Common problems of conveyors:
Material handling in mines accounts for a large proportion of the total mining cost. As a result, conveyor systems have become a common solution to improve operational efficiency. The challenge is that conveyors often operate under extremely harsh conditions, such as: dirty environments, high or low temperatures, and high humidity. If not properly maintained, conveyors can experience rapid belt wear and component failure, resulting in downtime and repairs. This has a corresponding negative impact on both productivity and profits.
Three common conveyor downtime problems and their solutions:
1. Belt deviation
Problem: Belt misalignment occurs when the belt deviates from its desired path. This is a serious problem that can lead to belt damage, equipment failure and material spillage. There are many reasons for belt deviation, such as insufficient belt tension, eccentric load, incorrect splicing, component deflection, material accumulation on components and components, and so on.
Solution: A better solution is to find the root cause of belt misalignment to prevent the same problem in the future. Conducting a belt inspection can help identify potential problems causing misalignment so that an appropriate solution can be developed. If the belt is slightly misaligned, the self-aligning idler can be used to correct the belt's trajectory and keep it running straight in the future.
2. Material return
Problem: When a small amount of material sticks to the belt, the conveyor will carry back the phenomenon. This can cause material to build up under the Conveyor Belt, or on idlers and drums. Certain materials, such as clay and certain ores, stick to the belt more easily than others. Although the return volume is very small, over a long period of time, there will be tons of materials accumulated, which has to be cleaned twice. Material carryback also creates safety and environmental hazards, increases cleanup costs, and often prevents conveyor systems from operating in optimal condition.
Solution: A simple solution is to install Belt Cleaners designed to prevent carryback. The benefits of a belt cleaner more than offset its upfront investment cost. Reduced material spillage saves maintenance costs and creates a safer work environment. In addition, clean belts prevent premature idler failure, extend belt life, and keep the system in optimal operating condition.
3. Belt damage
Problem: Belt damage can be caused by several factors, such as excessive impact force, misalignment, improper use of sealing systems or belt cleaners, stuck components, and insufficient pulley traction. Belts are the more expensive components of conveyors, so it is important to find the underlying cause of belt problems and take proactive steps to avoid irreparable damage.
Solutions: There are many causes of belt damage and therefore many different solutions. For example, installing buffer rollers or brackets in the feeding area can disperse the impact of falling material, thereby reducing wear and tear on the belt. With a proper sealing system, the belt can be prevented from being damaged by stuck material. With the proper roller wrap material, you can increase the friction and prevent the belt from slipping without damaging it quickly. These solutions all help to minimize maintenance downtime and are usually determined by a single belt inspection. Belt inspections can catch minor belt damage, preventing major failures in the future.