Common Conveyor Belt Problems and Solutions

1. Conveyor Belt Mistracking and Edge Damage

Belt wander occurs when the belt drifts laterally toward one side of the conveyor stringer during operation. Left uncorrected, the belt edges rub against structural steelwork, causing severe carcass delamination and catastrophic failure.

Diagnostic procedure begins by observing whether the mistracking occurs consistently at a specific physical location on the conveyor frame or moves along with a particular section of the belt. If the wander happens at a fixed location, the idler frames or pulleys at that location are out of square. If the wander travels with the belt, an uneven or crooked vulcanized splice is the probable root cause.

• Verify structural alignment using precision laser squaring along both stringer rails.
• Install self-aligning training idlers at 30-meter intervals on return and carry runs.
• Adjust chute baffle plates to ensure material is deposited centrally onto the receiving belt.

2. Material Carryback and Spillage Along the Return Run

Material carryback occurs when damp, sticky, or fine particles adhere to the conveyor belt surface past the discharge pulley. As the belt transitions through the return run, this residue drops onto return idlers, building up eccentric rings that exacerbate mistracking and damage idler bearings.

Primary single-blade scrapers positioned at the 3 o’clock position on the head pulley remove up to 70% of material. A secondary tungsten-carbide or polyurethane cleaner mounted directly behind the head pulley removes fine moisture films, keeping return runs pristine.

3. Drive Pulley Slippage and Lagging Wear

When the drive pulley rotates faster than the conveyor belt, friction burns through the bottom cover fabric. Slippage is commonly triggered by reduced belt tension, worn pulley lagging, or rainwater ingress between the pulley and belt interface.

Inspection begins at the take-up unit. Gravity take-ups must have free vertical carriage movement without bind, while screw take-ups require regular adjustment to restore calculated operating tension.

• Inspect pulley lagging for smooth spots; replace worn rubber with diamond-grooved or ceramic lagging.
• Verify counterweight mass matches design tension for full-load cold startup conditions.
• Increase the angle of belt wrap around the drive pulley using a properly positioned snub pulley.

4. Splice Separation and Joint Fatigue

Splices endure cyclic tension, bending stresses over pulleys, and scraper impact. Premature failure often stems from improper rubber curing during vulcanization, moisture contamination during joint preparation, or mismatched pulley diameters below the belt’s minimum bend radius.

• Enforce standardized cleanroom preparation procedures for hot and cold vulcanized splices.
• Conduct regular non-destructive visual and ultrasonic inspections for joint edge lift or cord fatigue.