cause tracking errors.
- Cleanliness: Remove buildup from the belt and pulleys to maintain smooth operation and prevent failures.
- False crowns: Debris on pulleys can create false crowns, leading to weight redistribution and tracking issues. Keep pulleys clear to avoid this.
2. Best Slipping
Conveyor belts need the right amount of tension to function properly. If there’s too much or too little tension, problems arise, and the belt can slip.
Main Causes of Conveyor Belt Slippage: Tension and balance are crucial for belt traction, leading to common slippage causes. Knowing these causes helps you monitor and prevent future issues. Common culprits include:
- Overloaded load: Ensure objects match the belt’s weight capacity to avoid slipping.
- Low temperatures: Cold conditions reduce belt-pulley grip, causing slippage. Opt for belts designed for cold environments.
- Improper lagging installation: Incorrectly applied lagging can fail to fix tension issues, leading to slippage. Seek professional help for lagging installation.
- Pulley problems: Worn or buildup-laden pulleys decrease belt grip. Regularly inspect pulleys for wear to prevent issues.
3. Seized Rollers
When rollers on a conveyor belt get stuck, it’s usually because they’re made of tough materials like steel, which is good for durability. But the downside is, that when they seize, they can develop sharp edges.
These sharp edges can cause big problems for the conveyor system.
- They can make the belt go off track, which is dangerous for workers nearby and can damage goods being transported.
- If the issue gets bad enough to shut down the whole system, it could take a while to fix.
Therefore, it’s important to keep an eye on the rollers to prevent this from happening.
4. Blockages
It’s easy for a package to get stuck on a conveyor belt. When this happens, other items behind it can also get trapped, leading to a buildup that clogs the system.
While you can’t always predict or prevent random occurrences, you can take steps to avoid blockages.
Regularly inspect your conveyor belts for any rough spots or areas where items might snag. Even if a problem seems minor now, it’s best to address it early before it becomes a bigger issue.
5. Material Carryback
Material carryback is when residue accumulates on the conveyor belt itself, typically from materials like clays or mineral ores. Even though it may start small, this buildup grows over time, causing issues with rollers and pulleys underneath the belt.
Aside from causing operational problems,
- Excessive material buildup can also pose safety risks, such as fire hazards and inhalation dangers.
- Moreover, it can lead to profit loss, especially if valuable materials are lost with each conveyor cycle.
To address material carryback, it’s essential to install a cleaning system that effectively removes residue from the belt, ensuring no material is left behind.
6. Material Spillage
Material spillage is a common problem along conveyor systems, especially at transfer and load points. It happens when materials accidentally slide or spill off the belt. While it might not be caused by mechanical issues, it can still lead to blockages or buildup, causing further problems down the line.
7. Belt tears And Rips
Belt tears and seam rips can occur depending on the materials you’re transporting. Products like sharp rocks or coal increase the likelihood of these issues. Even moving heavy packages can cause friction and thin spots that lead to tears.
These tears and rips disrupt belt function and reduce productivity.
Repairing them requires a good process, which may involve contacting a professional or having a trained team member perform the repairs to minimize downtime.
Now that we know what the various problems are, let’s look into different conveyor belt tracking methods.
Ways To Avoid Problems With Conveyor Belts
To ensure your conveyor system operates smoothly, it’s crucial to proactively prevent issues. This means staying vigilant and regularly inspecting your system for signs of excessive wear or any abnormalities.
Here are some key steps you can take to maintain smooth operation:
1. Look For Buildups
- During your routine conveyor belt inspections, it’s important to include a cleanliness check.
- Take the time to thoroughly examine every part of your system, checking from all angles and directions.
- Look out for any buildup of dirt, debris, or residue. Whenever you spot such buildup, make sure to remove it completely.
2. Keep Your System Clean on a Regular Basis
- Cleaning your system regularly complements the process of checking for buildups.
- By cleaning frequently, you lower the chance of buildups occurring in the first place.
- Make it a habit to clean your conveyor system regularly.
This way, you’re more likely to catch problems early and prevent any issues that could arise from dirt or excessive material buildup.
3. Check Frame Alignment Regularly
- Your conveyor won’t function smoothly if the frame is tilted or misaligned. This misalignment can occur due to regular machine motion or other factors.
- It’s crucial to regularly ensure that the conveyor frame is properly squared up and aligned.
- You can easily do this by using a standard level to confirm that both sides are even.
4. Ensure Even Alignment of End Pulleys
- While inspecting the frame for squareness, also check the alignment of the end pulleys.
- Make sure each pulley is evenly aligned with the conveyor frame. Misaligned pulleys can cause issues like belt slipping and accelerated wear on parts.
5. Verify Straight Belt Cuts
Checking that the belt is cut straight doesn’t need to be done every time you conduct maintenance, as a single inspection suffices. Nonetheless, it remains crucial to perform this check.
FAQs: How to track a Conveyor Belt: Common Issues and Solutions
How exactly does conveyor tracking function?
Conveyor belt tracking involves aligning and managing a conveyor belt to follow a specific path. It requires adjusting idlers, pulleys, and loading conditions to correct any deviation from the intended direction of the belt.
How do you maintain proper alignment of a conveyor belt?
To keep your conveyor belt centered and running smoothly, remember the acronym CITA: Clean, Inspect, Tension, Adjust. Following this process ensures your conveyor operates efficiently and prevents premature wear and tear.
What leads to conveyor belt fires?
Friction is a major culprit behind conveyor belt fires. When rollers seize up or bearings overheat, they can produce significant friction and heat. This poses a grave danger, especially in environments prone to explosions or fires.
Conclusion
By knowing about typical problems with conveyor belts, using a well-defined conveyor belt tracking procedure, preventive maintenance tactics, and keeping yourself updated, you can guarantee that your material flow stays smooth and effective.
Keep in mind that a well-kept conveyor system is a productive and profitable one. Start taking care of your conveyor belt today to maximize your operations for lasting success.
