In a previous article, I discussed conveyor belt damage types. However, this article is all about common conveyor belt problems and solutions. Actually, conveyor belts are moving paths that transport materials from one spot to another. They are now essential in many industries, from supermarkets to airports, for convenience.
However, like any machine, conveyor belts can also have problems over time. These problems can lead to downtime, lower productivity, and even safety hazards. But the good news is that most of those problems can be fixed with the proper knowledge and maintenance. This article will look at common conveyor belt problems and their solutions. So, let’s get started!
Why Conveyor Belt Problems Happen?
Conveyor belt problems don’t just appear out of nowhere. Several factors usually cause them. So, before we proceed and discuss the common issues, let’s first understand why it happens.
- Poor Maintenance: Poor maintenance is the leading cause of belt problems. If the conveyor is not cleaned, lubricated, or inspected regularly, minor issues can grow into big ones. So neglecting maintenance often leads to belt misalignment, damage, or motor failure.
- Overloading: Each type of conveyor belt has a limited weight capacity. However, placing too much weight or items on it can strain the belt. As a result, the motor and roller cannot move properly. This can cause slipping, stretching, or breaking of the belt.
- Misalignment: Proper alignment is very crucial for each part of the conveyor system. If rollers, pulleys, or the belt itself are not correctly aligned, the belt may run off-track. This can cause uneven wear and increase the risk of tearing.
- Harsh Environmental Conditions: This is another cause for conveyor belt issues. Extreme temperatures, humidity, and moisture can weaken the belt material. For example, heat can harden the rubber. However, moisture can cause corrosion of the belt material.
- Operator Error: This cause includes untrained, careless handling. For example, sudden starts, improper loading, or ignoring warning signs can speed up wear. This can cause severe damage to the entire conveyor system.
Common Conveyor Belt Problems and Their Solution
Have you understood why conveyor belt problems happen? Remember that each issue comes with its own set of challenges. However, with the right approach, you can solve most problems quickly and effectively. Below, I will go through some common conveyor belt problems along with their solutions. Let’s jump right in!
1- Belt Slipping
Belt slipping happens when conveyor belts do not have enough grip on the drive pulley. As a result, instead of turning smoothly with the pulley, the belt slides over it. This can slow down the movement of material and even stop the conveyor completely. But what causes this issue? The most significant cause is low belt tension. If the belt is too loose, it will not grip the pulley. Moreover, if there is any dust, grease, or oil between the pulley and the belt, it will reduce friction.
Solution: First of all, adjust the belt tension. Tighten it according to the manufacturer’s instructions. However, make sure that it is also not too tight. The reason is that an over-tight belt can cause wear. Secondly, you should regularly clean the belt and pulley. It should be dust and oil-free. But for this, you must follow the proper cleaning methods.
2- Belt Mistracking
It is another problem that happens when the conveyor belt does not run straight on its rollers. Instead, it moves to one side or the other. This is the most common issue with cintas transportadoras de tejido. If this problem is left unchecked, it can cause the belt edges to wear out quickly. The main reason behind belt mistracking is a misaligned roller and pulley. If these parts are not perfectly straight, the belt will drift off-center.
Solution: First, you should inspect the alignments. For example, realign the pulley and rollers so they are straight and level. After that, you should balance the weight. For this, make sure that the weight is loaded evenly in the center of the belt. Also, remove dust and oil from all contact points of the belt for smooth tracking.
3- Material Carryback
Material carryback is a problem when a small amount of the material sticks to the belt. Instead of falling off the discharge zone, fine dust and sticky material cling to the conveyor belt. As the belt moves back, this leftover material gets carried along the return path. Over time, these materials build up on the roller and under the belt, causing blockage. The common causes for this problem include wet, muddy, and sticky material..
Solution: You should install an effective belt cleaner and scraper. They will remove the material at the discharge point. Moreover, always choose the right cleaner for the right belt. For example, use a soft scraper for a delicate belt. However, for stronger ones like cintas transportadoras de cable de acero, use a stubborn cleaner. Lastly, regularly maintain those cleaners to ensure they work smoothly.
4- Excessive Belt Wear
Excessive belt wear means the conveyor belt’s surface is wearing out faster than usual. This can result in cracks, fraying, holes, or thinning of the belt material. When this happens too quickly, it can reduce the lifespan of the belt and increase the cost of replacement. Excessive belt wear occurs mainly due to carrying material with sharp edges. Those materials can cut and scratch the belt more frequently. Also, poor belt material can increase premature damage.
Solution: First, you should select a belt material and thickness suitable for the type of load. If the belt is carrying sharp-edged material, use a cover or skirts to reduce contact. Moreover, check the alignment of the pulley, belt, and roller regularly. Because proper tracking prevents uneven wear.
5- Belt Breakage
Belt breakage happens when the conveyor belt tears or snaps completely. This can stop the entire conveyor system instantly. As a result, production stops immediately, which can cause severe loss to the industry where every minute of downtime counts. Moreover, sudden belt breakage can also affect other parts, especially when running at speed. The one common cause for this issue is placing loads heavier than the belt’s capacity. Dropping the heavy object from a height can also increase the risk of belt breakage.
Solution: You should follow the load capacity limits while loading the materials. Do not exceed the manufacturer’s recommended weight. Moreover, install the impact bed on the belt to absorb the shocks of heavy material. Finally, you should replace the aged belt immediately. Don’t wait until the belt is too worn before replacing it.
6- Noise and Vibration
Sometimes, a conveyor belt system makes unusual noises or vibrates during operation. While little sound and vibration are regular, if it is repetitive noise, it means something is wrong. Seized rollers mainly cause this issue. They create friction, which can cause shaking and noise. Moreover, if the bolts, brackets, or guards are not tightened, they can rattle when the conveyor runs. However, belt rubbing against the frame and motor failing can also initiate this issue.
Solution: Check and replace the worn rollers or bearings that are making the noise. After that, make sure that all the nuts and bolts are secured tightly. Also, keep the belt in the center to avoid mistracking, which enhances rubbing and vibration. Lastly, address any unusual sound coming from the drive system immediately.
7- Overheating of the Belt
Overheating occurs when the conveyor belt becomes too hot during operation. This can weaken the belt material and cause it to harden or crack. Even in some cases, this overheating can cause safety risks, especially when working with flammable material. The primary cause behind this issue is excessive friction caused by tension or a damaged roller. Transporting material directly from the oven or kilns can also enhance belt overheating.
Solution: First, reduce the friction by adjusting the tension. For extra safety, you should use high-temperature conveyor belts. They are heat-resistant and do not melt or crack. Also, add ventilation fans or open panels to release trapped heat. Lastly, you must allow short breaks in between long runs to avoid overheating of the belt.
8- Belt Hardening or Cracking
Belt hardening or cracking occurs when the conveyor belt loses its flexibility. As a result, the surface becomes stiff, and visible cracks may appear. This makes it hard for the belt to bend smoothly around pulleys. It leads to noise and uneven movement. The primary reason for this issue is prolonged exposure to extreme hot or cold temperatures. These conditions change the internal texture of the belt and make it stiff. Also, contact with oils, chemicals, or harsh cleaners can make the belt stiff.
Solution: You should use the belt designed for the specific temperature and chemicals. Limit chemical exposure to harmful chemicals and use a resistant belt if necessary. Also, make sure to store the conveyor belts in cool, dry, and shaded areas away from direct sunlight. Lastly, check for cracks regularly and replace them when needed.
Preventive Maintenance Tip for Conveyor Belts
Keeping a conveyor belt in good shape is much easier than fixing it after it breaks down. It enhances the belt’s lifespan and saves your money and time. So, below are some maintenance tips to keep your belt running smoothly for a long time.
- Regular Inspections: First, check your conveyor belt regularly for signs of wear and damage. Also, look for frayed edges, loose bolts, or damaged rollers. Catching these issues earlier can save you from costly repairs.
- Lubricate Moving Parts: A dry surface can enhance the friction and cause overheating. So, continually lubricate the moving parts, such as rollers and bearings. However, you should choose the right lubricant according to the manufacturer’s guidelines.
- Monitor Belt Alignment: A misaligned belt can cause uneven wear and damage. So, make sure the belt runs straight. If needed, you should use tracking devices for complex conveyor systems.
- Check Belt Tension: Proper tension is very crucial for the smooth working of the belt. Too much stress can cause the belt to stretch or break. However, too little tension can cause slippage of the belt. Therefore, adjust the correct tension according to the manufacturer’s guidelines.
- Train Operators: Trained operators are crucial for efficient conveyor operation. So your operator should know how to run the conveyor system and spot earlier signs of problems. This reduces human error and extends the belt’s life.
Conclusión
Conveyor belts are the backbone of several industries. They help run several operations smoothly, quickly, and efficiently. However, sometimes these belts can face several problems. If those problems are not spotted in time, they can cause downtime and severe financial losses. That’s why I have discussed some of the common issues a conveyor belt often faces.
For example, sometimes the belt may be misaligned. This can cause slippage and wear to the belt. Moreover, frequent wear and tear, noise, vibrations, and overheating are also some common issues. However, the best thing is that you can solve these issues if you address them in time. With proper maintenance and preventive methods, you can even stop these problems.