conveyor belt troubleshooting: what to do if your system has issues

Accumulation of material on the belt, rollers or on other components, reduced speed, increased slippage, accelerated power consumption, and unusual noises or vibrations during operation are some of the symptoms of material build-up on conveyor systems.

To solve it, check the belt for substances adhered to the surface or edges, inspect pulleys for material deposits that can cause misalignment, and ensure chutes and hoppers are free from blockages and build-up.

Brushes, scrapers, or air nozzles can be employed to remove material, and automated cleaning solutions like belt cleaners or scrapers can continuously remove debris from the system during operation. High-pressure water or air could also be used to dislodge and remove stubborn dirt.

Adjustments to conveyor components also help. Ensuring proper belt alignment prevents material from accumulating on one side, while adjusting tension minimises slippage.

Evenly distributing the material load prevents uneven build-up, and using belts with anti-stick surfaces or coatings minimises substance adhesion.

Belt misalignment occurs when the equipment deviates from its intended path, causing it to run off track. This asymmetry can result in unusual noises, vibrations, and visible gaps between the machinery and the rollers or pulleys. Over time, it leads to uneven wear on the apparatus and other conveyor components, potentially shortening their lifespan.

To address the issue, the first step is to adjust the tracking mechanisms using the adjustment screws or rollers to realign the belt, ensuring it runs centrally along the conveyor.

Next, it is essential to realign the rollers and pulleys and thoroughly clean the devices to remove any debris. Additionally, inspect and replace any worn or damaged edges to maintain proper alignment and extend the equipment's lifespan.

Unusual noise in a conveyor system can manifest as grinding, squeaking, rattling, or other abnormal sounds during operation. These noises often indicate mechanical problems such as worn components, misalignment, or insufficient lubrication.

The solution is simple. Apply lubricant to all moving parts according to the manufacturer’s specifications, ensuring that bearings, rollers, and other components operate smoothly.

Inspect the bearings for wear or damage, and replace any piece of equipment that shows signs of wear to restore quiet and efficient operation. Similarly, examine the rollers and idlers for wear or misalignment.

Loose bolts, nuts, or other hardware can cause rattling noises as the conveyor operates. Tighten any loose components and replace any missing hardware to eliminate these noises.

Inspect the drive motor and gearbox. Sounds that are out of the ordinary from the motor or gearbox can indicate mechanical issues such as worn gears or bearings.

Before trying to fix the issues on your conveyor systems, remember that these pieces of equipment can be dangerous if not handled properly. Maintenance activities often require close interaction with belts, pulleys, and rollers, which can cause serious injuries. Wearing appropriate personal protective equipment (PPE), such as gloves and safety glasses, and adhering to safety guidelines can significantly reduce the risk of accidents.