Conveyor belts have revolutionized modern industrial workplaces tremendously. These innovative machines provide a hassle-free way to move sensitive or bulky materials over long distances, freeing up the human workforce of mundane tasks.
Belt conveyor systems also regulate product weight and volume, helping foster standardization. And although they’re typically bulky, the equipment can be installed in overhead space and rerouted over obstacles to maximize floor space.
But despite their undeniable efficiency, conveyor belts aren’t 100% fail-proof.
There have been widespread reports of conveyor belt accidents in the recent past, causing life-threatening injuries and even deaths. The surest way to minimize these incidents is by investing in a premium belt system and implementing a proper maintenance plan.
In this post, we highlight practical tips on maintaining your conveyor belt to forestall costly mechanical breakdowns.
1. Daily Inspections
Daily conveyor belt inspections don’t need to be extensive, as they mainly focus on checking for anomalies on the belt chain.
Examine your belt conveyor chain system for material spillage, belt slippage, and carryback while the machine is in operation. It’s also best to check for evidence of wear at the end of each workday, including fraying or material buildup.
These minor inspections can help to nip problems in the bud, averting major mechanical breakdowns and costly repairs.
2. Weekly Inspections
While daily conveyor belt inspections are critical, you may not uncover all mechanical issues during a normal, busy workweek. That’s where weekly check-ups come in.
For a better outcome, you can split the weekly examinations as follows;
Visual Inspections
Check for visual evidence of excessive wear on individual components of your belt conveyor system, such as holes, dents, frays, and tears.
Start with the belt chain before proceeding to the idlers and pulleys.
Auditory Inspections
Run your conveyor belt and listen attentively for abnormal sounds from the bearings and drive system.
While greasing typically fixes unusual conveyor sounds, enlist professional assistance if the sounds persist.
Tactile Inspections
Certain signs of conveyor belt malfunctions, such as excessive heat and strange vibrations, are best detected by hand.
Focus your inspections around the drive system and bearings.
Mechanical Inspections
Mechanical inspections involve probing for issues using maintenance tools.
Common target areas here include the general alignment and tension of the idlers and pulleys.
3. Belt Tracking
The efficiency of a conveyor belt is largely dependent upon the alignment of the belt chain.
A misaligned belt can damage your products by causing material spillage mid-transit. It may also increase wear along the edges of the conveyor belt, pulleys, and idlers, resulting in uneasy vibrations.
To properly track your conveyor belts, start by adjusting the idlers and pulleys. Then, adjust the take-up to align the belt with the idlers and pulleys.
4. Belt Splicing
Splices are designed to fix worn or torn sections of a conveyor belt. They let you change only the damaged section, avoiding high replacement costs.
Besides, splicing your conveyor belt reduces operational downtimes associated with replacing an entire belt.
The easiest way to splice a conveyor belt is by stretching the original belt to seal the damage. If the wear is extensive, you may need to patch up the entire section or replace it.
5. Belt Tensioning
Like splicing and tracking, the overarching goal of tensioning is to improve your conveyor belt’s efficiency.
Tensioning prevents material slippage while reducing excessive wear along the belt channel.
Read your user manual for proper tensioning guidelines. Besides, stick to the recommended tools to prevent undue damage to the machinery.
6. Regular Cleaning
Conveyor belts can trap dust and debris over time. Without timely removal, dirt build-up may cause belt slippage and accelerate wear through increased friction. Regular cleaning is essential to improve the efficiency and durability of your belt conveyor system.
Now, there’s no standard rule on how frequently to clean your conveyor belts. That would depend on the type of products the machine handles, frequency of use, and the general dust conditions of your workplace.
As for the cleaning method, a simple wipe-down using a soft fabric dipped in soapy water would do. Just be sure to steer clear of electrical components.
To dislodge encrusted dirt or stubborn stains, use an approved brush or scraping tool.
7. Routine Lubrication
Conveyor belts have multiple moving components, including the idler bearings and pulleys. Without proper lubrication, these parts can generate friction and accelerate the equipment’s wear.
Lubricating a conveyor belt is one of the few maintenance procedures you can undertake. However, enlisting professional assistance is necessary to choose the recommended industrial lubricant.
Apply the lubricant to all mobile components according to the manufacturer’s guidelines. Take care not to overapply, as excess grease can draw dirt and debris to the belt system.
8. Reinforcing Safety Measures
Information is power, and proper employee training can avoid many conveyor belt mishaps.
Subject every recruit to robust training on how to safely use conveyor belts. Ensure you also maintain dedicated handbooks on safety protocols, including how to handle sensitive materials and the procedures to follow in the event of equipment breakdowns or employee injuries.
Don’t forget to install basic conveyor belt safety features, including guard rails and emergency stop switches.
Summary
Maintaining a conveyor belt system requires a proactive approach. The trick is to schedule inspections as frequently as possible.
During these inspections, maintenance technicians can uncover potential issues with your conveyor systems and fix them before they escalate into significant breakdowns.
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