Belt Tracking & Conveyor Maintenance

Belt Tracking
&
Conveyor Maintenance

Training Presentation
2013

Belt Tracking & Maintenance
2013

What’s the Problem??

2013

Objectives
Productivity
Reliability
Unexpected downtime

Maintenance costs

Operate safely without incidents.

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.

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

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

2013

Rubber Price Rise

2013

Charles’s rule of maintenance
Material Spillage
+
Belt Damage
+
Component Damage
+
Structure Damage
=
Headaches, Wasted Time
& Wasted Money

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.

2013

Rule Zero
•

Comes before any other rule

•

Belt moves towards roller it contacts first

2013

Rule Zero
•

ALL pulleys, snub rollers, carrying idlers and
return idlers must be SQUARE with the frame
and PARALLEL to each other.

2013

Should we track at Pulleys
THIS
IS
NOT
FOR
BELT
TRACKING

2013

OF

180
°


2013

OF

220
°


2013

Should we track Pulleys
2~4°

• The Pulley has a massive affect on belt tracking

• If it is not parallel - you will pay

2013


2013

• LOW BELT TENSION

• HIGH BELT TENSION

2013

VERY IMPORTANT: Corrective Action
•

Before you start making
adjustments to idlers
and pulleys, try to find
and correct the cause
of mistracking

2013

Common Causes of Belt Misalignment

2013

Cause 1:
Material Spillage / Carry Back

Cause 1

2013

Cause 1
•

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

2013

Cause 1:

2013

Cause 1:
Possible solutions: Belt Support (K-SURE)

Before

After

2013

Cause 1:
Possible solutions: Skirting

2013

Cause 1:
Possible solutions: R.D.R.T roller

2013

Cause 1:
Possible solutions: K-Polymer Roller

2013

Cause 1:

Possible solutions: Scrapers

Different Scrapers
For
Different Applications

2013

Cause 2:
Belt Loading Not Central

Cause 2

2013

Cause 2:
•

Gravity is a harsh mistress

2013

Cause 2:

2013

Cause 3:
Extreme Weather

Cause 3

2013

Cause 3:
Extreme Weather
•

Strong winds

•

Rain causing slippage

•

etc

2013

Cause 4:
Not Enough Belt Tension

Cause 4

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

2013

Cause 5:
Rollers seized or uneven

Cause 5

2013

Cause 5:
Rollers seized or uneven
•

Seized trough rollers will cause belt to mistrack

2013

Cause 6:
Belt Camber

Cause 6

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

2013

Cause 6:
Belt Storage

2013

Cause 7:
Belt Camber

Cause 7

2013

Cause 7:
Disobeying ‘Rule Zero’

2013

Cause 7:
Disobeying ‘Rule Zero’
Windy day / Seized rollers / Not loaded centre / Build up

2013

SO YOU’VE DISOBEYED
‘RULE ZERO’
A Guide for Adjusting Idlers
Back to True

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.

2013

Belt Training

10 11 12
9
8

7

6

5

13
4

15 16 17 18 19
14
3 2

1

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.

2013

Equipment Options (current)

2013

Equipment Options (new)

2013

Position Trackers

3.5 X BW
ALLOWS BELT TO TRACK
BEFORE PARALLEL PULLEY
PARALLEL PULLEY WILL
KEEP BELT STRAIGHT

2013

Minimum 3.5 x Belt Width

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.

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.

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

2013

Conclusion
Tracking problems cause huge and unnecessary
expenses including:
-

Material waste
Maintenance costs
Clean up costs
Component damage / failure
Structure damage

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

2013

Bulk Materials Handling Products

MADE BETTER - since 1985

2013

Thank You

Belt Tracking & Conveyor Maintenance

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