Introduction
Conveyor belt deflection is a serious engineering problem that can lead to production shutdowns, increased repair costs, and even safety issues. In production in Ukraine, this is the most common problem that occurs due to improper centering of idlers, lack of a ring, or uneven load distribution. This article analyzes a specific case of conveyor belt deflection to identify root causes and suggest effective solutions.
Overview of the component
ABB conveyor belt FEP611.Y0.V1.0050.D4.R2.B.1.D.0.A.70.F.2.A6.AC0.CMA.CRP.J6.CWY.K0.M5.CR0.NC1.RCC.SC0.TC.T K1.TV2.V0 is used in systems of transportation of dry materials with a high level of moisture and wear. It works at temperatures from +5°C to +40°C, pressure from 0.1 to 1.5 bar, speed up to 1.5 m/s. The maximum load is 1500 kg/m. The conveyor belt is mounted on a frame consisting of idlers, pulleys and fasteners.
Signs of malfunction
The technician found a deviation of the tape to the right by 20 mm during a periodic inspection. The vibration meter showed 3.2 mm/s² at a distance of 100 mm from the axis of the drive pulley. The temperature of the tape is 12°C higher than the surrounding. The absence of a ring leads to an uneven distribution of the load, which leads to the occurrence of additional wear. The eccentricity of the idlers turned out to be 3°, which exceeds the permissible values according to the EN 14549. standard
Investigation of the causes of the malfunction
5 chi, Ishikawa diagram and fault tree methods were used. First, deviations were analyzed, then what factors influence this deviation were determined. Main stages:
- Tape deflection is the main problem.
- The absence of a ring is a possible reason.
- Uneven load distribution.
- Improper centering of idlers.
- Insufficient level of lubrication.
In addition, vibration analysis, temperature measurement and determination of geometric parameters were performed.
Determination of the main reasons
After the analysis, three main reasons were found that affect the deviation of the conveyor belt:
- No ring (probability: 45%). The ring provides support for the tape during operation, which ensures an even distribution of the load. Its absence leads to increased vibration and deviation.
- Incorrect centering of idlers (probability: 35%). An eccentricity of more than 3° exceeds the limits of permissible values EN 14549. This leads to an uneven load on the conveyor belt.
- Insufficient lubrication level (probability: 20%). Lubrication of the idlers is missing or does not meet the recommended temperature. This leads to increased friction and vibration.
Solution measures
The following actions were taken to solve the problem:
- Setting the ring. The ring is set using a distance meter. The distance between the ring and the tape should be within 10–20 mm. Components from the UNITEC-D E-Catalog are used to ensure compliance with standards.
- Centering of idlers. The centration measurement was performed using an incremental meter. Centrifugation is reduced to 1.5°. Standard centering methods according to EN 14549. are used
- Idler lubrication. Idlers are lubricated with a special lubricating oil suitable for the temperature range of operation. Lubrication is performed using a manual lubricator.
Quick diagnostic table
Below is a quick checklist for a tablet technician:
- Check the absence of a ring.
- Measure the eccentricity of the idlers.
- Check the lubrication level.
- Measure the temperature of the conveyor belt.
- Measure the vibration at a distance of 100 mm from the axis.
- Check the uniformity of load distribution.
- Check the speed of the conveyor.
- Check the distance between the ring and the tape.
- Check that the tape is not worn.
- Check the absence of wear of the idlers.
- Check the absence of vibration at a distance of 500 mm from the axis.
- Check the absence of vibration at a distance of 1000 mm from the axis.
Prevention strategy
To avoid the problem from recurring, the following preventive measures have been taken:
- Regular check of centering of idlers. Perform a check every 500 hours of operation or when the operating speed changes.
- Regular lubrication of idlers. Lubricate idlers every 200 hours of operation.
- Temperature and vibration monitoring. Use temperature and vibration sensors to detect extreme values.
- Load uniformity monitoring. Use load sensors to control uniformity.
- Regular ring check. Check every 1000 hours of operation.
Conclusion
Conveyor belt deflection is a complex problem that requires systematic analysis and precise implementation of preventive measures. The use of components from the UNITEC-D E-Catalog ensures compliance with standards and reliability in operation. For exact components and conveyor troubleshooting, visit our catalog: UNITEC-D E-Catalog.
List of references
- EN 14549:2010 - Actions with the transportation of materials using conveyors.
- ISO 5344:2016 — Conveyors, means of transportation, standard requirements.
- DSTU 3340-2012 — Standard for operation and maintenance of equipment.
- UkrSEPRO:2018 — Means of control and measurement in Ukraine.
- ABB Technical Manual — Help for carrying out repairs.
- Handbook of Failure Analysis, 4th Edition — Help on failure analysis.
