1. Belt Tracking Issues
Problem: Belt drifts laterally or fails to center.
Causes & Solutions:
| Root Cause | Solution | Preventive Tip |
| Debris buildup | Clean rollers, support strips, and belt surfaces daily. Install scrapers. | Use FDA-approved lubricants to reduce adhesion of sticky materials. |
| Misaligned rollers | Re-align drive/idle rollers to 90° relative to the conveyor centerline. | Laser alignment tools ensure precision during installation. |
| Uneven tension | Equalize tension adjustment rollers on both sides. | Mark tension settings with reference labels for quick visual checks. |
| Temperature imbalance | Calibrate heaters to ensure ≤12°C variation across the belt width. | Install infrared sensors to monitor real-time temperature distribution. |
| Edge stretching | Replace the belt or flip it temporarily (short-term fix only). | Avoid overloading edges; distribute product evenly. |
Key Note:
New belts may track differently. Always refer to "Tracking of Friction Driven Meshes" guidelines after installation.
2. Belt Slippage
Problem: Belt loses grip on drive rollers.
Causes & Solutions:
| Root Cause | Solution | Engineering Insight |
| Excessive load/conveyor length | Consult Wire Belt Company to verify belt specs match application demands. | Use torque sensors to monitor drive roller load capacity. |
| Low friction on drive roller | Increase roller diameter or apply high-friction coatings (e.g., rubber). | Replace smooth rollers with grooved designs for better grip. |
| Faulty tension mechanism | Inspect automatic take-up units for free movement; lubricate as needed. | Install tension indicators to visualize real-time adjustments. |
| Worn press roller | Adjust pressure or replace rollers to ensure uniform contact. | Use load cells to verify press roller pressure distribution. |
3. Premature Wear & Damage
Problem: Rapid belt degradation or coil distortion.
Causes & Solutions:
| Root Cause | Solution | Best Practice |
| Sharp wear strips | Polish edges to a smooth finish (Ra ≤1.6 µm). | Use UHMW-PE or Teflon-coated strips to minimize abrasion. |
| Debris-induced abrasion | Install rotating brushes or air knives for continuous cleaning. | Schedule weekly inspections of underside supports. |
| Corrosion | Switch to stainless steel (Grade 316) or plastic-coated belts for harsh environments. | Avoid chlorine-based cleaners in food processing. |
| Work-hardened coils | Replace belts showing cracks or reduced flexibility. | Avoid over-tensioning; follow manufacturer’s elongation limits. |
4. Vibration & Surging
Problem: Belt vibrates excessively or moves unevenly ("slip-stick" effect).
Causes & Solutions:
| Root Cause | Solution | Design Tip |
| Resonance from roller spacing | Adjust roller positions to avoid multiples of the belt’s cross-wire pitch. | Use CAD simulations to optimize roller layout during conveyor design. |
| Oval coil spirals | Upgrade to flat-spiral belts or larger-diameter rollers. | Prefer belts with longitudinal wire ≥3mm for smoother transitions. |
| Bearing failure | Replace seized bearings; use sealed, high-temperature variants. | Install vibration sensors for early fault detection. |
5. Operational Nuances
• "Break-In" Phase: Expect black debris initially due to surface polishing. Clean thoroughly after 8–12 hours of operation.
• Camber Correction: Reverse the belt direction periodically to balance wire stress (avoid if coils are brittle).
• Edge Guides: Limit guide contact force to ≤5N to prevent edge fraying.
Maintenance Checklist
1. Daily: Clean debris, inspect tension, and verify tracking.
2. Weekly: Lubricate bearings, check wear strip smoothness.
3. Monthly: Calibrate heaters, validate roller alignment.
Final Notes
• Documentation: Keep a log of adjustments, replacements, and belt performance.
• Consult Experts: Contact Wire Belt Company for material compatibility checks or complex vibration analysis.
By addressing root causes proactively and adopting predictive maintenance, operators can extend belt lifespan by up to 40% while minimizing unplanned downtime.
+86-15369679157
