Processandconveyorbelting

Tracking and tensioning

Introduction 1
Whypreventmistracking 1
Causesofmistracking 2
Explanationofmistracking 3
Tensioningofthebelt 4
Methodstocorrectmistracking 5
Conveyorbeltproblemsandcures 8


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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 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.




Causes of mistracking

Belt
Whenthebelt:
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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 Processandconveyorbelting

Tracking and tensioning

Frame
Theframemightnotbestable.

Belt support
Thesliderbedisperhapsnothorizontalorthereisadifferenceinsurfacesmoothness.
Rollersmaybemountedinatiltedpositionoroutoftheperpendicular.Diameterdifferences
cancauseproblemsaswellaspollution.

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


Explanation of mistracking

Rule: Abeltreachingadrum/pulleywillgetadeflectionfromthefirstcontactbetween
beltanddrum/pulley.Asaconsequencethebeltisrunningtothedirectionwhereitis
touchingtheturningdrumorpulley.


Cylindrical pulleys
Beltrun

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


Conical pulleys Beltrun

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

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 Processandconveyorbelting

Tracking and tensioning

Support rollers (tracking rollers) Beltrun

Thebeltwillruninthedirectionoftheperpendicularlineonthe
contactline(fig.3).

Rule: Abelt,runningagainstapulleyorroller,willgetaside
deviationofthefirstcontactspot*betweenbeltandpulley/roller.
Fig. 3


Fixed sliding strips or scrapers 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 Cylindricalpulleywith Apply non slip tape on a
Shape,difficulttomake conicalsides:imitationof cylindrical pulley
theconvexmodel

Dimension Length partition Pulley length mm

(drivepulleydia.80-300mm)
Diameterdifference=1%
butmaximum4mm A B A

D1= 101 A B A D2 D1
upto400 1/3 1/3 1/3
D2 100 400-800 1/4 2/4 1/4
800-1200 1/5 3/5 1/5
D1=largestdiameter NB:pulleylength= 1200-1600 1/6 4/6 1/6
D2=smallestdiameter beltwidth+50mm over1600 300 300


Which pulleys to be crowned:
1. Drivedrum.
2. Drivedrumsandtaildrumswhentheconveyorislongerthan4xthebeltwidth.

Recommendations:
Inprinciplethepulleysandrollersmustbeadjustable(e.g.bolt10inhole12).
Pulleyspreferablynotatthebuttend.
Forhighbeltspeeds(v=2m/s)balancethepulleys.
Nevercrowntheknifeedgesorsetthemoutofsquare.

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 Processandconveyorbelting

Tracking and tensioning

Tracking rollers

Flat (snub) tracking rollers
15-30
Mountthetrackingrollersinaspotwithlowbelttension
(usuallybeforethereturnpulley).Thearcofcontactmustbe
between15and30.Below15thecontactbetweenbelt
10%W
andpulleyistooshort,over30youwilladdtensionwhich
againwillcausemistracking.Theremustbesufficientfriction 300-600

betweentrackingrollerandbelt(e.g.non-sliplagging). Tensioning-/taildrum
andtrackingidler
Whenthebeltisheavilypolluted,mountingontheinsideof
thebeltispossible.

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

Thesideguideisonlysuitableforcorrectingtemporarymis-
trackingandforlateralstablebelts;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.

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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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 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
Excessivepositivetake-upforce Provideself-compensatingtake-up(spring
loadedorcounter-weight)
Belt slips and squeals
Belttoolooseinsufficienttraction Lagdrivepulley;increasetensionslightly
betweenbeltandpulley
Conveyorunder-belted Replacewithheavierorwiderbelt

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 Processandconveyorbelting

Tracking and tensioning

Tracking
Belt creeps partly to one side
Beltsplicecrooked Re-splice
Beltendsatfastenersnotslitsquare; UseaT-squareforslittingperfectlysquare;
fastenersnotjoinedsquarely replacewithcorrectsizefasteners
Belt slips creeps to one side
Improperbeltload Loadindirectionofbeltrun,atbeltspeed,
centredonbelt
Frozenrollers;rollersnotproperlylocated Lubricaterollers,improvemaintenance;
(oblique) relocateimproperlyplacedrollersand
checkalignmentwithaT-square
Frameorstructurecrookedornotlevelbelt Checkalignmentbystretchingastring
shiftstolowside alongframeedge,makecorrection;level
structure
Materialbuild-uponpulleys/rollers Cleanandimprovemaintenanceby
mountingscrapersorothercleaningdevice
Pulleys/rollersoutofline/oblique Re-checkandsquarewithaT-square
againstconveyoredge
Belt creeps at one spot only
Roller(s)-usuallyinfrontoftroublespot- Move(indirectionofbeltrun)thatroller
outofline(notperpendicularwithcentre endtowhichthebelthasshifted
line)Alsosee4.2,4.3and4.4
Belt creeps to one side at head pulley
Headpulleyorprecedingrollersoutofline Realignthepulley/rollersperpendicularto
(notperpendicularwithcentreline) beltcentreline,ormove(indirectionof
beltrun)thatpulley/rollerendtowhich
thebelthasshifted
Belt creeps to one side at tail pulley
Tailpulleyorclosereturnrollersareoutof Realignthepulleyperpendiculartobelt
line/oblique(notperpendicularwith centreline,ormove(indirectionofreturn
centreline) beltrun)thatpulley/rollerendtowhich
Alsosee4.2,4.3and4.4 thebelthasshifted
Belt wanders irregularly
Conveyorover-beltedasbeltistoostiffto Replacewithproperbeltoruselarger
properlyrunoverappliedpulleydiameter pulleydiameter
Improperoroff-centreloadingcancause Correctloadingprocedureoruseabelt
belttowander withV-guide
Splice and fastener
Belt fasteners pulling out
Incorrectsizefastenersapplied Re-lacewithpropersizefasteners
Excessivetensiononbelt Reducetensiontoapointwherebeltwill
runwithoutslip;lagdrivepulley
Pulleystoosmallforbeltthickness Uselargerpulleydiameterorathinnerbelt
ifpractical
Belttensiontoohighcausedbyslippage Increasepulleydiameterstoreducebelt
tensionandtheeffectofstiffnessof
fastenerorapplyanendlesssplicedbelt
Splice failure
Beltspeed/tensiontoohigh(duetospeed Increasepulleydiameterstoreducespeed
differencetop/bottomsideofbeltand differenceandheatingup
innerheatingupduetosharpbendingover
toosmalldrums)

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 Processandconveyorbelting

Tracking and tensioning

Pulleystoosmall Increasethepulleydiameter
Bendingofspliceinlateraldirection Removethecauseofbendingorapplyan
othersplice(e.g.T-splice)
The belt

Ply separation
Edgeofbeltwornorbrokendueto Checkalignmentofframe,pulleysand
excessiverubbing rollers

Pulleydia.toosmallforappliedbeltor Increasepulleydia.;reducetension(also
excessivetensiononbelt see1.3)
Damagebyabrasives,acid,heat,chemicals, Selectaproperlyresistantbelt
mildeworoil
Toomuchpulleycrowning Checkcrowningrecommendations
Excessive top side wear
Materialbuild-uponpulleys/rollers Cleanandimprovesupervision;install
scrapersorothercleaningdevice

Excessiveimpactofmaterialonbelt Reduceimpactorusecushionrollersatthe

impactpoints
Dirty,frozenormis-alignedreturnrollers Improvemaintenanceandsupervision;re-
alignrollersbyusingaT-squareagainst
conveyoredgeandrollers
Excessive pulley side wear
Beltslippingondrivepulley Lagdrivepulley;installsnubrollerfor
betterwraparounddrivepulley;slightly

increasebelttension

Materialbuild-uponbeltbottomside Removeaccumulationandinstallscrapers
tokeepthebottomsideofthebeltclean
Frozenordirtyrollers Lubricaterollers;improvemaintenance
Laggingsafetyscrewsprotrudingpulley Tightenscrewsandreplacelagging
lagging

Excessive edges wear

Beltedgesarefoldinguponconveyor
guardsorframe
Sideloadingcausesbelttoshifttoopposite
sideandtorubexcessively
Materialbuild-uponpulleyswillsidetrack
belt
Cover softening and cracking
Damagebyabrasives,acids,heat,
chemicals,mildeworoil
Pulleydiametertoosmallforbeltthickness
Excessivebelttension
Usestifferbeltifpractical;providemore
lateralclearance;smoothenroughareason
guardsorframe
Improvebyloadingindirectionofbeltrun;
useabeltwithV-guide
Installscraperstoprevent;build-upwill
forcethebeltagainsttheframe;applya
beltwithV-rope
Useproperlyresistantbelt
Increasepulleydiameterorusemore
flexiblebelt
Reducetension;lagdrivepulleyorprovide
self-compensatingtake-up

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