I. Conveyor Belt Misalignment
This is the most common problem, manifesting as the conveyor belt shifting to one side. In severe cases, it can wear down the edges or even tear.
Main Causes: Improper frame installation, non-parallel idlers, misaligned roller axes, and uneven material drop.
Solutions: Align the frame and the center lines of the head and tail rollers to ensure level and alignment; adjust the angle of the idler on the misaligned side to bring the belt back to the center; optimize the material drop point to ensure centered material drop; for long-distance belts, install self-aligning idlers or anti-misalignment devices.
II. Conveyor Belt Slippage
During startup or under heavy load, slippage occurs between the conveyor belt and the drive roller, affecting conveying capacity.
Main Causes: Insufficient tension, excessively smooth roller surface, and excessive belt load.
Solutions:
1. Issues causing belt wear: Adjust the tensioning device to increase the initial belt tension; apply rubber coating to the drive roller to increase friction; control the instantaneous feed rate to avoid overload startup; check for belt aging or severe elongation.
2. Issues causing belt wear: The surface or edges of the conveyor belt wear quickly, significantly shortening its service life.
3. Issues causing belt wear: Damaged or jammed idlers, excessive impact from falling material, and incomplete cleaning leading to material entrainment.
4. Issues causing belt wear: Regularly inspect idlers and replace them promptly if they are not rotating or making abnormal noises; install buffer idlers or buffer beds at the material drop point; install effective cleaners to reduce material adhesion and secondary wear; select appropriate belt models and cover rubber thickness.
5. Issues causing belt tearing: This often occurs in mining and sand and gravel production lines and is a relatively serious fault.
6. Issues causing belt tearing: Large, sharp materials falling directly onto the belt, or metal foreign objects being mixed in. Solutions:
V. Material Spillage
Material spillage occurs on both sides of the conveyor belt or at transfer points, affecting the on-site environment and equipment safety.
Main causes: Belt misalignment, poor sealing of the guide chute, mismatch between belt speed and feed rate, etc.
Solutions: First, solve the belt misalignment problem; optimize the guide chute structure and use wear-resistant sealing skirts; properly match the conveying capacity and belt speed; strengthen daily cleaning to avoid material accumulation affecting operation.
VI. Difficult Start-up or Frequent Stoppages
Equipment starts with difficulty, and motor protection trips.
Main causes: Excessive belt load, high bearing resistance, unreasonable electrical parameter settings, etc.
Solutions: Try to start with no load or reduced load; check the lubrication of idler rollers and drum bearings; properly set soft start or frequency converter parameters; design segmented start-up for long belt systems. VII. Other Common Problems
Excessive Conveyor Belt Elongation: May be caused by excessive tension, insufficient strength, or accumulated material debris. Solution: Recalculate the tension and use a belt with appropriate strength.
Drum Slippage: Caused by insufficient belt tension or wear of the rubber coating on the drum surface. Solution: Adjust the hydraulic tensioning device and apply a polyurethane anti-slip layer.
Abnormal Noise in the Transmission System: Caused by abnormal gear meshing clearance or misalignment of the coupling. Solution: Calibrate with a laser alignment instrument and replace the gear oil.
Testing and Operation Precautions:
No-load Test Run: Observe whether the conveyor belt is running off-center or slipping; check whether the reducer is running smoothly and whether the temperature of each bearing is normal; confirm that the tensioning winch and tensioning idler trolley are in the correct positions and are running smoothly; check whether the main and auxiliary drums, other drums, and idlers are working normally and rotating flexibly; if a brake is installed, test its sensitivity and reliability.
Loading and trial operation: Start with a light load, and gradually increase to full load after it is normal; readjust the conveyor belt tension to ensure that it does not slip on the rollers; further adjust the conveyor belt deviation; observe the working status of each conveyor belt cleaner.
