Finding the cause of broken shaft in powered roller conveyors

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Every conveyor fears experiencing problems, but it is normal for every conveyor to have issues. Just as everyone gets sick or catches a cold and fever, machines can also develop problems, which is due either to improper operation, prolonged use, or the fact that the equipment is old and needs to be replaced. Now, I’ll share with you the reasons why shaft breakage occurs in power roller conveyors. There are many reasons for this, and today I’ll share a few of the most common ones. First, check whether it is a problem with the conveyor equipment itself. If it is indeed a problem with the equipment, then it is due to insufficient design strength of the high-speed shaft of the reducer; such issues usually occur outside the shaft shoulder. The reason this happens frequently in this area is that there are transition fillets, and these transition fillets are very prone to fatigue damage. If the rounded corners in this area are too small, the bearing is likely to break, so it’s important to pay attention to this aspect when making a purchase. When choosing a power roller conveyor, one must take care of these subtle details. Secondly, when a broken shaft occurs in a powered roller conveyor, we also need to check whether the high-speed shaft is out of alignment. If the motor shaft and the high-speed shaft of the reducer are not aligned, the reducer’s shaft will operate under excessive load, and it is therefore normal for the shaft to break in such cases. At this time, we need to increase the bending moment on the shaft. Therefore, this requires us to check these aspects carefully during installation, making sure to adjust the positions properly to ensure concentricity; this issue must not be ignored even after maintenance. It is essential to carry out proper installation and maintenance of powered roller conveyors; otherwise, it will **increase our costs and reduce our profits. Finally, if a power roller conveyor is driven by two motors, it can also lead to shaft breakage. In other words, two motors are installed on the same drum for driving purposes, along with two reducers; this setup makes it more likely for the shaft to break, as sometimes the margin chosen for design is too small, which leads to shaft failure.