Why does the conveyor belt of the mucking loader break?

The conveyor belt of a mucking loader is a critical component that is subject to wear and tear during prolonged use. Over time, it is not uncommon for the belt to experience issues such as longitudinal tears, cracks, and surface damage. These are considered typical forms of damage to conveyor belts, and addressing them can be quite challenging. Minor issues can be resolved with cold vulcanization repairs, while more severe damage may require belt replacement and hot vulcanization splicing. These repairs not only cause inconvenience but also lead to unnecessary financial losses for companies.

Causes of Longitudinal Tears in the Conveyor Belt

Vibration and Impact: The vibrations and impacts that occur during operation can cause fasteners to loosen and fall off, leading to the detachment of components such as coal drop pipes and guide plates.

Foreign Objects: The presence of hard, sharp foreign objects in the material being conveyed can block the coal drop pipe, causing it to jam and leading to tears in the conveyor belt.

Damaged Rollers: Missing or defective rollers and roller frames can cause the conveyor belt to become scratched and eventually tear.

Severe Belt Misalignment: When the conveyor belt becomes severely misaligned, it can catch on the loader’s frame, leading to tears.

Sweeper Issues: If a belt cleaner becomes caught in the drum, especially a return belt cleaner with loose bolts, it can lead to tears due to the bouncing motion.

Causes of Cracks in the Conveyor Belt

Frequent Bending: The mucking loader’s conveyor belt is subject to frequent bending due to space constraints, leading to cracks over time.

Repeated Vulcanization: If the belt joint has undergone vulcanization more than twice due to various reasons, the likelihood of cracking increases.

Causes of Vulcanized Joint Tears

Small Drum Diameter: A smaller drum diameter increases the bending stress on the conveyor belt, leading to tears.

Poor Vulcanization Quality: If the quality of the vulcanized joint is poor, especially after more than two vulcanizations, the joint strength significantly decreases. This can also occur if the fabric layer is cut or ground too much during bonding, reducing the strength of the belt at that point.

Reversible Conveyors: In reversible conveyors, the overlapping joints are only aligned in one direction, making them more susceptible to being scraped by the sharp edges of equipment like belt cleaners and dischargers.

Short Work Cycles: Mucking loaders often have short work cycles with frequent startups, which create high instantaneous tension in the belt, leading to joint tears.

To prevent these issues and minimize the need for costly repairs, it is crucial to understand the causes of damage to the conveyor belt of mucking loaders. Regular maintenance, proper alignment, and careful operation can significantly reduce the risk of tears, cracks, and other damage, ultimately saving time and reducing operational costs.