I. Most Serious Problems (potentially leading to downtime or safety accidents)
1. Conveyor Belt Breakage
Consequences: The conveyor will immediately and completely stop, requiring replacement of the entire conveyor belt. Repair costs are high and time-consuming, and there is a possibility of secondary accidents such as material spillage and injury to personnel.
Main Causes: Long-term overload operation, excessive tension, material fatigue, or poor joint quality.
2. Severe Belt Misalignment
Consequences: The conveyor belt edge rubs violently against the frame, causing wear, tearing, and even fire. This also results in significant material spillage, seriously affecting production safety.
Main Causes: Improper installation of rollers or idlers, or non-parallel center lines.
3. Drive Motor Overheating or Burnout
Consequences: The motor will shut down due to protection mechanisms or be directly damaged, paralyzing the entire conveyor line. Repair or replacement costs are high.
Main Causes: Overloading, bearing lubrication failure, or poor heat dissipation.
4. Serious Transmission System Failure (e.g., chain breakage, gear damage)
Consequences: Power transmission interruption, conveyor cannot operate, possibly accompanied by severe abnormal noise and vibration, damaging other components.
Main Causes: Abnormal gear meshing clearance, coupling misalignment, or component fatigue fracture.
II. Serious Problems (Significantly Affecting Efficiency and Cost)
1. Frequent Slippage
Consequences: Decreased conveying efficiency, increased motor current, accelerated belt and roller wear, affecting production rhythm.
Main Causes: Insufficient tension, oil or water stains on roller surface, or excessive load.
2. Difficult Start-up or Frequent Shutdowns
Consequences: Equipment cannot start normally or shuts down protectively during operation, seriously affecting production continuity and increasing impact loads on electrical and mechanical components.
Main Causes: Excessive load, bearing jamming, or improper electrical parameter settings.
3. Unstable Speed
Consequences: Uneven material conveying may lead to blockages or insufficient material supply in downstream equipment, affecting the overall production process.
Main Causes: Unstable motor speed, loose transmission system, or large load fluctuations.
III. Other Common Problems (Usually solvable through adjustments)
1. Conveyor Belt Wear and Tearing
Consequences: Shortens conveyor belt life, increases replacement frequency and cost, and may lead to breakage in severe cases.
Main Causes: Friction with hard or sharp materials, environmental corrosion, or improper installation.
2. Material Spillage
Consequences: Pollutes the environment, increases cleanup workload, and spilled material may cause personnel to slip or equipment to jam.
Main Causes: Conveyor belt misalignment, poor sealing of the guide chute, or mismatch between belt speed and feed rate.
3. Excessive Abnormal Noise
Consequences: Usually indicates wear or loosening of components (such as bearings and rollers), a signal requiring maintenance, but does not directly cause machine shutdown.
Main causes: wear, friction, or loose parts in the rollers or bearings.
