Belt deviation is one of the common faults during the operation of a belt conveyor. There are various reasons for belt deviation, with the primary causes being low installation precision and poor daily maintenance. During installation, the head and tail pulleys, as well as the intermediate idlers, should be aligned on the same centerline and kept parallel to ensure that the conveyor belt does not deviate or deviates minimally. Proper alignment during installation is critical because even slight misalignments can cause cumulative stress on the belt, leading to premature wear or damage. Additionally, the belt joint must be correctly connected, with equal circumferences on both sides to maintain balance.
During operation, if deviation occurs, the following inspections should be conducted to identify the cause and make adjustments:
(1) Check the misalignment between the transverse centerline of the idlers and the longitudinal centerline of the belt conveyor. If the misalignment exceeds 3mm, adjustments should be made using the elongated mounting holes on both sides of the idler set. The specific method is to determine which side the belt is deviating toward; the corresponding side of the idler set should be moved forward in the direction of the belt’s travel, or the opposite side should be moved backward. Regular checks of idler alignment can prevent excessive belt tension and reduce energy consumption, improving the overall efficiency of the conveyor system.
(2) Check the deviation of the two planes of the bearing seats on the head and tail frames. If the deviation between the two planes exceeds 1mm, both planes should be adjusted to be in the same plane. The adjustment method for the head pulley is as follows: if the belt deviates to the right side of the pulley, the bearing seat on the right side should be moved forward, or the left bearing seat should be moved backward; if the belt deviates to the left side, the left bearing seat should be moved forward, or the right bearing seat should be moved backward. The adjustment method for the tail pulley is the opposite of the head pulley. Misaligned bearing seats can cause uneven belt tension, leading to increased friction and potential damage to both the belt and the pulley bearings. Using laser alignment tools can enhance precision during these adjustments.
(3) Check the position of the material on the conveyor belt. If the material is not centered on the cross-section of the belt, it will cause belt deviation. If the material shifts to the right, the belt will deviate to the left, and vice versa. To minimize or avoid such deviations, the material should be kept as centered as possible during operation. Installing material guides or baffles can help adjust the direction and position of the material. Uneven material loading can also contribute to belt deviation, particularly in industries handling heavy or irregularly shaped materials like mining or construction. Automated material centering systems, such as vibratory feeders or adjustable chutes, can further reduce deviation risks.