Not Just a Hidden Problem: Unveiling the Top Causes of Elevator Belt Failure in Cement Industry
The cement industry heavily relies on elevators installed at various production stages, with belt elevators being the most widely used type. Despite their significant role in the process, elevator issues often go unnoticed due to their enclosed nature within the system.
One frequent cause of elevator malfunctions is related to belt problems. Understanding these issues is crucial for ensuring smooth and efficient operation in the production line.This article dives into the most frequent causes of elevator belts failure in cement industry, helping you identify and address them before they cause significant downtime.
Belts under Scrutiny: Common Culprits of Elevator Woes
Slipping and Misalignment: Improper belt tracking can lead to the belt slipping on the drive pulley, reducing efficiency and causing material carryback. Misalignment can also put undue stress on the belt edges, accelerating wear.
Elevator belt must run centrally in the drive pulley and take-up pulley. During one rotation, the belt may move up to 30 mm to the right or to the left. The tolerance depends on the bucket elevator size. If the belt tracks off by more than 30 mm, the take-up pulley must be readjusted. The position of the take-up pulley is adjusted with the lateral take-up spindles. The take-up is to be located in the centre or in the upper third of the take-up distance. The running of the belt can only be corrected if the drive pulley is exactly aligned.
Regular checking and replacement of pulleys, tension bearings etc are necessary to ensure smooth operation.
Fastener Failure: Improper belt splicing techniques or using old types fasteners can damage the belt internally. This creates weak points susceptible to tearing under load. Using the new design of belt fasteners with rubber inside part can help to run your elevator belt much longer without issues.
Regularly check the screw of the belt clamping for their tightening torque. If one or several screws are defective, all screws have be changed by new once.
Heat Takes its Toll: Hot products in cement industry can significantly reduce a belt's abrasion resistance and flexibility. The rubber becomes harder and less elastic its tensile strength and elongation at breaking point can fall by as much as 80%, effectively destroying its operational strength and flexibility. At the same time, resistance to wear (abrasion) can decrease dramati¬cally, often by 40% or more.
Select quality elevator belt with right specifications and always monitor material temperature.
Stretching: Over time, belts naturally stretch due to constant use. Conversely, exposure to extreme temperatures or moisture fluctuations can cause them to stretch. These scenarios can lead to tracking issues and ultimately belt failure.
Bolt Tension Troubles: Overtightening the bolts on the belt structure can create excessive tearing and wearing of the belt from inside. Not Tightened bolts can be lost in elevator and lead to buckets dismounting and unplanned stops of production.
Use quality bolts and pay attention to the about bucket installation to the belt.
Worn Pulleys: Over time, pulley lagging wear, causing the belt to ride unevenly. This can lead to tracking issues, increased wear on the belt edges, and ultimately belt failure.
Regular maintenance and replacement of worn pulleys are necessary to ensure smooth operation.
Combating Belt Issues: Proactive Maintenance is Key
By implementing a regular maintenance program, you can identify and address these belt problems before they become major issues. Here are some key steps:
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Regular inspections: Visually inspect belts for signs of wear, damage, and misalignment.
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Belt tension monitoring: Ensure proper belt tension to prevent slipping and premature wear.
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Pulley maintenance: Inspect and replace worn pulleys to maintain proper belt tracking.
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Splice integrity checks: Regularly inspect belt splices for signs of damage or wear.
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Use high-quality fasteners: Invest in durable, high-quality fasteners designed for the specific application.
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Temperature monitoring: Control material temperatures to prolong belt life.
By addressing these common belt-related problems and implementing preventative maintenance measures, cement industry professionals can enhance the efficiency and reliability of their elevator systems. Stay informed about potential issues and take proactive steps to avoid downtimes in production.