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Tracking and Tensiong - 2007 PDF
Tracking and Tensiong - 2007 PDF
Tracking and Tensiong - 2007 PDF
Introduction 1
Whypreventmistracking 1
Causesofmistracking 2
Explanationofmistracking 3
Tensioningofthebelt 4
Methodstocorrectmistracking 5
Conveyorbeltproblemsandcures 8
Introduction
Therearemanyopinionsabouttensioningandtrackingofconveyorbelting.Ammeraal
Beltechhasgainedmuchexperiencewiththisphenomenon.Withregardtotensioningof
conveyorbeltingincombinationwithtracking,anextensiveknowledgeisavailable.This
modulegivesdirectionstopreventthenegativeinfluencescausedbymistrackingofconveyor
beltinginpractice.
Why prevent mistracking
Thecausesofmistrackingare:
maintenanceheadaches;
downtime;
beltdamage;
damageofequipment(overtensioning);
productdamage.
Maintenance headaches
Theroundtheclockeconomyisaskingforanextensionoftheoperatinghoursof
productionplants.Thismayresultinmaintenanceproblemscausedbymistrackingofthe
beltatanytimeduringthedayornight.Ingeneralthetechnicalservicecanbecalledto
solvetheseproblems,butthisisexpensiveandunpleasant.
Downtime
Mostofthecompaniesworkaccordingtoaproductionplan.Incaseofdowntimethereis
noproductionandthecompanyisfacinglackofearnings.Downtimehastobepreventedat
alltimes.
Belt damage
Ingeneralprocessandconveyorbeltingarevaluablepartsoftheconveyor.Mistrackingof
thebeltisusuallyresultinginconsiderablebeltdamage.Thisdamagecanusuallynotbe
repaired.Itresultsinhighandunexpectedexploitationcostsoftheequipment.Correct
tensioningandtrackingofbeltingcanpreventthis.
Equipment damage
Whenmountingthebeltwithtoomuchbelttensionusuallymuchdamageiscausedtothe
installation.Aninstallationisdesignedfortheapplication.Abelttensionhigherthan
calculatedwillcausebendingofthedrumsandshafts.Alsotheloadonthebearingswill
increase.Thisalwaysresultsinashorterservicelifeandpossibleunexpectedcosts.
Product damage
Productdamagehastobepreventedatalltimes.Incaseoffood
productionitisintolerablethatnon-foodsubstancesendupinthefood
product.Abeltrunningagainstmachinepartsbecauseofmistracking
resultsinfrayingedges.Theseparticleswilleventuallycontaminatethe
product.Thiscanbepreventedbyproperbelttensioningandtracking.
Causes of mistracking
Belt
Whenthebelt:
doesnothaveanevenlengthontheleftandrightsides;
hasdifferencesinthicknessontheleftandrightsides;
showsdifferentwearontheleftandrightsides;
isnotsplicedstraight;
iscurvedordeformed;
thisresultsinadifferenceinsurfacepressureand/orfrictiononthepulleydrive.
Othercausescanbe:
Anincorrectbelttension.Whenthetensionistoolow,thebeltwillgoinevery
direction.Whenthetensionistoohigh,thereisnocorrectionpossiblebecausethebelt
cannotslipsidewaysonthepulleys.
Anincorrectfabricconstruction(nottwistedSZ).
Fabricnotinthecorrectposition(angle)inthebelt(obliqueweft).
Pulleys
Causescanbethatthepulleysarenotparalleltoeachotherandsquarelyonthebelt.Orthe
pulleysarenothorizontal.Anotherreasonisadifferenceincoefficientoffrictionoverthe
pulleylength(wrongshape,pollution,wear)orthereisadifferenceindiameterononeside
towardstheother.
Note: Belt widthandpulleylengthmustgear.
Product
Possiblecausesareanasymmetricload,incline/decline,loading/unloadingononeside,or
temperaturedifferencesincombinationwiththeloadingsystem.
Frame
Theframemightnotbestable.
Belt support
Thesliderbedisperhapsnothorizontalorthereisadifferenceinsurfacesmoothness.
Rollersmaybemountedinatiltedpositionoroutoftheperpendicular.Diameterdifferences
cancauseproblemsaswellaspollution.
Various causes
Therecanbemorereasonsformistracking,likeabeltcleaner,sideskirts,knifeedge
transfersorweatherinfluences(wind).
Explanation of mistracking
Rule: Abeltreachingadrum/pulleywillgetadeflectionfromthefirstcontactbetween
beltanddrum/pulley.Asaconsequencethebeltisrunningtothedirectionwhereitis
touchingtheturningdrumorpulley.
Cylindrical pulleys
Beltrun
Whenapulleyisnotplacedsquaretothebelt,itwillresultinthe
situationasshowninfig.1.Thebeltwillmovetotheleftasanut
doesoverathreadedpin,withaspeedofDtg.
Inthemostextremecasethebeltwillfoldonthedrum.
Thebeltwillruntothesidewiththelowesttension.
Thebeltrunsinthedirectionoftheperpendicularlinetothe
contactline. Fig. 1
Thebeltrunsinthedirectionwhereittouchestheturning
drumorpulleyfirst.
Conical pulleys Beltrun
Fig.2showsthatthebeltmovestotherightonconditionthatthe
shaftsofthepulleysareparalleltoeachother.Thebeltwillrunto
thesidewiththehighesttension.
Asaresultofspeedandtensiondifferencethebeltwillshow
ahorizontalbendingjustbeforeittouchesthedrum.
Thereforethebeltwilltouchthedrumsomewhathigher(in
directionofbiggestconicaldiameter). Fig. 2
Thebeltwillruninthedirectionoftheperpendicularlineonthe
contactline(fig.3).
Rule: Abelt,runningagainstapulleyorroller,willgetaside
deviationofthefirstcontactspot*betweenbeltandpulley/roller.
Fig. 3
Fixed sliding strips or scrapers Beltrun
Abeltrunningonanon-movingsupportwill,contrarytoroller
support,deviateinthedirectionofthelastcontactspotbetween
beltandsupport.
Inpracticethesupportoffixedstripsconsistsof:
sliderbed,beginningofthebedmustbesquareonthebelt;
slidingstrips; Fig. 4
scrapers.
Thesamephenomenonoccursincasethesupportrollersdonotturnorturnwithdifficulty.
Tensioning of the belt
Thebelttensionhasadirectrelationwiththetrackingbehaviour.Toomuchtensionresultsin
verynervousbeltbehaviourandexcessivewearofmachinerycomponentslikebearingsand
shafts.Toomuchtensioncanevenresultinabreakingoftheshafts.Toolittletensiongives
beltslippageonthedrivedrumandresultsinnotfollowingthecrowning.
Beforemountingthebeltontheinstallationitisadvisabletoleavethebeltfortwelvehours
intheroomwherethebeltisgoingtobeused.
Whentheoldbeltisremoved,theinstallationcanbecleaned.Thenthebeltcanbemounted;
ifnecessaryitcanbemadeendlessonsite.
Theinstallationhastobeprovidedwithatensioningdevice;inmostcasesthisisthetail
drum.Thetensioninglengthoftheinstallationis1%ofthebeltlength.
Thebelthastobetensionedaftermounting.Thebestwaytodothisistomarktwolines
(withapitchof1000mm)atbothbeltsideswitharedpen.Thentensionthebeltleftand
rightequallyupto1003mm=0.3%pretension.Incaseofheavierloadover50kg/m2the
belttensioncanbeincreasedto0.5%.
Incaseofaninstallationwithaknifeedgethisprocedureisnotapplicable.Inthiscase
tensionthebeltonarunninginstallationtotheextentthatslippagedoesnotexistanymore.
Tracking rollers
Flat (snub) tracking rollers
15-30
Mountthetrackingrollersinaspotwithlowbelttension
(usuallybeforethereturnpulley).Thearcofcontactmustbe
between15and30.Below15thecontactbetweenbelt
10%W
andpulleyistooshort,over30youwilladdtensionwhich
againwillcausemistracking.Theremustbesufficientfriction 300-600
betweentrackingrollerandbelt(e.g.non-sliplagging). Tensioning-/taildrum
andtrackingidler
Whenthebeltisheavilypolluted,mountingontheinsideof
thebeltispossible.
Adjusting snub/stow pulleys
Theprincipleisthesameastheadjustingtroughassemblythat
ismountedupsidedown.Mountinreturnpartonbothbelt
edges,undersomebelttensionandfarfromenddrums(6
toe-in,15downwardstolateralhorizontalline).When
mistrackingbeltmustrun-uphighertotherollinordertoface
moreresistant.
Adjusting trough assemblies
Inpracticeoneoneachfivetroughassembliesisanadjustingone.
Note:Think of the proper mounting, because adjusting trough
assemblies are for one running direction. The rollers have to be
mounted toe-in (see sketch).
V-strips (flat belt)
ThisChevron-shapedprofileispushingthebelttothecenter
andcanonlybeusedincaseofheavybelts(over3kg/m2).By
thethrustlightbeltsmightfold.
Side rollers
Theseareonlysuitableforheavy,thickbeltingof10mm
thickness.Theyaremeantfortemporarymistracking,andnota
continuoussolution.
Note: Support rollers and trough assemblies can also be slightly adjusted.
Ropes
V-guidesandguideropes(squareandrectangular)canbeapplied
onthecentrelineofthebeltoratthesidesofthebelt.Theguide
tracksontheframeandnotonthepulley.Thepulleydiameterfor
V-guidesis6xtheheightoftheguide,forsquareandrectangular
ropes10xtheheight.
Strips
Guidestripsareusuallyappliedonthesidesofthebelt,thestrip
tracksontheframeandnotonthepulley.Aone-plystripneedsa
pulleydiameterof1.2xtheminimumpulleydiameterofthebelt
andatwo-plystrip1.4x.WhenAmtelstripsareused,thepulley
diametermustbe10xthestripthickness.
Note: V-guides, ropes and strips have a free space towards the pulley on the bottom side.
Only the belt is driven. If not, the guide will tear off the belt because of the differences in
circumference speed.
Rollers/cams
Guiderollers/camsareappliedincasesoflonglastinglateralforces
andhighdemandsonrunningstraight.
Variable tracking
Cause Cure
Stretch and slippage
Belt stretches excessively
Tensiononbelttoohigh Reducetensiontoapointwherebeltwill
runwithoutslippage;lagdrivepulley
Conveyorunder-belted Replacewithheavierorwiderbelt
Materialbuild-uponpulleys/rollers Cleanpulleys/rollers
Frozenrollers Removeicingontherollerstoincrease
frictionbetweenbeltanddrum
Excessivepositivetake-upforce Provideself-compensatingtake-up(spring
loadedorcounter-weight)
Belt slips and squeals
Belttoolooseinsufficienttraction Lagdrivepulley;increasetensionslightly
betweenbeltandpulley
Conveyorunder-belted Replacewithheavierorwiderbelt
Tracking
Belt creeps partly to one side
Beltsplicecrooked Re-splice
Beltendsatfastenersnotslitsquare; UseaT-squareforslittingperfectlysquare;
fastenersnotjoinedsquarely replacewithcorrectsizefasteners
Belt slips creeps to one side
Improperbeltload Loadindirectionofbeltrun,atbeltspeed,
centredonbelt
Frozenrollers;rollersnotproperlylocated Lubricaterollers,improvemaintenance;
(oblique) relocateimproperlyplacedrollersand
checkalignmentwithaT-square
Frameorstructurecrookedornotlevelbelt Checkalignmentbystretchingastring
shiftstolowside alongframeedge,makecorrection;level
structure
Materialbuild-uponpulleys/rollers Cleanandimprovemaintenanceby
mountingscrapersorothercleaningdevice
Pulleys/rollersoutofline/oblique Re-checkandsquarewithaT-square
againstconveyoredge
Belt creeps at one spot only
Roller(s)-usuallyinfrontoftroublespot- Move(indirectionofbeltrun)thatroller
outofline(notperpendicularwithcentre endtowhichthebelthasshifted
line)Alsosee4.2,4.3and4.4
Belt creeps to one side at head pulley
Headpulleyorprecedingrollersoutofline Realignthepulley/rollersperpendicularto
(notperpendicularwithcentreline) beltcentreline,ormove(indirectionof
beltrun)thatpulley/rollerendtowhich
thebelthasshifted
Belt creeps to one side at tail pulley
Tailpulleyorclosereturnrollersareoutof Realignthepulleyperpendiculartobelt
line/oblique(notperpendicularwith centreline,ormove(indirectionofreturn
centreline) beltrun)thatpulley/rollerendtowhich
Alsosee4.2,4.3and4.4 thebelthasshifted
Belt wanders irregularly
Conveyorover-beltedasbeltistoostiffto Replacewithproperbeltoruselarger
properlyrunoverappliedpulleydiameter pulleydiameter
Improperoroff-centreloadingcancause Correctloadingprocedureoruseabelt
belttowander withV-guide
Splice and fastener
Belt fasteners pulling out
Incorrectsizefastenersapplied Re-lacewithpropersizefasteners
Excessivetensiononbelt Reducetensiontoapointwherebeltwill
runwithoutslip;lagdrivepulley
Pulleystoosmallforbeltthickness Uselargerpulleydiameterorathinnerbelt
ifpractical
Belttensiontoohighcausedbyslippage Increasepulleydiameterstoreducebelt
tensionandtheeffectofstiffnessof
fastenerorapplyanendlesssplicedbelt
Splice failure
Beltspeed/tensiontoohigh(duetospeed Increasepulleydiameterstoreducespeed
differencetop/bottomsideofbeltand differenceandheatingup
innerheatingupduetosharpbendingover
toosmalldrums)
Pulleystoosmall Increasethepulleydiameter
Bendingofspliceinlateraldirection Removethecauseofbendingorapplyan
othersplice(e.g.T-splice)
The belt
Ply separation
Edgeofbeltwornorbrokendueto Checkalignmentofframe,pulleysand
excessiverubbing rollers
Pulleydia.toosmallforappliedbeltor Increasepulleydia.;reducetension(also
excessivetensiononbelt see1.3)
Damagebyabrasives,acid,heat,chemicals, Selectaproperlyresistantbelt
mildeworoil
Toomuchpulleycrowning Checkcrowningrecommendations
Excessive top side wear
Materialbuild-uponpulleys/rollers Cleanandimprovesupervision;install
scrapersorothercleaningdevice
Excessiveimpactofmaterialonbelt Reduceimpactorusecushionrollersatthe
impactpoints
Dirty,frozenormis-alignedreturnrollers Improvemaintenanceandsupervision;re-
alignrollersbyusingaT-squareagainst
conveyoredgeandrollers
Excessive pulley side wear
Beltslippingondrivepulley Lagdrivepulley;installsnubrollerfor
betterwraparounddrivepulley;slightly
increasebelttension
Materialbuild-uponbeltbottomside Removeaccumulationandinstallscrapers
tokeepthebottomsideofthebeltclean
Frozenordirtyrollers Lubricaterollers;improvemaintenance
Laggingsafetyscrewsprotrudingpulley Tightenscrewsandreplacelagging
lagging