Bulk material conveyor systems are essential in mining, sand plants, grain processing, and quarrying operations (to name a few) because they get large amounts of loose material from one place to another. The belts on bulk material conveyors alone can represent six-figure investments, let alone the entire system, so paying close attention to maintenance makes good financial sense.
In this article, you’ll learn:
What to look for during routine maintenance checks to spot potential problems
Common causes of issues with bulk material conveyors
What your team can fix themselves and when to call the pros
Bulk Material Conveyors: What to Look for to Spot Problems
Idler Performance
Idlers guide the belt along its path and are critical to conveyor performance. Troughing idlers (also known as carrying idlers) work underneath the burden area of the belt and return idlers work on the bottom side to guide the belt back toward the tail pulley. In-house maintenance teams should check to ensure that idlers are spinning smoothly. Stuck or skipping idlers can cause premature belt wear.
Bearing Lubrication
To keep your system running smoothly, your team should be checking to ensure proper bearer lubrication on idlers and pulleys. Proactive lubrication will prevent those stuck or skipping idlers that can wear on your belts.
Carryback and Scraper Tension
If you notice spilled product underneath your return idlers, that indicates carryback on your conveyor system. Carryback is often caused by improper scraper tension, usually when the scraper is under-tensioned, allowing product to fall through the gap at the head section of the conveyor. Another symptom to look for is grooves cut across your belt, which can happen due to scrapers being tensioned too tightly. On systems with dual scrapers, we often see the primary scraper under-tensioned and the secondary scraper over-tensioned. Product spilling underneath the belt not only causes waste but can also lead to a housekeeping headache, not to mention safety issues such as slip-and-fall hazards.
Premature Belt Cover Wear
Belt Wear from Improper Tracking
Belt wear along the sides could indicate a tracking issue since it’s a sign that the conveyor belt is rubbing against the conveyor frame. We often see teams attempt to correct belt tracking by adjusting the tail or take-up pulleys, which is not recommended and can lead to even bigger headaches. The tail pulley and take-up pulleys should only be used to adjust belt tension, not tracking. To correct improper tracking, the position of the final return idlers before the tail pulley should be adjusted.
Belt Wear from Improper Scraper Tension
We also previously mentioned that grooves across the top of your belt cover can be a sign of an over-tensioned scraper, but premature cover wear can also result from the scraper running at an improper angle. This issue will cause the scraper blade to dig into the belt cover, which can lead to needing to replace the belt before its typical end of life. Replacing scrapers and their springs proactively is one way to ensure you get the longest possible life out of your belts.
Belt Wear from Product Impact
Load zones should be equipped with rubber idlers instead of the typical metal material seen in most troughing idlers or return idlers. Rubber idlers provide a cushion for heavy product as it’s being loaded onto the belt. Without this extra give, the impact of heavy product can pinch the belt cover against the center fabric of the belt (known among professionals as the “belt carcass”). Over time, excess impact and pinching the top cover of the belt can expose the belt carcass and compromise the belt’s performance and strength. Proactive repair and replacement, along with ensuring rubber idlers are used, will prevent premature belt cover wear due to product impact.
When to Call a Professional for Bulk Material Conveyor System Repair or Maintenance
If you spot any of the issues we identified in this article, it’s a good idea to call your conveyor maintenance partner. Unless your team is trained and experienced in correcting issues like belt tracking, belt tension, idler issues, and scraper angle and tension, we recommend having a professional assist you with solving the issue. It’s also important to address the root cause of system issues so that small hiccups don’t become big problems — and also so problems can be fixed during normal business hours with minimal downtime instead of at 2:00 a.m.!
Any time you replace the belt on your heavy-duty conveyor system, be sure to call your maintenance partner. We have the proper equipment needed to perform belt changeovers quickly and efficiently, saving you time and headaches.
Are you a Midwest manufacturer looking for a reliable maintenance and repair partner? Connect with an ACME Constructors expert today!
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