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.
This copper mill facility was processing crushed ore the consistency of sand. They were using conventional guide roller trackers that kept failing. Due to the design of the guide rollers they continually came in contact with the belt’s edge which made them slow to react and caused premature “side wear” on the belt. The operators were prone to “tying the guide rolls off” which eliminated “the ability for it to train/align the belt.” Also, “build-up” of carry-back on the external pivot caused freeze-up (stop working) making it vulnerable to the elements of the harsh environment.
Install ASGCO 36” Troughing Tru-Trainer® prior to where the problem of miss alignment occurred on the “load-carrying side of the belt.” Conventional training devises utilize “guide rolls” that cause premature belt wear and are slow to react to belt miss tracking. At no time does the ASGCO Troughing Tru-Trainer wing’s contact the belt’s edge.
ASGCO Tru-Trainer Troughing Idler’s unique center roller does all the belt’s steering. It’s quicker to react than conventional trainers with guide rolls. The internal sealed pivot was protected from the harsh elements and fugitive build-up in the copper mill, which caused the other conventional guide roller pivots to “freeze up” and not perform. ASGCO’s Tru-Trainer Troughing Idler’s superior belt tracking performance is saving them money due to less spillage, less downtime and less belt wear.
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.
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