1. Direct damage to the conveyor belt itself: Excessive tension will cause the belt to be under high stress for a long time, leading to:
Material fatigue and structural damage: The skeleton layer (such as polyester canvas) is continuously stretched, the bonding interface fails, and the cover rubber bulges, delamination, or even peeling occurs;
Frequent joint breakage: Vulcanized joints or mechanical fasteners crack due to excessive force, especially during startup and braking impacts;
Permanent tensile deformation: The belt is "stretched," loses its elastic recovery ability, and affects transmission accuracy and tension stability.
2. Accelerated Damage to Bearings and Shafts: The tension force, transmitted radially through the rollers, acts directly on the support system.
Bearing Overload Failure: Excessive radial force on the rollers and motor bearings leads to ball pitting, cage breakage, grease leakage, and ultimately, seizure or shaft misalignment.
Motor Shaft Bending or Breakage: When tension is excessive and the pulley is positioned far from the bearing, the increased lever arm causes the bearing to experience a greater bending moment, making it highly susceptible to plastic deformation or breakage.
3. Damage to Rollers and Tensioning Devices:
Roller Coating Peeling or Deformation: Overtightening causes uneven stress on the rollers, leading to cracking and peeling of the coating due to increased shear force.
Tensioning Device Structural Deformation: The guide rod of a counterweight-type tensioner may bend, and the threads of a screw-type tensioner may wear or strip, resulting in loss of adjustment function.
4. Causes instability in the frame and steel structure. The longitudinal tension of the conveyor belt is transmitted to the entire support system:
Frame beam bending: Long-term overload operation causes visible deflection in the beams, and connecting bolts break due to stress concentration;
Loosening of the column foundation: Horizontal tension causes the anchor bolts to loosen or crack, causing the entire frame to shift, further aggravating deviation and vibration.
5. Increased energy consumption and induces secondary failures.
Decreased transmission efficiency: Although the risk of slippage is reduced, internal friction and bearing wear increase, resulting in a decrease in overall energy utilization;
Abnormal vibration and noise: System resonance causes the idlers and frame to loosen, indirectly leading to derivative failures such as deviation and tearing.
