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Belt conveyors are widely used in industries such as mining, metallurgy, coal, transportation, hydropower, and chemicals, thanks to their advantages including large conveying capacity, simple structure, easy maintenance, low cost, and high versatility. Problems with belt conveyors can directly affect production; this article shares the common issues that arise during the operation of belt conveyors and their possible causes. 19 common problems and possible causes of belt conveyors: 1. Deviation of the conveyor belt at the tail drum – Possible cause: a. Jammed idler rollers ； b. Accumulation of debris ； c、Insufficient counterweight ； d. Improper loading, spillage ； e. The idlers, drums, and conveyor are not aligned on the center line. 2. Possible reasons for the conveyor belt to deviate at any point: a. Unbalanced load ； b. Accumulation of debris ； c idler rollers are not properly installed ； d The conveyor belt is under transitional tension on one side ； e. Improper loading, spillage ； f. Idlers, drums, and conveyors are not on the centerline. 3. Possible reasons for the belt to deviate at any point: a、Poor performance of the belt’s vulcanized joints, improper selection of mechanical fasteners ； b、Edge wear ； c. The conveyor belt is arc-shaped. 4. Possible reasons for the conveyor belt to deviate at the head drum: a. The idler rollers, drum, and conveyor are not aligned on the same central line ； b. Accumulation of debris ； c、Wear of the rubber surface on the drum ； d. Improper installation of idler rollers. 5. Possible reasons for the conveyor belt to deviate to one side over an entire length on several specific idlers: a. The idlers, drums, and conveyor are not aligned on the same central line ； b、Improper installation of idler rollers ； c. Accumulation of debris. 6. Possible reasons for conveyor belt slippage: a. Idler rollers getting stuck ； b. Accumulation of debris ； c、Wear of the rubber surface on the drum ； d、Insufficient counterweight ； e. Insufficient friction between the conveyor belt and the drum. 7. Possible reasons for belt slippage during startup: a. Insufficient friction between the belt and the drum ； b、Insufficient counterweight ； c、Wear of the rubber surface on the drum ； d. The conveyor belt does not have sufficient strength. 8. Possible reasons for excessive stretching of the conveyor belt: a. Excessive tension ； b. The conveyor belt does not have sufficient strength ； c、Accumulate material shavings ； d. Excessive counterweight ； e. Asynchronous operation of the dual-drive rollers ； f. Damage caused by chemicals, acids, heat, and rough surfaces. 9. Possible reasons for the conveyor belt to break at or near the buckle, or for the buckle to become loose: a. Insufficient strength of the conveyor belt ； b、The drum diameter is too small ； c、Excessive stress ； d、Wear of the rubber surface on the drum ； e. Excessively large counterweight ； f. There are foreign objects between the conveyor belt and the drum ； g. Asynchronous operation of the dual-drive rollers ； h、Poor performance of the conveyor belt vulcanized joints and improper selection of mechanical buckles. 10. Possible reasons for the failure of sulfurized joints: a. Insufficient strength of the conveyor belt ； b、The drum diameter is too small ； c、Excessive stress ； d. There are foreign objects between the conveyor belt and the drum ； e. Asynchronous operation of the dual-drive rollers ； f、Poor performance of the conveyor belt vulcanized joints and improper selection of mechanical buckles. 11. Severe wear of the upper cover adhesive, including tearing, drilling, breaking, and puncturing; possible causes: a. Accumulation of debris ； b、Improper loading, spillage ； c、The relative loading speed is too high or too low ； d、The load exerts excessive impact on the buckle ； e. Damage caused by chemicals, acids, heat, and rough surfaces. 12. Possible reasons for severe wear of the lower cover adhesive: a. Idler roller jammed ； b. Accumulation of debris ； c、Wear of the rubber surface on the drum ； d. There are foreign objects between the conveyor belt and the drum ； e. Insufficient friction between the conveyor belt and the drum ； f. Damage caused by chemicals, acids, heat, and rough surfaces. 13. Possible reasons for severe wear at the edge of the conveyor belt: a. Unbalanced load ； b、Excessive tension on one side of the conveyor belt ； c、Improper loading, spillage ； d、Damage caused by chemicals, acids, heat, and rough surfaces ； e. The conveyor belt is arc-shaped ； f. Accumulation of material shavings ； g、Poor performance of the conveyor belt vulcanized joints and improper selection of mechanical buckles. 14. Possible causes of punctate and striated bubbles in the coating layer: damage caused by chemicals, acids, heat, and rough surface substances. 15. Possible causes of conveyor belt hardening and cracking: a) Damage caused by chemicals, acids, heat, and rough surface materials ； b. Small drum diameter ； c. Wear of the rubber surface on the drum. 16. Possible causes of cracking and embrittlement of the coating layer: damage caused by chemicals, acids, heat, and rough surface substances. 17. Possible reasons for longitudinal grooves in the upper cover adhesive: a. Improper installation of the side baffles ； b、Idler roller stuck ； c、Accumulate material shavings ； d. The load exerts excessive impact on the buckle. 18. Possible reasons for longitudinal grooves in the lower covering adhesive: a. Idler roller jammed ； b. Accumulation of debris ； c. Wear of the rubber surface on the drum. 19. Possible reasons for damage at the groove formation of the idler roller: a. Excessive gap between idler rollers ； b、The slope at the grade change point is too steep. Methods for dealing with common problems in belt conveyors 1. On solid-core conveyor belts that do not curve, for belts with delamination, pay attention to the following points: a) Avoid collisions with the delaminated belt ； b) Avoid storing the stratified conveyor belt in humid environments ； c) The conveyor belt must be straightened first during the running-in period ； d) Inspect the entire conveyor system. 2. Poor performance of the conveyor belt’s vulcanized joints, improper selection of mechanical fasteners a) Use appropriate mechanical fasteners ； b) Re-tighten the conveyor belt after it has been in operation for a while ； c) If there is a problem with the vulcanized joint, cut off this joint and make it again ； d) Regular observation. 3. Stretching and deformation on one side of the conveyor belt does not occur in solid-core conveyor belts; for other types of conveyor belts, pay attention to the following: the conveyor belt requires sufficient time for breaking in. If the belt has not been properly broken in or is an old belt, remove the stretched and deformed section and create a new joint. 4. Excessive counterweight a) Recalculate and adjust the counterweight accordingly ； b) Reduce the tension to the critical point and re-fix it ； c) If it is a winch tensioning, make appropriate adjustments. 5. If the counterweight is insufficient, recalculate and adjust the counterweight accordingly. 6. Damage caused by chemicals, acids, alkalis, heat, and rough surfaces: a) Use conveyor belts designed for such special conditions ； b) Use sealed mechanical fasteners or vulcanized joints ； c) The conveyor shall be equipped with measures such as rain and sun protection. 7. Adjust the dual-drive rollers appropriately to ensure asynchronous operation of the rollers. 8. If the conveyor belt is not strong enough due to an increased amount of coal at the center or loading point, or a reduced belt speed, the tension should be recalculated and a conveyor belt with appropriate strength should be used. 9. Edge wear prevention prevents the conveyor belt from drifting; remove sections of the conveyor belt with severe edge wear. 10. If the gap between the idlers is too large, adjust it; even under full load, the gap between the idlers should not exceed 10 mm. 11. Excessive impact from the load on the conveyor belt and buckles: a) Use flow chutes and buffer plates designed according to the operating conditions properly ； b) Install impact-resistant idlers ； c) Install the tail coal first if possible ； d) If the side baffle is not clogged with coal, adjust the gap between the side baffle and the conveyor belt. 12. Idlers, drums, and conveyor not on the center line a) Re-align ； b) Install limit switches ； c) Consult the conveyor operation manual. 13. Improper loading, material spillage: a) The feeding direction and speed should match those of the conveyor belt, ensuring that the loading point is located at the center of the conveyor belt ； b) Use appropriate feeders, flow channels, and side baffles to control the flow rate. 14. Insufficient friction between the conveyor belt and the drum a) Use buffer drums to increase the wrap angle ； b) Use a coated drum ； c) Use trough-type rubber rollers in humid environments ； d) Install appropriate cleaning devices on the conveyor belt ； e) Check the initial tension. 15. Accumulation of material debris (on drums and idlers) a) Install cleaners, scrapers, etc ； b) Remove debris. 16. There is foreign matter between the conveyor belt and the drum a) Use the side guards properly ； b) Remove debris and other foreign objects. 17. Drum rubber surface wear a) Replace the rubber surface ； b) Use of trough-shaped adhesive surfaces in humid environments ； c) Address loose and protruding adhesive-surface screws. 18. The relative loading speed is too high or too low. a) Adjust the material flow channel or correct the conveyor belt’s operating speed ； b) Consider using impact-resistant idlers, and pay close attention to operating conditions. The above are the common problems of belt conveyors and the corresponding solutions. To extend the service life of these conveyor systems and to ensure they can perform their functions more effectively, it is necessary to carry out regular maintenance on them. Only in this way can production efficiency be truly improved, as well as economic benefits.