For a majority of manufacturers, conveyors are an integral aspect of their entire operation. They play a crucial part in the production process and material handling. Working with a practical conveyor system increases efficiency and promotes a safer workplace. When this system fails to function, production and business operations cease. The best way to avoid this is to keep up with your maintenance duties. Preventive maintenance will save you money on repairs and replacement components while minimising downtime. Therefore, your conveyor system must undergo routine monthly maintenance and inspection to detect any faults or miscalibrations.
In this article, we will be going over the preventive maintenance checkpoints of conveyors so you may adequately maintain them to avoid wasted production time and resources.
What is the importance of consistent conveyor maintenance?
The significance of conveyors in the manufacturing process is incontestable. Nevertheless, we frequently operate as if the proper operation of conveyors is a given. We only perform maintenance work when there is an issue. Conveyor systems are designed to work around the clock and include many moving parts dispersed over a vast area, which is the primary cause of the lack of maintenance. For extensive maintenance, the entire conveyor system must be shut down.
Often, this necessitates the suspension of some or all production operations. Unfortunately, this maintenance delay frequently causes problems in the future. Minor issues accumulate and lead to catastrophic, costly failures that could have been avoided. Regular conveyor maintenance should, therefore, never be neglected. It must be planned and scheduled as part of routine plant operations. It is the only approach to minimise planned downtime for maintenance activities and lessen the likelihood of extended downtime due to a breakdown.
Basics of conveyor maintenance
Understanding the equipment used in your conveyor system is the first step in ensuring conveyor safety. Answering the following questions will allow you to anticipate the required maintenance chores associated with your prefered cleanroom conveyor system.
- How often will system maintenance and repairs be required?
- How detailed are inspections and repairs?
- What components or tools are necessary for conveyor maintenance and cleaning?
Consider every conveyor component, including the high-performance chain, belt, and track. Are replacement parts for each component easily accessible? Consider that decreased availability of replacement components could result in production halts or delays for your company. As you progress through this article, bear in mind that routine maintenance can help prevent the following major conveyor issues:
- Belt Mistracking: This issue happens when a mining conveyor belt pulls to one side and deviates from its intended path. Conveyor belts must follow a predetermined route. Most of the time, the track is a straight path. Any misalignment of conveyor belts might result in side-to-side movement of the belts. This will cause the conveyor belt to deteriorate. This severe issue can cause damage to other components, belt damage, and material spilling.
- Belt Slippage: Materials being carried on a conveyor system may accidentally fall off or spill into the mechanism of the conveyor. Material spillage frequently happens at the intersections of conveyor belts. Mining conveyor belts require exact tension to prevent slipping. The conveyor belt will slip off the pulleys if overloaded or underloaded. Belt slippage can cause motor or belt failure. According to the manufacturer’s requirements, tighten your belts. Some factories take additional design precautions to prevent this substance from escaping. If the spillage is recurrent, you must evaluate the conveyor system for anomalies or flaws that could be causing it.
- Debris: Various materials are transported by conveyor systems almost each and every day. The materials being handled and moved around may leave debris of all sizes behind. The surroundings of the conveyor system also add to the accumulation of trash, which can eventually make its way to the conveyor mechanism. This can result in damaging clogs, impeding the functionality of conveyor systems. Regular cleanups are required to avoid such an anticipated issue. Debris accumulation should be inspected as part of your usual maintenance procedures.
Different conveyor components you should adjust or replace
Replace worn-out or malfunctioning components equipment as needed to prevent further damage. The items listed below are the components you should be observing.
- Scrapers: High-performance scrapers will endure significantly longer than those of inferior quality. As necessary, replace scrapers that are faulty or worn.
- Idlers: Examine your idlers and replace them if necessary.
- Belt repairs: Repair any rips in the belt in accordance with the handbook. Please do not attempt to close tears with mechanical fasteners since they are only a temporary solution.
- Rollers and idlers: During your monthly or weekly inspections, repair or replace any broken or damaged idlers or rollers.
- Dust containment system: During your monthly or weekly inspections, repair or replace any faulty components of the dust containment system.
- Replace lagging: Pulley lagging is the layer of material adhered to the shell of a conveyor pulley. Its purpose is to safeguard the cover, increase friction with the conveyor belt, and expel water from the pulley. Replace this part approximately every three to five years, unless ceramic
Checklist for the proper maintenance of a conveyor
Adhering to a consistent maintenance routine can reduce unplanned downtime. A conveyor manufacturer’s maintenance checklist details all conveyor components that require periodic examination.
- Weekly maintenance
The motor, belt lacing, and drive chain are included in the conveyor’s weekly inspections. Using a laser temperature gun, the motor’s operating temperature is measured. The motor’s condition can be determined by comparing the operating temperature to a baseline. The maintenance checklist also visually examines the conveyor belt’s lacings and chain. Both should be tensioned and tracked accurately. Utilise a high-quality mineral or synthetic oil to lubricate the chain.
- Monthly maintenance
The monthly conveyor inspection checklist is the most exhaustive. The drive motor, motor mounting bolts, gearbox, bearings, and v-belts are among the components that must be visually inspected for evidence of abnormal operation. Any abnormal vibration or sound must be addressed immediately to prevent a future breakdown. Adjust the tracking of the drive chain and conveyor belt. Make any required modifications to both.
- Quarterly maintenance
An overall structural security inspection and lube are part of the quarterly checklist. Examine the entire length of the conveyor structure for signs of damage or loose hardware. Specific areas to inspect include the bearings and bearing mounting bolts. Inspect the head and tail pulley set screws and mounting hardware. Replace missing hardware and repair damage before resuming conveyor operation. Lubricate the bearings along the entire length of the conveyor with grease or oil—depending on the type of bearings and the manufacturer’s recommendations.
Consistent proper maintenance on a conveyor can significantly increase its productivity and lifespan, but not all models are constructed from high-quality materials. The guide we have provided above will enable you to undertake routine maintenance on your conveyor system. Consider that the material transported by your conveyor may impact the suggested maintenance plan. A malfunctioning conveyor can frequently halt all operations until repairs are made—a malfunctioning conveyor results in enormous costs. Adhering to a thorough maintenance routine can reduce unplanned downtime and wasted resources.
If you are in search of a trustworthy mining equipment supplier, then Oreflow is the team that you need to get in touch with as soon as possible! We strive to design, build, and distribute high-quality mining and mineral processing equipment and have a strong track record of meeting or exceeding customer expectations. Our broad list of clients demonstrates that Overflow works with most of the largest consulting and mining firms for capital and consumables. We have gained a solid reputation for its conveyor, belt, and apron feeder ideas and manufacturing, some of which are included into our own plant designs. Our conveyors and belt feeders utilise in-house belt scrapers, ploughs, impact beds, and various varieties of idler frames and rollers. Thus sparing customers the trouble of sourcing spares from several providers and allowing them to deal directly with the original equipment manufacturer.