8 Warning Signs of Impending Conveyor Maintenance

Starting off simply are any loose components you may come across.  This may not seem very harmful to your equipment at first, but this could have dangerous consequences if left untreated. For example, according to the British Engineering Services, one of their more recent projects involved assisting a previous company with a burnt down factory. This happened due to a loose component which allowed oil to leak out and eventually ignite. 

Clearly what happened here was a worst-case scenario, but that doesn’t diminish the importance of constantly checking your machine. Even though the outcome can be devastating, the simple fix for this problem is:  

• Tighten the loose parts 

• Consistently monitor upkeep.

#2 Belt Slippage 

Belt slippage is another common problem that often occurs with conveyors. This can slow belt speeds, disrupt product flow, a potentially damage any material that it carries. This (just like loose components) may not seem too dysfunctional at a glance. However, a slow belt can impact the efficiency of your system, which greatly lowers your ROI.  

Some fixes for belt slippage include: 

• Checking belt tension 

• Inspect drive components 

• Clean any debris 

This is one of the signs that is fairly obvious at a glance. You may see cracks, frays, or even complete cuts in the belt. The wear and tear could cause a multitude of problems including product damage, excessive downtime, and even additional safety concerns. If left untreated, damaged belts may eventually require a full replacement, which depends on your system’s needs, could be a very costly purchase. 

Some fixes for this issue include: 

• Repairing current belt 

• Replacing the belt 

• Fully remove from service

Conveyors often make a variety of noises when operational. As you become familiar with your equipment, you can distinguish between what’s normal and abnormal. Now, some noise can be a one-time sputter or catch in the belt. However, if you constantly hear the same noise repeatedly, that’s when you may need to consider an inspection. The most common reasons for this are loose components, inadequate lubrication, and heavily worn components. 

Usual fixes include: 

• Properly lubricate pieces 

• Constant service checks 

• Replacement of worn parts

Much like a damaged belt, debris can be very noticeable from a distance. Debris buildup is usually caused by inadequate or infrequent cleaning, which should be included in a preventive maintenance schedule. This schedule all depends on how often it’s used, how long it runs, and what products are usually transported. This accumulation may cause belts to jam or additional safety hazards. 

The main way to remedy this is: 

• Clean the debris 

• Identify the source 

• Stop the source 

Even in scenarios where conveyors are not involved, the dangers of overheating are very prevalent. One major example of this is the Samsung Galaxy Note 7 incident back in 2016. According to Dan Doyle Law Group, due to overheating, many of the devices began to catch fire causing damage and some injuries. The same principle of overheating can be applied to machines as well. If a conveyor’s motor or electrical circuitry begins to malfunction, it can create a serious safety hazard. 

Some of the main causes of overheating include inadequate lubrication, overloaded motors, or any faulty bearings and gears. Solutions to this problem are: 

• Detailed inspection 

• Check machine handling procedures  

• Properly lubricate 

Unlike many of the other mentioned signs, this function acts more like a protective measure than a warning sign. Whenever a motor trips, production on the line completely stops. This is done to safeguard the motor and the additional pieces that run the belt. Most of the time, the motor will trip due to any debris build up, belt misalignment, or even too much weight. Whatever the cause, the last thing you want to do is continually have it trip. When it continuously trips, you lose valuable time and potentially product. 

The solution for this includes: 

• Checking for debris 

• Inspecting the drive settings 

• Reporting any issues

Belt misalignment is a common malfunction that occurs for many different pieces of equipment. There are a few different causes of this, some more intricate than others. Main causes for this include debris buildup, misaligned pulleys, damaged rollers, and uneven loading. If left untreated, it could cause accelerated wear on equipment, material spillage, and unexpected downtime. Not only does this affect machine safety, but employees as well. Employees may be tempted to reach in and fix the fault themselves. It’s important to dissuade your employees from this as it could cause a number of injuries or permanent damage. 

Solutions to consider are: 

• Recheck belt alignment 

• Replace damaged components 

• Correct the loading process 

Whether you’re in the market for a new system or need help with preventive maintenance, we can help. At Russell Conveyor, we make custom in-house conveyor systems to fit your needs. If you need help with preventive maintenance, Russell+ is our monthly subscription service offering four separate tiers. Services include spare parts, remote support, predictive repair planning, resident technician options, and much more. 

Ready to put your upkeep in trusted hands? Contact us at (336) 526-3014 and let’s talk about how we can support your business. 

For more information on how to make an effective preventive maintenance plan, read our blog on how to build the best plan for your company.