Conveyor lines are the foundation of operations for material handling and distribution facilities.
System failure and unexpected downtimee, whether caused by a problem with the belt or by conveyor motor failures, can result in you needing costly replacement parts or repairs, and can lead to lost business. You can’t ship if your lines are down. Those costs can quickly skyrocket as you need to pay overtime and put stress on other lines to keep up.
Addressing and troubleshooting the issues that cause motor and system failure will not only prevent downtime and stress and keep packages moving but will also reduce repair costs and prevent future conveyor motor failure.
Every motor will eventually fail, but there are a number of issues or reasons that a motor will experience premature failure. Many of these issues start with the belt.
When there is too much or too little tension on the conveyor belt, the motor must work harder to compensate, which can cause failure. A loss of tension can also lead to the belt slipping, which can ruin the belt or cause the motor to fail.
Solution: If the conveyor system is forced to frequently manage loads that exceed its weight limit or that of the belt, then the motor will struggle with increased tension. Problems with the traction on the pulley can also cause tension problems. Regularly inspect the system and weights, and test the tension on the belt.
Related to belt tension problems, increased friction and drag on the motor will cause stress that leads to conveyor motor failure. An engine that runs hot due to friction and drag is one that is at additional risk.
Solution: Check the friction between the belt and the conveyor bed. Worn slider bed steel, runners and frequent belt replacement can mean there are factors that increase friction and drag on the motor. Belts that make contact directly on the steel slider beds lead to increased belt wear and increased drag on the motor. A simple solution is Crown’s Slider Strips with ultra-slick UHMW, which are easy to apply with self-adhesive strips, reducing the drag and protecting the belt and metal from wear.
Tears and damage to the belt will occur and can lead to system failure, especially in sections that have been spliced, or connected. These sections are especially susceptible to tension. A belt tear or separation at the splice will not only damage the belt but can ruin the engine. Abrasive material or damage from packaging can also cause tears.
Solution: Check the splicing on the belt to ensure it isn’t causing undue damage. Check the belt with weight on it and as packages impact it to see if the splicing holds. Keep the belt clear of abrasive materials.
Issues with the rollers, especially ball-bearing and metal rollers, can cause several problems, including misaligned belts, increased drag on the engine, and uneven wear on the belt. Metal rollers are durable, but over time they can get worn and develop sharp edges that can damage the belt and be dangerous for employees. Seized, or stuck, return rollers can lead to motor failure.
Solution: Make sure to check the rollers for damage, especially rollers with ball bearings. Look for debris in the roller. Debris can increase friction with the roller and cause damage. When possible, try to replace the roller with one that doesn’t use ball bearings, like Crown’s Silent Roller, which offers quieter and more efficient operations.
When the conveyor belt isn’t aligned — for example, one side of the conveyor is providing all the tension to the belt, or the belt isn’t on the pulley system — then your motor must struggle and run hotter to compensate. This can cause motor damage or failure. This will also cause uneven belt wear, leading to compounding problems with your system.
Solution: If you experience frequent alignment issues with your system, check that the frame of the conveyor isn’t damaged. Review the alignment of the rollers, pulleys, and idlers. Material buildup can also cause misalignment, as can uneven wear or increased and misaligned drag on the belt.
Regular inspections and routine maintenance can identify many of the issues and problems we’ve covered here. When a problem is discovered, addressing it quickly can prevent increased repair costs and downtime for the system.
That said, you should also look for long-term solutions that will prevent many issues from happening. Crown Plastics offers a full line of innovative material handling solutions using ultra-slick, high-quality UHMW, which provide quieter, more efficient system operation and increased wear resistance. These products include:
If you have questions or want to speak to an expert in material handling solutions about the challenges facing your facility, then contact Crown for a free consultation. Don’t wait until your line is down, contact Crown today.