Processandconveyorbelting

Tracking and tensioning

Introduction

Whypreventmistracking
Causesofmistracking
Explanationofmistracking
Tensioningofthebelt
Methodstocorrectmistracking

1
2
3
4
5

Conveyorbeltproblemsandcures

Introduction

Therearemanyopinionsabouttensioningandtrackingofconveyorbelting.Ammeraal
Beltechhasgainedmuchexperiencewiththisphenomenon.Withregardtotensioningof
conveyorbeltingincombinationwithtracking,anextensiveknowledgeisavailable.This
modulegivesdirectionstopreventthenegativeinfluencescausedbymistrackingofconveyor
beltinginpractice.

Why prevent mistracking

Thecausesofmistrackingare:

maintenanceheadaches;
downtime;
beltdamage;
damageofequipment(overtensioning);
productdamage.

Maintenance headaches
Theroundtheclockeconomyisaskingforanextensionoftheoperatinghoursof
productionplants.Thismayresultinmaintenanceproblemscausedbymistrackingofthe
beltatanytimeduringthedayornight.Ingeneralthetechnicalservicecanbecalledto
solvetheseproblems,butthisisexpensiveandunpleasant.

Downtime
Mostofthecompaniesworkaccordingtoaproductionplan.Incaseofdowntimethereis
noproductionandthecompanyisfacinglackofearnings.Downtimehastobepreventedat
alltimes.
Belt damage
Ingeneralprocessandconveyorbeltingarevaluablepartsoftheconveyor.Mistrackingof
thebeltisusuallyresultinginconsiderablebeltdamage.Thisdamagecanusuallynotbe
repaired.Itresultsinhighandunexpectedexploitationcostsoftheequipment.Correct
tensioningandtrackingofbeltingcanpreventthis.

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January2007

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Processandconveyorbelting

Tracking and tensioning

Equipment damage
Whenmountingthebeltwithtoomuchbelttensionusuallymuchdamageiscausedtothe
installation.Aninstallationisdesignedfortheapplication.Abelttensionhigherthan
calculatedwillcausebendingofthedrumsandshafts.Alsotheloadonthebearingswill
increase.Thisalwaysresultsinashorterservicelifeandpossibleunexpectedcosts.

Product damage
Productdamagehastobepreventedatalltimes.Incaseoffood
productionitisintolerablethatnon-foodsubstancesendupinthefood
product.Abeltrunningagainstmachinepartsbecauseofmistracking
resultsinfrayingedges.Theseparticleswilleventuallycontaminatethe
product.Thiscanbepreventedbyproperbelttensioningandtracking.

Belt
Whenthebelt:

Causes of mistracking

doesnothaveanevenlengthontheleftandrightsides;
hasdifferencesinthicknessontheleftandrightsides;
showsdifferentwearontheleftandrightsides;
isnotsplicedstraight;
iscurvedordeformed;

thisresultsinadifferenceinsurfacepressureand/orfrictiononthepulleydrive.

Othercausescanbe:
Anincorrectbelttension.Whenthetensionistoolow,thebeltwillgoinevery
direction.Whenthetensionistoohigh,thereisnocorrectionpossiblebecausethebelt
cannotslipsidewaysonthepulleys.
Anincorrectfabricconstruction(nottwistedSZ).
Fabricnotinthecorrectposition(angle)inthebelt(obliqueweft).

Pulleys
Causescanbethatthepulleysarenotparalleltoeachotherandsquarelyonthebelt.Orthe
pulleysarenothorizontal.Anotherreasonisadifferenceincoefficientoffrictionoverthe
pulleylength(wrongshape,pollution,wear)orthereisadifferenceindiameterononeside
towardstheother.

Note: Belt widthandpulleylengthmustgear.

Product
Possiblecausesareanasymmetricload,incline/decline,loading/unloadingononeside,or
temperaturedifferencesincombinationwiththeloadingsystem.

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January2007

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Processandconveyorbelting

Tracking and tensioning

Frame
Theframemightnotbestable.

Belt support
Thesliderbedisperhapsnothorizontalorthereisadifferenceinsurfacesmoothness.
Rollersmaybemountedinatiltedpositionoroutoftheperpendicular.Diameterdifferences
cancauseproblemsaswellaspollution.

Various causes
Therecanbemorereasonsformistracking,likeabeltcleaner,sideskirts,knifeedge
transfersorweatherinfluences(wind).

Rule:

Explanation of mistracking
Abeltreachingadrum/pulleywillgetadeflectionfromthefirstcontactbetween

beltanddrum/pulley.Asaconsequencethebeltisrunningtothedirectionwhereitis
touchingtheturningdrumorpulley.

Cylindrical pulleys

Whenapulleyisnotplacedsquaretothebelt,itwillresultinthe
situationasshowninfig.1.Thebeltwillmovetotheleftasanut
doesoverathreadedpin,withaspeedofDtg.
Inthemostextremecasethebeltwillfoldonthedrum.
Thebeltwillruntothesidewiththelowesttension.
Thebeltrunsinthedirectionoftheperpendicularlinetothe
contactline.
Thebeltrunsinthedirectionwhereittouchestheturning
drumorpulleyfirst.

Conical pulleys

Beltrun

Fig. 1

Beltrun

Fig.2showsthatthebeltmovestotherightonconditionthatthe
shaftsofthepulleysareparalleltoeachother.Thebeltwillrunto
thesidewiththehighesttension.
Asaresultofspeedandtensiondifferencethebeltwillshow
ahorizontalbendingjustbeforeittouchesthedrum.
Thereforethebeltwilltouchthedrumsomewhathigher(in
directionofbiggestconicaldiameter).

Fig. 2

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January2007

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Tracking and tensioning

Support rollers (tracking rollers)

Beltrun

Thebeltwillruninthedirectionoftheperpendicularlineonthe
contactline(fig.3).

Rule: Abelt,runningagainstapulleyorroller,willgetaside
deviationofthefirstcontactspot*betweenbeltandpulley/roller.

Fixed sliding strips or scrapers

Fig. 3

Beltrun

Abeltrunningonanon-movingsupportwill,contrarytoroller
support,deviateinthedirectionofthelastcontactspotbetween
beltandsupport.

Inpracticethesupportoffixedstripsconsistsof:
sliderbed,beginningofthebedmustbesquareonthebelt;
slidingstrips;
Fig. 4
scrapers.
Thesamephenomenonoccursincasethesupportrollersdonotturnorturnwithdifficulty.

Tensioning of the belt

Thebelttensionhasadirectrelationwiththetrackingbehaviour.Toomuchtensionresultsin
verynervousbeltbehaviourandexcessivewearofmachinerycomponentslikebearingsand
shafts.Toomuchtensioncanevenresultinabreakingoftheshafts.Toolittletensiongives
beltslippageonthedrivedrumandresultsinnotfollowingthecrowning.

Beforemountingthebeltontheinstallationitisadvisabletoleavethebeltfortwelvehours
intheroomwherethebeltisgoingtobeused.
Whentheoldbeltisremoved,theinstallationcanbecleaned.Thenthebeltcanbemounted;
ifnecessaryitcanbemadeendlessonsite.
Theinstallationhastobeprovidedwithatensioningdevice;inmostcasesthisisthetail
drum.Thetensioninglengthoftheinstallationis1%ofthebeltlength.

Thebelthastobetensionedaftermounting.Thebestwaytodothisistomarktwolines
(withapitchof1000mm)atbothbeltsideswitharedpen.Thentensionthebeltleftand
rightequallyupto1003mm=0.3%pretension.Incaseofheavierloadover50kg/m2the
belttensioncanbeincreasedto0.5%.

Incaseofaninstallationwithaknifeedgethisprocedureisnotapplicable.Inthiscase
tensionthebeltonarunninginstallationtotheextentthatslippagedoesnotexistanymore.

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Processandconveyorbelting

Tracking and tensioning

Methods to correct mistracking
Fixed tracking possibilities or adjustable by hand:
Crowningofthepulleys.
Trackingrollers:flattrackingroller,snubpulley,adjustingtroughassembly,
V-rollers/strips.

Fixedprovisionsontheconveyor:siderollers,sideguides.
Fixedprovisiononthebelt.
Trackingropes,trackingstrips,guiderollers.
Variabletracking:withuseofthebelt,trackingdeviceswithowndrive.

Crowning of the pulleys

Emergency solution or test

Convexpulley:ideal
Shape,difficulttomake

Cylindricalpulleywith
conicalsides:imitationof
theconvexmodel

Apply non slip tape on a

cylindrical pulley

Dimension

Diameterdifference=1%
butmaximum4mm

Length partition

Pulley length mm
(drivepulleydia.80-300mm)

D1= 101
D2 100

D1=largestdiameter

B
A
A

NB:pulleylength=

upto400
400-800
800-1200
1200-1600

1/3
1/4
1/5
1/6

1/3
2/4
3/5
4/6

1/3
1/4
1/5
1/6

over1600

300 300

D2 D1

D2=smallestdiameter
beltwidth+50mm

Which pulleys to be crowned:

1. Drivedrum.

2. Drivedrumsandtaildrumswhentheconveyorislongerthan4xthebeltwidth.

Recommendations:
Inprinciplethepulleysandrollersmustbeadjustable(e.g.bolt10inhole12).
Pulleyspreferablynotatthebuttend.

AmmeraalBeltech

Forhighbeltspeeds(v=2m/s)balancethepulleys.
Nevercrowntheknifeedgesorsetthemoutofsquare.

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Tracking and tensioning

Tracking rollers

Flat (snub) tracking rollers

Mountthetrackingrollersinaspotwithlowbelttension
(usuallybeforethereturnpulley).Thearcofcontactmustbe
between15and30.Below15thecontactbetweenbelt
andpulleyistooshort,over30youwilladdtensionwhich
againwillcausemistracking.Theremustbesufficientfriction
betweentrackingrollerandbelt(e.g.non-sliplagging).
Whenthebeltisheavilypolluted,mountingontheinsideof
thebeltispossible.

15-30

10%W

300-600

Tensioning-/taildrum
andtrackingidler

Adjusting snub/stow pulleys

Theprincipleisthesameastheadjustingtroughassemblythat
ismountedupsidedown.Mountinreturnpartonbothbelt
edges,undersomebelttensionandfarfromenddrums(6
toe-in,15downwardstolateralhorizontalline).When
mistrackingbeltmustrun-uphighertotherollinordertoface
moreresistant.

Adjusting trough assemblies

Inpracticeoneoneachfivetroughassembliesisanadjustingone.

Note:Think of the proper mounting, because adjusting trough

assemblies are for one running direction. The rollers have to be
mounted toe-in (see sketch).

V-strips (flat belt)

ThisChevron-shapedprofileispushingthebelttothecenter
andcanonlybeusedincaseofheavybelts(over3kg/m2).By
thethrustlightbeltsmightfold.

Side rollers
Theseareonlysuitableforheavy,thickbeltingof10mm
thickness.Theyaremeantfortemporarymistracking,andnota
continuoussolution.
Note: Support rollers and trough assemblies can also be slightly adjusted.
Fixed provisions on the conveyor

Thesideguideisonlysuitableforcorrectingtemporarymistrackingandforlateralstablebelts;notforverythinbelts.Itis
nocontinuoussolution.Thematerialofthesideguideise.g.
beechwoodornylon.

Note: The guide must be bevelled at the side where the belt is going in.
Do not mount the guide close to the exit side of a return drum.
AmmeraalBeltech

January2007

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Processandconveyorbelting

Tracking and tensioning

Fixed provisions on the belt
Ropes
V-guidesandguideropes(squareandrectangular)canbeapplied
onthecentrelineofthebeltoratthesidesofthebelt.Theguide
tracksontheframeandnotonthepulley.Thepulleydiameterfor
V-guidesis6xtheheightoftheguide,forsquareandrectangular
ropes10xtheheight.

Strips
Guidestripsareusuallyappliedonthesidesofthebelt,thestrip
tracksontheframeandnotonthepulley.Aone-plystripneedsa
pulleydiameterof1.2xtheminimumpulleydiameterofthebelt
andatwo-plystrip1.4x.WhenAmtelstripsareused,thepulley
diametermustbe10xthestripthickness.

Note: V-guides, ropes and strips have a free space towards the pulley on the bottom side.
Only the belt is driven. If not, the guide will tear off the belt because of the differences in
circumference speed.

Rollers/cams
Guiderollers/camsareappliedincasesoflonglastinglateralforces
andhighdemandsonrunningstraight.

Variable tracking
Tracking with use of the belt
Aflattrackingrollerismountedonthebottomsideofthebelt,in
theupperpartinfrontofloadingpoints,approx.2000mm
beforethereturnpulley.
Principle:whenthebeltgoestotherightside,thetrackingroller
willattherightsideturnintherunningdirectionofthebelt.Asa
resultofthis,thebeltwillbeguidedbacktothecentre.Thisis
influencedbybeltweight,productweightandfrictionbetween
beltandroller.

Trackingtroughassembliesareusedforbeltingwithoneortworunningdirections.
Theassembliesareautomaticallyadjusting.

Beltwithonerunningdirection

Beltwithtworunningdirections

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January2007

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Processandconveyorbelting

Tracking and tensioning

Tracking devices with own drive
Becauseofthelargescaleofpossibilitiesintrackingequipment,welimitourselvestoa
numberofdistinguishingcharacteristics:
Drive:pneumatic,pneumatic/hydraulic,electric.
Amountoftracking:minimum/maximum,proportional.
Manneroftracking:byfriction(seetrackingroller),byclampingthebelt(Foxwell),by
influencingthebelttension.
Mannerofsignalising:bydirectbeltcontact(pneumatictracer,microswitch),without
contact(ultrasonar,photocell,pneumatic,approximationswitch).

Conveyor belt problems and cures

Stretch and slippage

Belt:

stretchesexcessively
slipsandsqueals

Tracking

Belt:

creepspartlytooneside
creepstooneside
creepsatonespotonly
creepstoonesideatheadpulley

creepstoonesideattailpulley
wandersirregularly

Splice and fastener

Beltfastenerspullingout
Splicefailure

The belt

Plyseparation
Excessivetopsidewear
Excessivepulleysidewear
Excessiveedgeswear

Coversofteningandcracking

Cause

Cure
Stretch and slippage
Belt stretches excessively

Tensiononbelttoohigh

Reducetensiontoapointwherebeltwill
runwithoutslippage;lagdrivepulley

Conveyorunder-belted

Replacewithheavierorwiderbelt

Materialbuild-uponpulleys/rollers

Cleanpulleys/rollers

Frozenrollers

Removeicingontherollerstoincrease
frictionbetweenbeltanddrum
Provideself-compensatingtake-up(spring
loadedorcounter-weight)

Excessivepositivetake-upforce

Belt slips and squeals

AmmeraalBeltech

Belttoolooseinsufficienttraction
betweenbeltandpulley

Lagdrivepulley;increasetensionslightly

Conveyorunder-belted

Replacewithheavierorwiderbelt

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Tracking
Belt creeps partly to one side
Beltsplicecrooked
Beltendsatfastenersnotslitsquare;
fastenersnotjoinedsquarely

Re-splice
UseaT-squareforslittingperfectlysquare;
replacewithcorrectsizefasteners

Belt slips creeps to one side

Improperbeltload
Frozenrollers;rollersnotproperlylocated
(oblique)
Frameorstructurecrookedornotlevelbelt
shiftstolowside
Materialbuild-uponpulleys/rollers
Pulleys/rollersoutofline/oblique

Loadindirectionofbeltrun,atbeltspeed,
centredonbelt
Lubricaterollers,improvemaintenance;
relocateimproperlyplacedrollersand
checkalignmentwithaT-square
Checkalignmentbystretchingastring
alongframeedge,makecorrection;level
structure
Cleanandimprovemaintenanceby
mountingscrapersorothercleaningdevice
Re-checkandsquarewithaT-square
againstconveyoredge

Belt creeps at one spot only

Roller(s)-usuallyinfrontoftroublespot-
outofline(notperpendicularwithcentre
line)Alsosee4.2,4.3and4.4

Move(indirectionofbeltrun)thatroller
endtowhichthebelthasshifted

Belt creeps to one side at head pulley

Headpulleyorprecedingrollersoutofline
(notperpendicularwithcentreline)

Realignthepulley/rollersperpendicularto
beltcentreline,ormove(indirectionof
beltrun)thatpulley/rollerendtowhich
thebelthasshifted

Belt creeps to one side at tail pulley

Tailpulleyorclosereturnrollersareoutof
line/oblique(notperpendicularwith
centreline)
Alsosee4.2,4.3and4.4

Realignthepulleyperpendiculartobelt
centreline,ormove(indirectionofreturn
beltrun)thatpulley/rollerendtowhich
thebelthasshifted

Belt wanders irregularly

Conveyorover-beltedasbeltistoostiffto
properlyrunoverappliedpulleydiameter
Improperoroff-centreloadingcancause
belttowander

Replacewithproperbeltoruselarger
pulleydiameter
Correctloadingprocedureoruseabelt
withV-guide

Splice and fastener

Belt fasteners pulling out
Incorrectsizefastenersapplied
Excessivetensiononbelt

Re-lacewithpropersizefasteners
Reducetensiontoapointwherebeltwill
runwithoutslip;lagdrivepulley

Pulleystoosmallforbeltthickness

Uselargerpulleydiameterorathinnerbelt
ifpractical

Belttensiontoohighcausedbyslippage

Increasepulleydiameterstoreducebelt
tensionandtheeffectofstiffnessof
fastenerorapplyanendlesssplicedbelt

Splice failure
Beltspeed/tensiontoohigh(duetospeed
differencetop/bottomsideofbeltand
innerheatingupduetosharpbendingover
toosmalldrums)

AmmeraalBeltech

January2007

Increasepulleydiameterstoreducespeed
differenceandheatingup

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Processandconveyorbelting

Tracking and tensioning

Pulleystoosmall

Increasethepulleydiameter

Bendingofspliceinlateraldirection

Removethecauseofbendingorapplyan
othersplice(e.g.T-splice)

The belt

Ply separation
Edgeofbeltwornorbrokendueto
excessiverubbing

Checkalignmentofframe,pulleysand
rollers

Pulleydia.toosmallforappliedbeltor
excessivetensiononbelt

Increasepulleydia.;reducetension(also
see1.3)

Damagebyabrasives,acid,heat,chemicals,
mildeworoil

Selectaproperlyresistantbelt

Toomuchpulleycrowning

Checkcrowningrecommendations

Excessive top side wear

Materialbuild-uponpulleys/rollers

Cleanandimprovesupervision;install
scrapersorothercleaningdevice

Excessiveimpactofmaterialonbelt

Reduceimpactorusecushionrollersatthe
impactpoints

Dirty,frozenormis-alignedreturnrollers

Improvemaintenanceandsupervision;realignrollersbyusingaT-squareagainst
conveyoredgeandrollers

Excessive pulley side wear

Beltslippingondrivepulley

Lagdrivepulley;installsnubrollerfor
betterwraparounddrivepulley;slightly
increasebelttension

Materialbuild-uponbeltbottomside

Removeaccumulationandinstallscrapers
tokeepthebottomsideofthebeltclean

Frozenordirtyrollers
Laggingsafetyscrewsprotrudingpulley
lagging

Lubricaterollers;improvemaintenance
Tightenscrewsandreplacelagging

Excessive edges wear

Beltedgesarefoldinguponconveyor
guardsorframe

Usestifferbeltifpractical;providemore
lateralclearance;smoothenroughareason
guardsorframe

Sideloadingcausesbelttoshifttoopposite
sideandtorubexcessively

Improvebyloadingindirectionofbeltrun;
useabeltwithV-guide

Materialbuild-uponpulleyswillsidetrack
belt

Installscraperstoprevent;build-upwill
forcethebeltagainsttheframe;applya
beltwithV-rope

Cover softening and cracking

Damagebyabrasives,acids,heat,
chemicals,mildeworoil
Pulleydiametertoosmallforbeltthickness

Useproperlyresistantbelt

Excessivebelttension

Reducetension;lagdrivepulleyorprovide
self-compensatingtake-up

Increasepulleydiameterorusemore
flexiblebelt

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January2007

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