1. Conveyor Belt Slippage
Core Cause: Insufficient friction between the rollers and the conveyor belt, typically manifested as a belt speed below 95% of the roller speed.
Common Causes:
Insufficient tension (e.g., insufficient counterweight, limited tensioning stroke);
Water, oil, or dust on the roller surface;
Overloading of materials or excessively rapid start-up;
Aging and elongation of the conveyor belt leading to tension failure.
Solutions:
Adjust the tensioning device, add counterweight, or cut and re-vulcanize;
Clean the roller surface and keep it dry;
Blow rosin powder into the rollers to increase the coefficient of friction;
Control the load and avoid overloading.
2. Conveyor Belt Misalignment
Root Cause: Mechanical installation errors, material impact, or component wear causing the belt to deviate from the centerline.
Main Symptoms: The belt shifts to one side, potentially causing material spillage, edge wear, or even tearing.
Prevention and Control Measures:
Calibrate the parallelism of the drive roller and idler rollers
Install self-aligning idler roller sets for automatic deviation correction
Optimize the material drop point position to ensure centered material fall
Use an AI vision system for real-time monitoring and early warning
3. Cracking and Crazing
Causes Analysis:
Material aging, edge friction, improper joint treatment
High temperature, high humidity, or frequent start-stop environments accelerate deterioration
Solution Strategies:
Minor cracks: Fill with special repair adhesive and grind smooth.
Severe cracks: Replace the damaged section and re-vulcanize the joint.
Daily Prevention: Regularly check for wear and avoid overload operation.
4. Wear and Thinning
High-Risk Areas:
Feed inlet, reversing roller contact area, deviation friction area
Main Causes:
Material impact and scraping by hard objects
Material sticking to the rollers causing uneven local stress
Improper design of the guide chute causing continuous friction
Solutions:
1. Install buffer rollers and strip screens;
2. Install V-type sweepers to remove adhering substances;
3. Use wear-resistant rubber-coated rollers or ceramic rollers.
5. Joint Damage
Common Problems: Delamination of vulcanized joints, broken or misaligned steel threads.
Consequences: Reduced joint strength, prone to breakage or misalignment.
Prevention Recommendations:
1. Use a stepped vulcanization process to ensure the joint is perpendicular to the centerline;
2. Regularly inspect the joint condition and repair any abnormalities promptly.
