Top 5 Signs of Conveyor Pulley Failure and How to Prevent It

MineAlpine is one of the mining operation where conveyor pulleys are used in abundance. These fly wheels keep materials flowing along the conveyer belt that makes everything run smoothly. But, as with all things mechanical, conveyor pulleys do break down. It’s important to know what the signs of conveyor pulley failure are and how they can be prevented in order to keep your mining operations as efficient as possible.

Written by: DoverMEI Preventing Conveyor Pulley Failure - Top 5 Issues to Avoid

1. Abnormal sounds: If you detect any common odd noises from the conveyor head pulley, like squeaks, grinds or pounding, these may indicate a failure. Those sounds might mean that the bearings are shot or there is some detuning in how the pulley system operates.

2. Similar to the above, vibration too can signal that the conveyor pulley has failed. If the   Conveyor snub pulley   shakes more than it normally does, suspect that there is an issue with your pulley alignment or bearings. Too much vibration can cause the pulley parts to wear out.

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4. Troubleshooting: It’s tracking off centre or misalignedProblems with belt alignment can be the root-cause of so many other problems if the conveyor starts to case mis-tracking.Belt, it could be a sign that there is issues with the conveyor pulley. These grooves prevent misalignment of the pulley and reduce very high side loads that can be applied to the excess stress on the components of a damaged pulley.

5. Hot to touch pulley: The   Tail pulley conveyor   feels hot, then it may be because of the friction in the pulley mechanism. Overheating will cause the bearings to wear out prematurely, and could also lead to premature pulley failure.

6. Signs of Wear and Tear: Regularly you should be checking your conveyor pulley for wear and tear, patterns to look out for include cracks, dents or even rust. These evidences could mean that the pulley is getting close to its end of life and it needs replacement soon.

The importance of keeping your conveyor pulley maintained to avoid breakdowns.

Failing to properly maintain conveyor pulleys can result in catastrophic equipment failure which, in addition to damaging other types of associated mechanical equipment and causing downtime, poses serious safety risks. Conveyor Pulleys should not be worn to the point of a ShowdownThe above is an interesting fact that any none maintenanced pulley component will have significantly less life which could result in more instances of mining hold ups and breakdowns on site through out the service life. In the worst case scenario, a damaged pulley system may force the entire conveyor belt to be stopped and thereby cause delays in production as well as large economic losses for MineAlpine.

Proactive Measures to Avoid Conveyor Pulley Failures

MineAlpine can also take a proactive approach with preventative maintenance to avoid conveyor pulley failures. Routine inspections and maintenance inspections can help to uncover early issues that may lead to major concerns if not addressed on the conveyor pulley. Pulley cleanup- Regular cleaning of the pulleys to remove soil and grime can also reduce the likelihood of premature wear on these components. Also, consideration towards corrrect pulley alignment and belt tensioning will contribute significantly to the life of the pulley system.

How to Keep Your Conveyor Pulleys Tensioned

1. Routine inspection: Regularly inspect the conveyor pulley and look for wear on the surface layer.

2. Oiling: Adequate oiling of the pulley bearings may decrease friction and prevent too-early wear.

3. Clean: Keeping the pulleys clean from dirt and debris can prevent excessive wear.

4. Training: Train operators and maintenance personnel in how to properly maintain the conveyor pulleys to extend the life of a system.

What to Do to Prevent Your Conveyor Pulley from Failing And Costing You Down Time

1. Develop and schedule a preventative maintenance plan with routine service for the conveyor pulley.

2. Hold extra parts to minimize the time spent when any part fails so as not to waste long downtime.

3. Provide emergency response training to maintenance personnel in the event of a conveyor pulley failure.

4. When you inspect your   Conveyor pulley types system frequently, you can catch problems early before they lead to expensive downtime.

By recognising the red flags of conveyor pulley failure and responding with preventative actions, MineAlpine can help keep operations running smoothly and prevent costly downtime from occurring as a result of hole-in-the-sheave failures. Avoiding failures through regular inspection, good lubrication and staff training in maintenance procedures will all serve to prolong the life and enhance the reliability of a conveyor pulley which will go some way towards optimising return on investment, as well as better safety standards at mining operations.