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Belt conveyors are a type of conveying system that uses friction to transport loose materials or finished items. Due to their variety of styles, Bifa mainly sells: inclined belt conveyor, curved conveyor belt, small conveyor belt, bottomless conveyor, cleated conveyor belt, etc. They are cost-effective and simple in structure. It is a common problem that they deviate during traansportation. This article discusses the problem of “How to track a conveyor belt?” from the following aspects: several possibilities of belt conveyor out of track, how to adjust belt after this problem occurs, and How to design belt conveyor to reduce out of track.
This situation is usually caused by installation. Since the centers of the three are not in a straight line, the longitudinal center line of the belt is not perpendicular to the axis of the roller, causing the belt conveyor to deviate during operation.
Belt conveyors has multiple rollers. The installation position of all rollers must be perpendicular to the center line of the belt and parallel to the horizontal plane. If the installation level of the rollers is not enough, the rollers will move axially, or one end of the rollers will be in front and the other end will be in the back. , so that the installation position of the roller is not perpendicular to the longitudinal centerline of the belt, or the axis of the drum is not parallel to the horizontal plane, then the resultant force of the external force on the belt in the belt width direction is not zero, and the belt will deviate in the direction of the resultant force.
Commonly used belt joints include mechanical joints and vulcanized joints. No matter which method is used, the joints are required to be flat. If the joints are not straight, the tension on both sides of the belt will be inconsistent, resulting in out-of-track during operation. The out-of-track caused by the incorrect tape joint will occur wherever the tape joint runs.
When the belt conveyor is installed, the symmetry between the center line of the roller group and the center line of the conveyor frame shall not be greater than 3.0 mm, and the upper surface of the rollers shall be located on the same horizontal plane or inclined plane. If the installation error of the roller group is too large or the fastening bolts are loose, the belt will deviate.
The conveyor belt is easily damaged during operation. When the degree of damage on both sides of the center line of the conveyor belt is different, the stretch rate on both sides often changes. When the stretch rate on both sides is greatly different, the belts on both sides will be damaged. When the elongation is inconsistent, it is easy to cause the belt to deviate.
When the material unloading point is not in the middle of the belt, the load on the belt will be unevenly distributed along both sides of the longitudinal centerline due to the eccentric load. When the difference between the two is large, it will directly cause the conveyor belt to deviate during operation. If the conveyor belt does not deviate when it is unloaded, but always deviates to one side when it is heavily loaded, it means that the conveyor belt has been eccentrically loaded. At this time, the position of the hopper or conveyor should be adjusted so that the conveyor belt is evenly loaded to prevent it from wandering.
When the material falls onto the belt, the gravity and inertia of the material will impact the belt, which may cause the belt to deviate.
For materials with a certain viscosity such as iron powder, they will stick to the rollers and rollers unevenly after being scattered, causing the rollers or rollers to become partially uneven and causing out of track due to uneven tension. The phenomenon of bulk materials becomes more serious after out of track, causing a vicious cycle. This type of failure is more likely to occur during wet weather and harbor operations. Therefore, the tape cleaner must ensure normal operation.
If the error between the center line of the load-bearing belt conveyor and the installation position of the idler is large, the belt will be subject to lateral force during operation, causing the belt to deviate to one side in the load-bearing section. If the installation position of the reversing roller and idler roller group is incorrect, then whether it is the return section or the load-bearing section, the out of track will become lighter as it goes forward, and will gradually return to the center line of the frame. However, if the driving drum is tilted, the out of track caused by it will become more and more serious.
The density of the belt core is uneven and the force is uneven along the width direction. Under the action of tension, the elongation of the belt during operation is inconsistent, causing the belt to deviate. If the uneven density of the belt is caused by a system failure of the production equipment and has a certain regularity, the out of track direction will also show a certain regularity.
Due to the operator’s unskilled skills, weak sense of responsibility, and lax acceptance during the installation and debugging process, the belt tensioning device did not work properly. Different tension levels and uneven stress on both sides of the belt caused the belt to deviate.
After a cycle of use, the belt will relax, resulting in uneven stress distribution within the belt, thereby increasing the chance of belt out of track.
If the centerline of the rack is skewed and the left and right sides of the rack are tilted horizontally, the belt may be subject to a certain lateral tension, pulling the belt to a certain side.
During the operation of the belt, severe vibration of the belt conveyor equipment will also cause the belt to deviate, especially the radial runout of the idler roller.
Adjust the head, tail and middle frame of the belt conveyor so that the centers of the three are on the same straight line.
Adjust the installation position of the roller so that the axis of the roller is perpendicular to the longitudinal center line of the tape and parallel to the horizontal plane. Taking the first roller as an example, if the bearing seat of the belt deviates to which side, move the bearing seat of that side to the running direction of the tape, or move the bearing seat of the other side to the opposite direction of running. However, it should be noted that the actual offset between the center line of the roller and the center line of the tape must be determined before adjustment to ensure the correct position of the roller after adjustment.
Cut off the incorrect tape joint and redo the belt joint. Make the joints straight, and the straightness tolerance on the 10m length should not be greater than 20mm. In addition, it is best to segment the nailed belt buckles along the length of the troughed roller to ensure the troughing performance at the tape joint, prevent and reduce pin breakage, and avoid tape tearing accidents.
If the roller frame is misaligned, the roller frame on the side of the out of track can be moved a little toward the direction of the belt. Generally, the out of track can be corrected by moving a few rollers. When the out of track is serious, the roller frame needs to be recalibrated to control the level error of the roller group within the allowable out of track. If the belt out of track is caused by loose bolts fixing the roller frame, retightening the loose bolts can solve the problem.
It can be solved by strengthening the inspection and maintenance of the belt and repairing or replacing the damaged belt in time.
Adjust the position of the unloading point so that it is in the middle of the tape.
Use a reasonably structured guide plate to avoid direct unloading of large objects or large heights. You can also install several sets of buffer rollers under the unloading port.
Remove the accumulated material on the surface of the drum or roller to eliminate it. At the same time, the empty section spring cleaner should be adjusted. The contact length between the cleaner and the conveyor belt in the direction of the drum axis should be greater than 85% of the bandwidth to ensure that materials can be removed at any time.
Adjust the roller group to the correct position. When the belt in the middle part of the belt conveyor deviates, the mounting holes on both sides of the roller bracket can be modified and processed to make it a longer hole. When the belt deviates to the left, the left side of the roller group faces the direction of belt running. Move forward, or move backward on the right side; when the belt deviates to the right, the right side of the roller group moves forward toward the belt running direction, or moves backward on the left side.
Users should choose manufacturers with good reputation and rich production experience. They should also be equipped with complete technical service personnel who can solve user problems in a timely manner and implement good three-guarantee services for their products.
View “How to track a conveyor belt video” by Bifa conveyor YouTube channel.
The belt conveyor must be inspected after being used for a period of time. If the belt is aging and deformed, it must be replaced in time.
Correct the skewed frame. The skew of the rack includes the skew of the center line of the rack and the inclination of both sides of the rack. The problem can only be solved fundamentally by reinstalling the rack to ensure that the center line of the rack and both sides of the rack are flat.
Find out the cause of vibration and solve it in time.
Kunshan Bifa Automation Technology Co., Ltd. as conveyor belt factory has a strong customization capability and R&D design department. Which fundamentally solves the problem of belt out of track:
1) Adding one or more grooves to the rollers and load-bearing pallets of the belt conveyor, and matching them with at the same time, protruding guide bars are added to the back of the belt. In this way, the belt offset problem is solved through physical means.
Bifa’s mini conveyor belt adopts this design and is loved by customers.
Grooved roller
3D model of belt conveyor with guide strips
mini mover conveyor
2) Designing the motor in the middle of the conveyor can ensure that the driving force is evenly distributed, reducing the tension difference and misalignment of the belt during operation, thereby effectively avoiding the belt deviation. This design is often used in belt conveyor systems that require high precision and high stability, especially in long-distance or heavy-load applications.
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