I. Daily inspection and cleaning
1. Surface cleaning
Frequency: Clean once a day or after each shift. Food, pharmaceutical and other industries need to clean at any time during production intervals.
Method:
Use a soft brush or dry cloth to remove surface dust and debris.
Stubborn stains can be wiped with a neutral detergent (such as dishwashing liquid) mixed with warm water. Avoid using strong acids, strong alkalis or organic solvents (such as gasoline, acetone) to prevent corrosion of the rubber layer.
The food industry needs to be rinsed with a high-pressure water gun (water pressure ≤ 0.5MPa) and ensure that it is completely dry before running.
2. Foreign matter inspection
Check whether there are sharp objects (such as metal chips, glass slag), oil stains or entanglements (such as thread ends, plastic film) on the surface of the conveyor belt and around the rollers and rollers, and clean them in time to prevent scratches or deviations.
3. Operation status observation
Observe whether the conveyor belt is stable when starting, and whether there is abnormal vibration or noise.
Check whether the material is transported evenly to avoid partial loads that cause increased local wear.
2. Regular maintenance items
1. Tension adjustment
Frequency: Check once a week and adjust according to load changes or seasons (such as high temperatures in summer, appropriate relaxation is required).
Method:
Use a tension meter to measure the conveyor belt tension to ensure that it is within the design range (usually 80%-90% of the rated tension).
If the tension is too large, it will cause cracking of the rubber layer and fatigue of the base material; if it is too small, it is easy to cause deviation and slipping.
When adjusting, the lubrication of the roller bearing needs to be checked simultaneously to avoid abnormal tension due to increased resistance.
2. Joint inspection
Frequency: Check the joint once a month, and the high temperature and high load environment needs to be shortened to weekly.
Method:
Observe whether there is cracking, degumming or warping at the joint, and use your fingers to gently press to check the bonding strength of the rubber layer.
If the joint is found to be loose, it is necessary to stop the machine immediately for re-vulcanization or mechanical connection (such as using steel buckles) to avoid accidents caused by breakage.
3. Maintenance of rollers and rollers
Frequency: Clean the rollers and rollers once a quarter and add grease every month.
Method:
Remove the material adhered to the surface of the roller, check whether the rotation is flexible, and replace the rollers that are stuck or severely worn.
The roller bearings need to be regularly filled with high-temperature resistant grease (such as lithium-based grease) to ensure good lubrication and reduce running resistance.
4. Deviation correction
Frequency: Observe daily and adjust immediately if deviation is found.
Method:
Minor deviation can be corrected by adjusting the tail wheel tensioning device or the position of the guide plate.
For serious deviation, check whether the roller is installed horizontally and whether the roller group is aligned. If necessary, reinstall or add anti-deviation rollers.
III. Preventive maintenance measures
1. Environmental control
Temperature: Ensure that the working environment temperature is within the design range of the conveyor belt (conventional type -10℃ to +80℃), avoid high temperature exposure or low temperature freezing.
Humidity: Install dehumidification equipment in a humid environment to prevent rollers from rusting or materials from absorbing moisture and agglomerating.
Dust prevention: For scenes with large dust (such as mines and cement), install sealing covers or dust removal devices to reduce the wear of particles on the conveyor belt.
2. Load management
Avoid overloading. The weight of the material transported at a time shall not exceed 120% of the rated load of the conveyor belt.
Distribute the material evenly to prevent excessive local pressure from causing deformation of the rubber layer or breakage of the base material.
3. Storage specifications
Unused conveyor belts should be rolled into a tube for storage to avoid permanent deformation caused by folding or heavy pressure.
The storage environment should be dry and ventilated, away from heat sources and chemicals, and the temperature should be controlled between 5℃ and 35℃.
IV. Common fault handling
1. Cracks in the rubber layer
Reason: excessive tension, aging, contact with sharp objects.
Handling:
Minor cracks can be repaired with cold glue of PVC patch sheets. The surface needs to be cleaned and roughened before applying glue.
Severe cracks need to be cut off and replaced with new joints. It is recommended to use hot vulcanization process to ensure strength.
2. Deviation
Reason: The roller is installed tilted, the rollers are not parallel, and the material is overloaded.
Handling:
Re-adjust the level of the roller to ensure that it is perpendicular to the center line of the conveyor belt.
Check whether the roller group is aligned and replace bent or damaged rollers.
3. Slipping
Reason: Insufficient tension, slippery roller surface, excessive load.
Handling:
Increase the tension to the design value and clean the oil on the roller surface.
If the roller rubber is worn, it needs to be re-rubbed or replaced with an anti-slip roller.
4. Abnormal noise
Reason: Damaged roller bearing, roller eccentricity, friction between the conveyor belt and the frame.
Handling:
Replace the damaged roller bearing and check the dynamic balance of the roller.
Adjust the gap between the conveyor belt and the frame to avoid edge friction.
V. Long-term outage maintenance
Clean and dry: Clean the conveyor belt thoroughly before outage to ensure that there is no residual material or moisture.
Relax tension: Adjust the tension to the minimum to avoid long-term compression and deformation of the rubber layer.
Cover protection: Wrap the conveyor belt with a dust cover or plastic film to prevent dust accumulation or ultraviolet aging.
Regular operation: Run it without load for 10-15 minutes every 2-3 weeks to prevent parts from rusting or sticking.
VI. Maintenance records and data analysis
1. Establish files: record the time, items, replaced parts and causes of each maintenance to form a maintenance log.
2. Data analysis: Optimize maintenance plans (such as shortening inspection cycles or replacing high-loss parts) by statistically analyzing data such as failure frequency and wear parts.
3. Supplier support: Regularly invite suppliers to conduct professional inspections and use their equipment (such as tension testers and infrared thermometers) to improve maintenance accuracy.
