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If not maintained properly, the conveyor may experience rapid belt wear and component failures, resulting in downtime and repairs. This will have a corresponding negative impact on both productivity and profits. Therefore, we must raise awareness of the most common problems with conveyors, as well as how to address and prevent them in the future. Material transportation in mines accounts for a large proportion of the total mining costs. Therefore, conveying systems have become a common solution to improve operational efficiency. The challenge is that conveyors typically operate under extremely harsh conditions, such as: a dirty environment, excessively high or low temperatures, and high humidity. If not maintained properly, the conveyor may experience rapid belt wear and component failures, resulting in downtime and repairs. This will have a corresponding negative impact on both productivity and profits. Therefore, we must enhance our awareness of the most common problems with conveyors, as well as how to address and prevent them in the future. 1. Belt deviation: The problem occurs when the belt deviates from its intended path. This is a serious problem that can lead to belt damage, equipment failure, and material spillage. There are many reasons for belt misalignment, such as insufficient belt tension, uneven loading, incorrect splicing, skewed components, and accumulation of material on the components and parts. Solution: The best approach is to identify the root cause of the belt deviation in order to prevent the same problem from occurring in the future. Conducting a belt inspection helps identify all potential issues causing misalignment, so that appropriate solutions can be devised. If the belt is slightly misaligned, auto-aligning idlers can be used to correct its path and ensure it runs straight going forward. Do you really know the 4 patterns of belt deviation in belt conveyors and the 17 influencing factors? 2. Material backflow: Problem – When a small amount of material adheres to the belt, the conveyor experiences a backflow phenomenon. This will cause the material to accumulate under the conveyor belt, or on the idler rollers and drums. Certain materials, such as clay and certain ores, stick more easily to the belt than other materials. Although the amount of material sent back is minimal, over time it adds up to tons, forcing a second cleanup process. Returning materials also poses safety and environmental hazards, increases cleanup costs, and generally hinders the conveyor system from operating at its optimal level. Solution: A simple solution is to install a belt cleaner designed specifically to prevent backflow. The many benefits brought by the net bander more than offset its initial investment cost. Reducing material spillage can save on maintenance costs and create a safer working environment. Furthermore, a clean belt can prevent idlers from wearing out prematurely, extend the belt’s lifespan, and keep the system in optimal operating condition. 3. Belt damage: There are several reasons for belt damage, such as excessive impact forces, misalignment, improper use of the sealing system or belt cleaner, stuck components, and insufficient traction from the drums. The belt is the most expensive component of a conveyor, so it is necessary to identify the potential causes of belt problems and take proactive measures to avoid irreversible damage. Solution: There are many reasons that can cause belt damage, so there are also numerous different solutions. For example, installing buffer idlers or brackets in the feeding area can distribute the impact force of the falling material, thereby reducing wear and tearing on the belt. By using an appropriate sealing system, it is possible to prevent the belt from being damaged by stuck materials. Using the appropriate roller coating material can increase friction, prevent the belt from slipping, and avoid premature damage. These solutions all help to minimize downtime for repairs, and the decision is usually made through a single belt inspection. Belt inspection can detect minor belt damage, thereby preventing serious failures in the future.