Conveyor Belt Tracking: Prevent Misalignment
Conveyor Belt Alignment
Proper conveyor belt alignment plays a significant role in efficiency at a bulk material handling plant. Misalignment occurs when there is a problem with the conveyor belt tracking, the process for keeping the conveyor belt on its proper path.
Just a few causes of conveyor belt mistracking might include:
damaged idler frames
uneven skirting pressure
too much belt tensioning
lack of transition idlers
uneven or misaligned pulleys
conveyor rollers of different diameters
improper belt splicing
worn self-aligning idlers
The consequences of improper conveyor belt tracking can range from uneven belt wear to a complete slipping of the conveyor belt to a side, causing the entire system to misalign. In addition, the problems that begin at the belt can ripple through production, leading to shutdowns for inspection, maintenance, repair, and potential safety risks.
Frequent monitoring of the conveyor belt is good business practice. Doing so allows operators to spot and resolve any developing issues before they become hazards or reasons for halting production.
At the same time, even careful inspections can miss something, and even the most reliable personnel can make a mistake. Worn or ineffective conveyor components also contribute to problems with belt tracking and alignment.
Operators can achieve greater command of material flow by increasing their awareness of the causes of misalignment and the engineered solutions that will prevent them.
Misalignment: What to Watch For
The conveyor belt’s path is crucial to all operations on the floor. However, a conveyor belt that constantly slips or alters shape can significantly set back daily business goals.
The following are a few leading factors behind improper conveyor belt tracking.
Material build-up
The leading cause of mistracking is the build-up of product, debris, and other primary materials on the bottom side of the belt or pulleys. In particular, the build-up can form a crown or raised portion on the pulley, making the belt mistrack.
Carryback is another effect of excess material build-up. Even small amounts of residue can become a problem when they accumulate beneath the belt over time. Carryback can also cause material spillage, leading to fire and health hazards and lost product and profit.
During scheduled inspection and maintenance, always be sure to check the entire system for cleanliness from all directions. In addition, well-engineered conveyor components such as training idlers, impact beds, diagonal plows, and belt scrapers should be part of a comprehensive conveyor belt tracking system as well.
Seized rollers & sharp edges
Many conveyor belts are made from metallic materials such as steel. This is good for belt durability and lifespan, but it also means that when the rollers seize up, they can form sharp edges that make the belt mistrack down the centerline of the conveyor belt.
In addition to potentially damaging materials and products on the belt, sometimes severely, these sharp edges can develop into a significant safety hazard. A required shutdown for maintenance and repairs can be extensive as well. Therefore, the rollers should be checked often.
Idlers
Improper installation or essential wear and tear can make return idlers frozen, dirty, or misaligned. In addition, idlers that halt or freeze can have a significant effect on conveyor belt tracking. Therefore, these parts should be checked regularly for cleanliness, wear, and alignment.
Belt cutting
Unfortunately, some conveyor belts can be cut incorrectly when they are manufactured. This will make them crooked from the get-go and contribute to flawed conveyor belt tracking.
New or replacement conveyor belts should be inspected for proper cutting during installation. If a belt has already been installed, the belt can be removed from the frame and laid flat on the floor for proactive troubleshooting. If the conveyor belt arcs or curves at any point, it is not straight and should be promptly replaced.
On a similar note, a crooked or slanted frame can misguide the conveyor belt and cause misalignment. The frame should be inspected from all angles to confirm that it is level and square. Check the end pulleys to ensure they are even with the conveyor frame as well.
Snub rollers should likewise align with the frame to apply proper tension to the belt, as they are crucial to conveyor belt tracking.
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