Belt Tracking & Conveyor Maintenance: Training Presentation

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 incident

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.
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Should we track at Pulleys

THIS
IS
NOT
FOR
BELT
TRACKING
2013

180
°
OF
2013

220
°
OF
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180
°
OF
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Should we track Pulleys

2~4°
• The Pulley has a massive affect on

belt tracking
2013

2013

• LOW BELT TENSION
• HIGH BELT TENSION

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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 Ba
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
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

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Cause 1:
Possible solutions: K-Polymer Roller
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Cause 1:
Possible solutions: Scrapers
Different Scrapers
For
Different
Applications
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Cause 2:
Belt Loading Not Central
Cause 2
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Cause 2:
• Gravity is a harsh mistress
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Cause 2:
• Gravity is a harsh mistress
2013
Cause 2:
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Cause 3:
Extreme Weather
Cause 3
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Cause 3:
Extreme Weather
• Strong winds
• Rain causing slippage
• etc
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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
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Cause 5:
Rollers seized or uneven
Cause 5
2013
Cause 5:
Rollers seized or uneven
• Seized trough rollers will cause belt to
mistrack
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Cause 6:
Belt Camber
Cause 6
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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
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Cause 7:
Disobeying ‘Rule Zero’
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Cause 7:
Windy day / Seized rollers / Not loaded centre /
Build up
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Cause 7:
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Cause 7:
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SO YOU’VE DISOBEYED
‘RULE ZERO’
A Guide for Adjusting Idlers

Back to True
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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.
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Belt Training
14 15 16 17 18 19
13
10 11 12
9 1
3 2
5 4
8 7 6
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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)

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Equipment Options (new)

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Equipment Options (new)

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Position Trackers
3.5 X BW
ALLOWS BELT TO TRACK
BEFORE PARALLEL PULLEY
PARALLEL PULLEY WILL
KEEP BELT STRAIGHT
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Minimum 3.5 x Belt

Width
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•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
bi-directional 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 changin
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
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Belt Tracking

What’s the Problem??

Operate safely without incident

The goal in achieving proper and consistent

What is belt tracking?

•Material spillage at transfer points

•Damage to edge of conveyor belt

•Damage to conveyor components

•Damage to conveyor structure

Rubber Price Rise

Charles’s rule of maintenance

Belt Tracking – SO FAR

• Understanding that belt mis-

• Don’t accept that conveyors will

• Comes before any other rule

• Belt moves towards roller it contacts

Should we track at Pulleys

Should we track at Pulleys

Should we track at Pulleys

Should we track at Pulleys

Should we track Pulleys

• The Pulley has a massive affect on

Should we track Pulleys

Should we track Pulleys

• HIGH BELT TENSION

VERY IMPORTANT: Corrective Action

• Before you start

Common Causes of Belt Misalignment

Possible solutions: Skirting

Possible solutions: R.D.R.T roller

Possible solutions: Scrapers

• Belt should be tensioned

• Belt should be tensioned

If %camber exceeds ½% the belt manufacturer

%camber = maximum deviation

A Guide for Adjusting Idlers

The training process should

Several idlers should be

Equipment Options (current)

Equipment Options (new)

Equipment Options (new)

Minimum 3.5 x Belt

•The picture below shows which direction the

•Below is another technique used to

The great thing is…

You don’t necessarily need to spend a

Bulk Materials Handling

MADE BETTER - since 1985

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