Belt Tracking & Conveyor Maintenance

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About Kinder & Co

Kinder & Co is a privately owned Australian company highly respected by its customers and business partners.

The company was founded in 1985 by Neil and Christine Kinder. Over 27 years , earned a reputation second-to-none by delivering excellence in the bulk solids materials handling industries.Kinder & Co is a family operation.

Today Kinder is recognised as a leading independent supplier and manufacturer of innovative and practical solutions to improve and maintain the running efficiency of conveyor and bulk materials handling equipment used to convey a variety of products that include ore, quarried products, grain, sugar, salt and coal.

For more information:
Kinder & Co
Phone: 03 9587 9244
Email sales@kinder.com.au
Website: http://www.kinder.com.au

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Belt Tracking & Conveyor Maintenance

  1. 1. Belt Tracking & Conveyor Maintenance Training Presentation 2013
  2. 2. Belt Tracking & Maintenance 2013 What’s the Problem??
  3. 3. Belt Tracking & Maintenance 2013 Objectives Productivity Reliability Unexpected downtime Maintenance costs Operate safely without incidents.
  4. 4. Belt Tracking & Maintenance 2013 Belt Tracking • Efficiently • Safely • Reliably The goal in achieving proper and consistent belt tracking is to ensure safe, consistent, trouble-free, economical conveyor system operation — in short, to be able to walk away from the system and not worry about its operation for reasonable periods of time.
  5. 5. Belt Tracking & Maintenance 2013 What is belt tracking? Tracking (or training) is defined as the procedure required to make the conveyor belt run “True” or “centered” under ALL operating conditions
  6. 6. Belt Tracking & Maintenance 2013 Why bother? A conveyor belt must run “true” to avoid: •Material spillage at transfer points •Damage to edge of conveyor belt •Damage to conveyor components •Damage to conveyor structure
  7. 7. Belt Tracking & Maintenance 2013 Rubber Price Rise
  8. 8. Belt Tracking & Maintenance 2013 Charles’s rule of maintenance Material Spillage + Belt Damage + Component Damage + Structure Damage = Headaches, Wasted Time & Wasted Money
  9. 9. Belt Tracking & Maintenance 2013 Belt Tracking – SO FAR • Understanding that belt mis-tracking is the root cause of spillage, reduced belt life, component failure and structure damage. • Don‟t accept that conveyors will not track true under all operating conditions and work towards rectifying the faults.
  10. 10. Belt Tracking & Maintenance 2013 Rule Zero • Comes before any other rule • Belt moves towards roller it contacts first
  11. 11. Belt Tracking & Maintenance 2013 Rule Zero • ALL pulleys, snub rollers, carrying idlers and return idlers must be SQUARE with the frame and PARALLEL to each other.
  12. 12. Belt Tracking & Maintenance 2013 Should we track at Pulleys THIS IS NOT FOR BELT TRACKING
  13. 13. Belt Tracking & Maintenance 2013 OF 180 ° Should we track at Pulleys
  14. 14. Belt Tracking & Maintenance 2013 OF 220 ° Should we track at Pulleys
  15. 15. Belt Tracking & Maintenance 2013 OF 180 ° Should we track at Pulleys
  16. 16. Belt Tracking & Maintenance 2013 Should we track Pulleys 2~4° • The Pulley has a massive affect on belt tracking • If it is not parallel - you will pay
  17. 17. Belt Tracking & Maintenance 2013 Should we track Pulleys
  18. 18. Belt Tracking & Maintenance 2013 Should we track Pulleys • LOW BELT TENSION • HIGH BELT TENSION
  19. 19. Belt Tracking & Maintenance 2013 VERY IMPORTANT: Corrective Action • Before you start making adjustments to idlers and pulleys, try to find and correct the cause of mistracking
  20. 20. Belt Tracking & Maintenance 2013 Common Causes of Belt Misalignment
  21. 21. Belt Tracking & Maintenance 2013 Cause 1: Material Spillage / Carry Back Cause 1
  22. 22. Belt Tracking & Maintenance 2013 Cause 1 Material Spillage / Carry Back • CLEANLINESS is essential to good belt tracking. • Foreign matter in essence creates a new roll or pulley face • Ineffective scrapers • Poorly designed or maintained transfer point
  23. 23. Belt Tracking & Maintenance 2013 Cause 1: Material Spillage / Carry Back
  24. 24. Belt Tracking & Maintenance 2013 Cause 1: Material Spillage / Carry Back Possible solutions: Belt Support (K-SURE) Before After
  25. 25. Belt Tracking & Maintenance 2013 Cause 1: Material Spillage / Carry Back Possible solutions: Skirting
  26. 26. Belt Tracking & Maintenance 2013 Cause 1: Material Spillage / Carry Back Possible solutions: R.D.R.T roller
  27. 27. Belt Tracking & Maintenance 2013 Cause 1: Material Spillage / Carry Back Possible solutions: K-Polymer Roller
  28. 28. Belt Tracking & Maintenance 2013 Cause 1: Material Spillage / Carry Back Possible solutions: Scrapers Different Scrapers For Different Applications
  29. 29. Belt Tracking & Maintenance 2013 Cause 2: Belt Loading Not Central Cause 2
  30. 30. Belt Tracking & Maintenance 2013 Cause 2: Belt Loading Not Central • Gravity is a harsh mistress
  31. 31. Belt Tracking & Maintenance 2013 Cause 2: Belt Loading Not Central • Gravity is a harsh mistress
  32. 32. Belt Tracking & Maintenance 2013 Cause 2: Belt Loading Not Central
  33. 33. Belt Tracking & Maintenance 2013 Cause 3: Extreme Weather Cause 3
  34. 34. Belt Tracking & Maintenance 2013 Cause 3: Extreme Weather • Strong winds • Rain causing slippage • etc
  35. 35. Belt Tracking & Maintenance 2013 Cause 4: Not Enough Belt Tension Cause 4
  36. 36. Belt Tracking & Maintenance 2013 Cause 4: Not Enough Belt Tension • Belt should be tensioned enough to conform to crown on head pulley • Belt should be tensioned enough to eliminate slippage
  37. 37. Belt Tracking & Maintenance 2013 Cause 5: Rollers seized or uneven Cause 5
  38. 38. Belt Tracking & Maintenance 2013 Cause 5: Rollers seized or uneven • Seized trough rollers will cause belt to mistrack
  39. 39. Belt Tracking & Maintenance 2013 Cause 6: Belt Camber Cause 6
  40. 40. Belt Tracking & Maintenance 2013 Cause 6: Belt Camber If %camber exceeds ½% the belt manufacturer should be contacted %camber = maximum deviation from straight x 100 ---------------------------------------------------straight belt length
  41. 41. Belt Tracking & Maintenance 2013 Cause 6: Belt Storage
  42. 42. Belt Tracking & Maintenance 2013 Cause 7: Belt Camber Cause 7
  43. 43. Belt Tracking & Maintenance 2013 Cause 7: Disobeying ‘Rule Zero’
  44. 44. Belt Tracking & Maintenance 2013 Cause 7: Disobeying ‘Rule Zero’ Windy day / Seized rollers / Not loaded centre / Build up
  45. 45. Belt Tracking & Maintenance 2013 Cause 7: Disobeying ‘Rule Zero’
  46. 46. Belt Tracking & Maintenance 2013 Cause 7: Disobeying ‘Rule Zero’
  47. 47. Belt Tracking & Maintenance 2013 SO YOU’VE DISOBEYED ‘RULE ZERO’ A Guide for Adjusting Idlers Back to True
  48. 48. Belt Tracking & Maintenance 2013 Belt Training The training process should begin at the head pulley end of the return belt, with the work being carried out on the return idlers in the direction of the belt travel towards the tail end, then along the carrying idlers to the discharge end.
  49. 49. Belt Tracking & Maintenance 2013 Belt Training 10 11 12 9 8 7 6 5 13 4 15 16 17 18 19 14 3 2 1
  50. 50. Belt Tracking & Maintenance 2013 Belt Training To correct belt wander always face in the direction of belt travel, then if the belt is running to the right, advance the right side of the idler set in the direction of the belt travel. Several idlers should be adjusted slightly rather than one or two too much.
  51. 51. Belt Tracking & Maintenance 2013 Equipment Options (current)
  52. 52. Belt Tracking & Maintenance 2013 Equipment Options (new)
  53. 53. Belt Tracking & Maintenance 2013 Equipment Options (new)
  54. 54. Belt Tracking & Maintenance 2013 Position Trackers 3.5 X BW ALLOWS BELT TO TRACK BEFORE PARALLEL PULLEY PARALLEL PULLEY WILL KEEP BELT STRAIGHT
  55. 55. Belt Tracking & Maintenance 2013 Minimum 3.5 x Belt Width
  56. 56. Belt Tracking & Maintenance 2013 •The picture below shows which direction the conveyor belt will track towards once rollers have been shifted from square to stringers. •The angle has been exaggerated for demonstration and should not exceed 2 degrees in the field.
  57. 57. Belt Tracking & Maintenance 2013 •Below is another technique used to help aid belt tracking. •This is unbiased to a particular side. •This technique cannot be used on bidirectional conveyors.
  58. 58. Belt Tracking & Maintenance 2013 My Suggestions 1. Square up all rollers and pulleys before adjusting anything 2. Ensure belt scraper is tensioned (lightly) and effective 3. Ensure belt is being tracked properly into tail drum 4. Ensure belt is loaded centrally NOTE: If you have constantly changing conditions then a self tracker is a MUST
  59. 59. Belt Tracking & Maintenance 2013 Conclusion Tracking problems cause huge and unnecessary expenses including: - Material waste Maintenance costs Clean up costs Component damage / failure Structure damage
  60. 60. Belt Tracking & Maintenance 2013 Conclusion Any cost spent tracking your belt „true‟ is NOT and will NEVER be a costly exercise compared to the expenses of NOT tracking your belt „true‟ The great thing is… You don‟t necessarily need to spend a cent
  61. 61. Belt Tracking & Maintenance 2013 Bulk Materials Handling Products MADE BETTER - since 1985
  62. 62. Belt Tracking & Maintenance 2013 Thank You

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