What Are The Most Common Conveyor Belt Installation Mistakes

Whether attached to a tunnel boring machine or part of an elaborate logistics mechanism, conveyor belts need to be fit for purpose, highly versatile and durable.

Whilst specialist repair services will ensure that your vulcanised rubber belt conveyor will work effectively and function properly if it breaks, it is also important to know why it failed in the first place.

The answer is that even the most reliable conveyor belt can break if there are mistakes in the installation process which create unnecessary pressure or a less than hospitable environment for the electronics, the motor, the rubber belt or all three.

The best way to explain this is to explore some of the most common mistakes made when installing conveyor belts, why they can cause outsized damage to your belt and your industrial processes, and what you can do to avoid any future issues.

How Can An Uneven Floor Affect Your Conveyor Belt?

Before installing a conveyor belt, you need to ensure that the flooring or platform it is being laid on is solid, secure, prepared and even. This ensures an even load on the conveyor bearings, avoids the belt drifting to one side and minimises long-term damage.

Laying a conveyor belt on an uneven floor, even if it looks even, can cause the bearing to fail prematurely, cracks in the frame, a need for adjustments to the conveyor belt to stop it and everything on it drifting to one side, and constant work stoppages for repairs and adjustments.

As well as this, an uneven base causes additional grinding, whirring and vibrations which can shake components loose.

This is true even with conveyor belts designed to move, such as those attached to tunnel boring machines or heavy earthmoving or mining equipment, in which case the base or platform of the conveyor belt also needs to be even in order to avoid costly repairs.

Thankfully, using levels on the frame itself to ensure it is aligned correctly, measuring at multiple points across the length of your belt and checking after tightening or periods of prolonged use can help avoid issues later.

Has The Tension Of The Conveyor Belt Been Set Correctly?

The tension of your conveyor belt is absolutely vital in determining the long-term prospects of your conveyor belt, but setting the right level of tension depends on the environment, the belt design itself and the expected payload and throughput the belt would be expected to carry.

One of the most common mistakes made during installation is not following manufacturer’s advice and focusing on the specific needs of your belt when installing it, guessing the tension you need rather than using tools, and not accounting for the break-in period of a belt.

Ultimately, the result is a belt that is either set too tightly and thus risks snapping, fraying or burning out the motor, or a belt that is too loose, causing slippage, drifting and payload movement.

If this is spotted earlier enough, it will only cost you time and a small adjustment fee. However, if it is left long enough with too much or too little slack, you could end up spending thousands of pounds on replacement belts, motors and/or bearings.

It is best to use a tension meter for any precision work, but you can use a deflection method approved by the manufacturer of your belt to determine the most appropriate tension of the belt.

Has The Conveyor Belt Been Properly Lubricated?

Anything with motors and bearings needs to be appropriately lubricated, but it is important not to overcompensate and over-grease your belt.

The belief, much like concerns over tension level, is based on a fear of not having enough lubrication. A lack of lubrication increases friction, which in turn leads to increased wear, higher temperatures and ultimately component failure.

However, too much lubrication can often cause the exact same problems, as well as damaging seals and potentially causing contamination of payloads, something that can lead to costly fines when dealing with careful waste management.

As well as this, it is essential not to pour additional fresh lubricant onto old lubricant without purging it and cleaning it out, as this can make the lubricant significantly less effective.

You also need to use the right lubricant for your particular use case, rather than just any old grease or oil. A generic lubricant used to stop a hinge from squeaking may not be the most appropriate option.

Stick to recommended volumes of lubrication, run your conveyor belts to ensure that the grease is distributed before checking to make sure it works, and wipe away any excess.