Belt conveyors are widely used in mining, metallurgy, coal, transportation, hydropower, chemical and other departments because of their advantages of large conveying capacity, simple structure, convenient maintenance, low cost and strong versatility. Problems with belt conveyors will directly affect production. This article shares common problems and possible causes in the operation of belt conveyors.
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19 common problems and possible causes of belt conveyors
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1. The conveyor belt deviates at the tail roller
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Possible reasons: a. The idler is stuck; b. The material is accumulated; c. Insufficient counterweight; d. Improper loading and sprinkling; e. The idler, roller and conveyor are not on the center line.
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2. The conveyor belt deviates at any point
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Possible reasons: a. eccentric load; b. accumulation of scraps; c. rollers are not properly installed; d. transitional tension on one side of the conveyor belt; e. improper loading and sprinkling; f. .
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3. Part of the conveyor belt deviates at any point
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Possible reasons: a. The performance of the vulcanized joint of the conveyor belt is poor, and the mechanical buckle is not properly selected; b. The edge is worn; c. The conveyor belt is curved.
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4. The conveyor belt deviates at the roller of the machine head
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Possible reasons: a. The idler, the roller and the conveyor are not on the center line; b. The accumulation of scraps; c. The rubber surface of the roller is worn; d. The idler is improperly installed.
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5. On several specific rollers, the conveyor belt deviates to one side for the entire section
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Possible reasons: a. The idler, roller and conveyor are not on the center line; b. The idler is improperly installed; c. The accumulation of scraps.
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6. Conveyor belt slips
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Possible reasons: a. The idler is stuck; b. The material is accumulated; c. The rubber surface of the roller is worn; d. The counterweight is insufficient; e. The friction between the conveyor belt and the roller is insufficient.
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7. Conveyor belt slips when starting
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Possible reasons: a. Insufficient friction between the conveyor belt and the roller; b. Insufficient counterweight; c. The rubber surface of the roller is worn; d. The strength of the conveyor belt is not enough.
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8. The conveyor belt is overstretched
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Possible reasons: a. Excessive tension; b. Insufficient strength of conveyor belt; c. Accumulation of scraps; d. Excessive counterweight; e. Asynchronous operation of double-drive rollers; f. Caused by chemical substances, acid, heat, and rough surface substances damage.
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9. The conveyor belt is broken at or near the buckle, or the buckle is loose
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Possible reasons: a. The strength of the conveyor belt is not enough; b. The diameter of the drum is too small; c. Too tight; d. The rubber surface of the drum is worn; e. The counterweight is too large; f. There is foreign matter between the conveyor belt and the drum; g. The rollers run asynchronously; h. The performance of the vulcanized joint of the conveyor belt is poor, and the mechanical buckle is improperly selected.
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10. Fracture of vulcanized joint
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Possible reasons: a. The strength of the conveyor belt is not enough; b. The diameter of the drum is too small; c. Too tight; d. There are foreign objects between the conveyor belt and the drum; e. Incorrect choice of buckle.
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11. The upper covering rubber is seriously worn, including tearing, gouging, breaking, and puncturing
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Possible reasons: a. Accumulation of swarf; b. Improper loading, sprinkling; c. The relative loading speed is too high or too low; d. The load has too much impact on the buckle; e. Chemical substances, acid, heat, rough surface damage caused by substances.
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12. The lower cover rubber is seriously worn
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Possible reasons: a. The idler is stuck; b. The material is accumulated; c. The rubber surface of the roller is worn; d. There are foreign objects between the conveyor belt and the roller; e. The friction between the conveyor belt and the roller is insufficient; f. Chemical substances, acid , heat, damage caused by rough surface substances.
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13. The edge of the conveyor belt is seriously worn
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Possible reasons: a, eccentric load; b, excessive tension on one side of the conveyor belt; c, improper loading, sprinkling; d, damage caused by chemical substances, acid, heat, rough surface substances; e, the conveyor belt is curved; f. Accumulation of scraps; g. Poor performance of conveyor belt vulcanization joints and improper selection of mechanical buckles.
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14. There are dotted and striped bubbles in the covering layer
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Possible causes: damage caused by chemicals, acids, heat, rough surfaces.
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15. Conveyor belt hardening and cracking
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Possible reasons: a. Damage caused by chemical substances, acid, heat, and rough surface substances; b. The diameter of the drum is small; c. The rubber surface of the drum is worn.
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16. Embrittlement and cracking of the covering layer
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Possible causes: damage caused by chemicals, acids, heat, rough surfaces.
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17. There are longitudinal groove marks on the cover glue
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Possible reasons: a. Improper installation of the side baffle; b. The idler is stuck; c. Accumulation of scraps; d. The impact of the load on the buckle is too great.
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18. The lower cover glue has longitudinal groove marks
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Possible reasons: a. The idler is stuck; b. The scrap is accumulated; c. The rubber surface of the roller is worn.
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19. The idler is damaged at the groove
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Possible reasons: a. The gap between the idlers is too large; b. The slope of the changing point is too large.
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Solutions to common problems of belt conveyors
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1. The conveyor belt is curved
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On the whole core conveyor belt that will not happen, pay attention to the following points for the layered belt:
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a) Avoid squeezing the layered conveyor belt;
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b) Avoid storing layered conveyor belts in humid environments;
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c) When the conveyor belt is running in, the conveyor belt must be straightened first;
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d) Check the entire conveyor system.
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2. Poor performance of conveyor belt vulcanized joints and improper selection of mechanical buckles
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a) use suitable mechanical buckles;
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b) Re-tension the conveyor belt after running for a period of time;
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c) If there is a problem with the vulcanized joint, cut off the joint and make a new one;
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d) Regular observation.
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3. One side of the conveyor belt is elongated and deformed
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It will not happen on the whole core conveyor belt. For other conveyor belts, pay attention to the following points: The running-in time of the conveyor belt should be long enough. If the conveyor belt is not running well or the old conveyor belt, remove the stretched and deformed part and make a new one. connector.
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4. The counterweight is too large
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a) Recalculate and adjust the counterweight accordingly;
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b) Reduce the tension to the critical point and fix it again;
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c) If the winch is tensioned, make appropriate adjustments.
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5. Insufficient counterweight
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Recalculate and adjust weights accordingly.
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6. Damage caused by chemical substances, acids, alkalis, heat, rough surface substances
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a) Select conveyor belts designed for special conditions;
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b) Adopt sealed mechanical buckle or vulcanized joint;
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c) The conveyor shall take measures such as rain and sun protection.
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7. Asynchronous operation of double-drive drums
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Make appropriate adjustments to the rollers.
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8. The strength of the conveyor belt is not enough
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Due to the increase in the amount of coal passing at the center point or the loading point, or the reduction of the belt speed, the tension should be recalculated and a conveyor belt with a suitable belt strength should be used instead.
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9. Edge wear
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Prevent the conveyor belt from deviating, and remove the part of the conveyor belt with serious edge wear.
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10. The idler gap is too large
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Adjust the gap, even if it is fully loaded, the gap between the idlers should not be greater than 10mm.
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11. The impact of the load on the conveyor belt and buckle is too large
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a) Correctly use the flow trough and buffer plate designed according to the working conditions;
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b) Install impact-resistant rollers;
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c) If possible, charge the coal first;
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d) If the side baffle is not stuck with coal, adjust the gap between the side baffle and the conveyor belt.
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12. The idler, roller and conveyor are not on the center line
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a) re-alignment;
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b) Install limit switches;
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c) Consult the conveyor manual.
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13. Improper loading and sprinkling
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a) The feeding direction and speed should be consistent with the running direction and speed of the conveyor belt to ensure that the loading point is in the center of the conveyor belt;
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b) Use suitable feeders, runners and side baffles to control flow.
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14. Insufficient friction between conveyor belt and roller
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a) Use a buffer roller to increase the wrapping angle;
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b) Use a rubber-coated roller;
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c) Use a grooved rubber roller in a humid environment;
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d) Install appropriate cleaning devices on the conveyor belt;
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e) Check the initial tension.
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15. Accumulation of swarf (on drums and idlers)
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a) Install cleaners, scrapers, etc.;
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b) Remove swarf.
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16. There is a foreign body between the conveyor belt and the roller
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a) Correct use of side baffles;
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b) Remove foreign objects such as scraps.
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17. The rubber surface of the roller is worn
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a) Replace the rubber surface;
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b) Use grooved rubber surface in humid environment;
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c) Deal with loose and protruding rubber surface screws.
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18. The relative loading speed is too high or too low
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a) Adjust the flow chute or correct the running speed of the conveyor belt;
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b) Consider using impact-resistant idlers and pay close attention to operating conditions.
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The above are the common problems of belt conveyors and related solutions. In order to prolong the service life of the conveyor equipment, and for the equipment to perform better production operations, the belt conveyors should be regularly maintained, so as to truly to improve production efficiency and improve economic efficiency.