1. Improve installation and alignment accuracy:
Ensure the drive roller and idler roller axes are perpendicular to the frame centerline, with a deviation ≤0.05mm;
Ensure the idler roller assembly is level and aligned during installation to avoid imbalance caused by bracket tilting or ground settlement;
The conveyor belt joint must be flat and perpendicular to the centerline to prevent force-induced deviation.
2. Optimize structural design to prevent deviation:
Use self-aligning idler assemblies: such as vertical rollers or trough-type self-aligning idlers, which can automatically correct the direction in the early stages of deviation;
Set forward-tilting idlers: tilt the two sides of the trough-type idlers outward by 2°~3° to create a guiding force so that the belt automatically returns to center;
Use conveyor belts with guide strips: in conjunction with grooved rollers, physically limit and prevent lateral movement;
Make the rollers into a drum-shaped structure with a larger middle and smaller sides: utilizing the automatic correction principle, they can be pulled back to the center when deviating.
3. Control Material Drop and Load Balance
Adjust the feeding device to ensure material falls centered on the belt, avoiding lateral impact;
Prevent local overloading or uneven loading, maintain uniform loading, and reduce belt misalignment caused by uneven tension.
4. Strengthen Daily Maintenance and Cleaning
Regularly clean the surfaces of rollers and idlers of adhering materials (such as slag and glue) to prevent uneven diameter from causing tension deviation;
Check that the tensioning device is working properly, maintaining appropriate tension and balance on both sides;
Install V-type sweepers or "gravity-diving cleaning brushes" for continuous self-cleaning.
5. Introduce Intelligent Monitoring and Automatic Correction Systems
AI Vision Detection System: Identifies the belt edge position in real time through a camera, automatically issues warnings, and links the actuator to adjust the belt misalignment;
Differential Detection System: Calculates the belt misalignment based on sensor data, triggering an alarm or automatic adjustment when a threshold is reached;
The self-developed "AI Inspection Worker" platform enables autonomous belt misalignment and fault prediction, significantly improving operational stability.
