Conveyor efficiency, safety and productivity are critical components to any mining operations or bulk shipping terminal. Therefore conveyor belt mis-tracking or mis-alignment can be a major concern.
The problem, as shown in the pictures of the right, conventional training idlers are not effective. Some of the problems are; the side-guide rollers and exposed center pivot will seize, which can creates sever belt edge damage, the trainer in most cases is tied off in one direction therefore not allowing the trainer to actuate when need and lastly conventional tracking idlers will not work on reversing conveyor systems. On one particular reversing conveyor system the customer had a conveyor belt mis-alignment switch sending and alarm nearly every day.
After a complete survey of the conveying systems and the biggest problems were identified, it was recommended to the customer that they install ASGCO Tru-Trainer® series of conveyor belt tracking idlers approximately 20’-30’ (7m-10m) prior to any conveyor pulley. After the installation of the Tru-Trainers the customer has not had a single belt mis-alignment alarm on any conveyor that now has a Tru-Trainer; including the reversing conveyors.
The Tru-Trainer series of Conveyor Belt Tracking idlers employs a patented, unique highly effective tracking action, which in non-damaging to the conveyor belt and reacts immediately if the belt begins to steer off center. Because it does not rely on contact with the belt edge in order to guide the belt, belt edge damage which frequently occurs with conventional tracking systems, is avoided.
The customer is a larger coal burning power plant that has had FGD Scrubber Conveyors in service for many years to help control the plants emissions. The product that is being conveyed is a synthetic gypsum product that is either conveyed or shipped to a nearby gypsum board plant. This product is very sticky and corrosive and builds up on the conventional return idlers and return trainers. This causes the belt to mis-track and rub the conveyor structure.
After ASGCO representatives surveyed the conveyor and pointed out some of the problems that were causing the belt mis-tracking, the benefits of installing two return Tru-Trainers to help keep the conveyor belt centered on the conveyor were discussed.
After installing the Tru-Trainers the belt immediately centered itself on the conveyor system. The customer watched the performance of the Tru-Trainer Flat Return Idlers and was extremely impressed.
A ready-mix plant had difficulty properly tracking the vital conveyor belt that feeds the mixer. The problem was essentially that the conveyor belt was difficult to keep in alignment, which caused serious belt edge damage, and in turn de-lamination and spillage in the conveyor load zone. Read more
Challenge: Problems of continuous misalignment on a short reversing feeder conveyor belt was causing severe damage to the belts. These were replaced monthly at a cost of $741 USD/each belt, however, down time is $73,059 USD per hour and the replacement of this belt needs a time of 4 hours. That is the equivalent to $292,237 USD of downtime related to the conveyor. Read more