11 Biggest Conveyor Challenges & How to Overcome Them
Here’s a summary of the most common challenges regarding conveyor systems, along with practical solutions.
1. How do I properly track the belt?
Solution: Correct belt tracking should primarily be done with the return idlers, not the take-ups.
2. How can I prevent material from getting into the S-drive pulleys?
Solution: Install a V-plow in front of the S-drive and check the UHMW (Ultra-High Molecular Weight Polyethylene) components to ensure they’re still intact and have sufficient wear life.
3. What’s the proper way to change tires on the wrap drive, and how do I avoid breaking the bead seal?
Solution: Deflate the tire, install the new one, and inflate it to a maximum of 12 PSI. If bead seals continue to break, consider installing tubes.
4. How do I adjust the flashing on slide packs with flip-up extensions?
Solution: Use a long extension and swivel socket to access the area.
5. Why does the head shaft on the TS need to be stepped down twice?
Solution: The extra thickness in the pulley helps prevent shaft deflection, and stepping down the shaft end accommodates the gear reducer. We’ll consult our engineers for additional insight on why this two-stage process is necessary.
6. How can I avoid belt slippage in cold weather?
Solution: Ensure proper belt tension, add a snub pulley at the head end if necessary, and check that the head pulley lagging isn’t too smooth or worn. For extreme conditions, consider upgrading to a ceramic head pulley.
7. How do I prevent material from entering the e-chain?
Solution: For material larger than the finished product (3” minus), consider installing rock boards. Make sure the hopper skirting contacts the belt, check the sealing system, and perform regular inspections and cleaning of the e-chain.
8. How can I avoid rocks ripping the belt?
Solution: Installing a Chevron wing pulley may help, as well as checking the flashing at the feed point to prevent loose material from reaching the return strand.
9. How can I perform bearing changes in confined areas, and why do tail pulley bushings sometimes come loose?
Solution: Ensure that bushings are torqued properly. If slippage persists, you may need to add a keyway to the shaft for extra security.
10. How can I improve consistency in my belt scale readings?
Solution: Make sure your belt scale is properly calibrated, adjust it as material characteristics change, and ideally, install it on a stationary conveyor for best results.
11. How do I prevent material from slipping on the belt in cold weather?
Solution: Instead of using a propane torch, consider an infrared heater with a motion detector to automatically switch off when the belt stops.
Need Additional Assistance?
If you have more questions about conveyors—or anything related to crushing, screening, and conveying—our team is always here to help. Don’t hesitate to give us a call. We’re happy to provide guidance and solutions for all your operational challenges.