Typical troubles on belt conveyor operation and how to prevent them

Belt conveyors are effective for transporting large amount of raw material or fuel and so widely used in material industry, energy industry and so on.

Accidents are relatively decreasing nowadays but it may cause various troubles when facilities become old.

So, it is important to understand characteristics of belt conveyors for stable operation of belt conveyors and safety of workers.

This article shows such typical troubles and those countermeasures.

Popular causes of this trouble are following:

1. Pulley or roller has got dirt, build-up, adhesion, etc.
2. Roller is not rotating properly or broken.
3. Transporting material is changed. (loaded on side, etc.)
4. Skirt rubber is damaged or load material is bitten inside.
5. Conveyor belt is damaged.

Then, it may cause; "conveyor belt snaking (or misalignment)" ➡ "material drop" ➡ "production loss and maintenance cost raise".

Popular causes of this trouble are following:

1. Belt slip between conveyor belt and drive pulley.
2. Heat due to malfunction or rotating parts (bearing, roller, etc.).
3. Friction heat between misaligned belt and frame.
4. Heat generated from accumulated dust at roller stand, etc.
5. Ignition from the site work using fire.

Then, it may cause; "fire accident" ➡ "production loss, maintenance cost raise, human injury, health damage and air pollution".

Popular cause of this trouble is following:

Wrong material or obstacles like sharp solid or metal mixed in the transporting material sticks through the conveyor belt and stuck in the impact roller just below the transferring chute.

Then, it may cause; "belt rip accident" ➡ "production loss and maintenance cost raise".

Popular causes of this trouble are following:

1. Frequent belt slip between conveyor belt and drive pulley.
2. Rubber of belt surface is worn and the fabric is exposed.
3. Crack or scratch on the inner fabric observed 10% or over.
4. Bear tear damage or scratch.
5. There are many repair portions.

Then, it may cause; "belt cut break accident" ➡ "production loss, maintenance cost raise and serious human injury accident".

Popular causes of this trouble are following:

1. Transferring conveyor has conveyor belt slipping.
2. Transporting material is stuck in the transferring chute and not charged on the belt conveyor.

Then, it may cause; "blocking chute accident" ➡ "production loss, maintenance cost raise and environmental pollution".

Popular causes of this trouble are following:

1. Someone started the conveyor during the repair work.
2. Self-driving system started the conveyor during the repair work.
3. Build-up material removing work without stopping the conveyor.
4. Unintentionally touched with rotating pulley at the conveyor not having the safety cover.

Then, it may cause; "human caught in the machine" ➡ "serious human injury and production loss".