Conveyor mistracking and belt lift-off are suppressed, improving stable operation and maintainability.

The following issues were encountered in the coal transport line at the power plant. The belt lifted at the steep conveyor angles and was forced down by the wheels, causing frequent damage and belt mistracking.

Belt mistracking just before the tail pulley reduced transport stability. The conveyor had to be stopped every time mistracking occurred, which affected work efficiency and safety.

These problems not only caused transport problems, but also increased operating costs due to regular stoppages and maintenance.

By installing a gate-type carrier idler to prevent lift-off at steep conveyor angles, belt lift-off and the resulting belt mistracking are prevented. Unlike conventional methods that use wheels to press down on the belt, this design integrates a pressure roller and guide roller to minimize damage to the belt and ensure stable operation.

An A-type pressure return idler (3-layer type) is installed in front of the tail pulley to correct belt mistracking. This prevents the belt from entering the pulley in a mistracked state, improving the straightness of the belt and the balance of the entire line.
Previously, the conveyor had to be stopped each time to make adjustments, but with the introduction of handle-type return idlers, adjustments can now be made in real time during operation, greatly improving worker safety and efficiency.

Stable transport and improved surrounding environment through measures against belt mistracking and blow-off

Belt mistracking occurred on a belt conveyor transporting coal due to uneven loading. The mistracking caused bulk material spillage and loss of raw materials, and also worsened the dusty environment around the conveyor.

In particular, prolonged mistracking accelerated wear on the belt and rollers, increasing the risk of equipment trouble.

In addition, spillage occurred from the gap between the skirt rubber and the rollers in the chute section. Not only did this require regular cleaning, but the dust scattered around also affected the working environment.

Case study of improving coal drop prevention in a coal conveyor line

On conveyor lines that transport coal, due to the nature of the conveyed material, it frequently adheres to the underside of the belt, and when it passes through the return roller, the adhered material tends to fall off, causing spillage.

In particular, when the coal is wet or contains a large amount of fine powder, it easily sticks to the underside of the belt, peels off on the rollers during operation, and accumulates on the bottom and around the conveyor, deteriorating the working environment and requiring regular cleaning.

In addition, depending on where the falling coal occurred, cleaning was required in areas with poor footing or near moving parts, which was a safety concern. In this case, the following measures were taken to reduce the burden of cleaning work and improve work safety.

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