19 Common Belt Conveyor Problems and Solutions

Part 1: Causes of Common Conveyor Belt Problems

1.Problem: The conveyor belt drifts at the tail drum

Possible causes:

The idler rollers are jammed and cannot rotate freely.

Debris and dust have accumulated on the drum or idler rollers.

The counterweight (the weight used to tension the conveyor belt) is insufficient.

Incorrect loading position, or material spilling onto the conveyor.

Idlers and drums are not aligned with the conveyor’s centerline.

2.Cause: Conveyor belt deviates at any point

Possible Causes:

Material is loaded unevenly, pressing down on only one side of the belt.

Accumulation of debris.

Idlers are installed in the wrong position.

Excessive tension on one side of the conveyor belt.

Improper loading or material spillage.

Idlers, drums, and the conveyor belt are not aligned with the centerline.

3.Cause: The conveyor belt drifts only at a specific fixed point

Possible causes:

Poor quality of the conveyor belt’s vulcanized joint, or use of an unsuitable mechanical buckle (the metal fastener connecting the conveyor belt).

The edges of the conveyor belt are worn.

The conveyor belt itself has become curved.

4.Problem: The conveyor belt drifts at the head drum

Possible causes:

The idlers, drums, and conveyor belt are not aligned.

Accumulation of debris.

The rubber layer on the drum surface is worn.

Improper installation of the idlers.

5.Problem: The conveyor belt drifts to one side over several specific idlers

Possible causes:

Misalignment of the idlers, drums, and the conveyor’s centerline.

Incorrect installation of the idlers.

Accumulation of debris.

6.Problem: Conveyor belt slippage

Possible causes:

Idler rollers are jammed.

Accumulation of debris.

Wear on the drum rubber surface.

Insufficient counterweight.

Insufficient friction between the conveyor belt and the drum.

7.Problem: Conveyor belt slipping during startup

Possible causes:

Insufficient friction between the conveyor belt and the drum.

Insufficient counterweight.

Wear on the drum’s rubber surface.

The conveyor belt lacks sufficient strength to withstand the startup tension.

8.Problem: Conveyor belt is too long

Possible causes:

The conveyor belt is over-tensioned.

Insufficient strength of the conveyor belt itself.

Accumulation of debris.

Counterweight is too heavy.

The two drive rollers are not running in sync.

The conveyor belt has been damaged by chemicals, acids, heat, or abrasive materials.

9.Cause: Breakage at or near the belt splice, or loose splice

Possible causes:

Insufficient strength of the conveyor belt.

The drum diameter is too small, causing excessive belt bending.

Excessive tension.

Wear on the drum surface.

The counterweight is too heavy.

Foreign objects are caught between the belt and the drum.

The two drive drums are not running in sync.

Poor-quality vulcanized splices or incorrect selection of mechanical belt fasteners.

10.Problem: Vulcanized joint failure

Possible causes:

Insufficient conveyor belt strength.

Drum diameter is too small.

Excessive tension.

Foreign objects between the conveyor belt and the drum.

Asynchronous operation of dual-drive drums.

Poorly manufactured vulcanized joints or improper mechanical belt buckles.

11.Problem: Severe wear on the top cover (including tears, pitting, breaks, and punctures)

Possible causes:

Accumulation of debris.

Improper loading, resulting in material spillage.

The material loading speed is too fast or too slow relative to the conveyor belt speed.

Excessive impact force from the material against the belt fasteners.

Damage to the conveyor belt caused by chemicals, acids, heat, or abrasive materials.

12.Problem: Severe wear on the lower cover rubber

Possible causes:

Jammed idlers.
Accumulation of debris.
Wear on the drum surface.
Foreign objects between the conveyor belt and the drum.
Insufficient friction between the conveyor belt and the drum.

Damage caused by chemicals, acids, heat, or abrasive materials.

13.Problem: Severe wear on the conveyor belt edges

Possible causes:

Uneven material loading.
Excessive tension on one side of the conveyor belt.
Improper loading or spillage.
Damage caused by chemicals, acids, alkalis, high temperatures, or abrasive materials.

The conveyor belt is curved into an arc.

Accumulation of broken material.

Poor performance of vulcanized splices or improper selection of mechanical fasteners.

14.Problem: Spots or streaks of bubbles on the cover layer

Possible causes:

Damage to the conveyor belt surface caused by chemicals, acids, heat, or abrasive materials.

15.Problem: Conveyor belt hardening and cracking

Possible causes:

Damage caused by chemicals, acids, heat, or abrasive materials.

Drum diameter is too small.

Drum rubber surface wear.

16.Problem: Cover layer becoming brittle and cracking

Possible causes:

Damage caused by chemicals, acids, heat, or abrasive materials.

17.Problem: Longitudinal grooves in the upper cover rubber

Possible causes:

Side guards installed incorrectly.

Idler rollers jammed.

Accumulation of debris.

Excessive impact of material on the belt fasteners.

18.Problem: Longitudinal grooves in the lower cover rubber

Possible causes:

Jammed idler rollers.

Accumulation of debris.

Wear on the drum lining.

19.Problem: Damage at the groove of the idler rollers

Possible causes:

Excessive clearance between idler rollers.

The gradient at the transition point (slope change point) in the conveyor line is too steep.

Part 2: Troubleshooting Common Conveyor Belt Issues

1.Troubleshooting: Conveyor Belt Curving into an Arc

This issue does not occur with solid-core conveyor belts. For layered belts, follow these steps:

Avoid impacts and compression of the layered conveyor belt.

Do not store layered belts in damp environments.

Before running in (initial use), the conveyor belt must be straightened.

Check the alignment of the entire conveyor system.

2.Solution: Poor performance of vulcanized splices or improper selection of mechanical belt fasteners

Select appropriate mechanical belt fasteners.

Readjust the tension after the conveyor belt has been in operation for a period of time.

If there is a problem with the vulcanized splice, cut off the old splice and make a new one.

Regularly inspect the condition of the splice.

3.Solution: One side of the conveyor belt is stretched and deformed

This situation does not occur with solid-core conveyor belts. For other types of conveyor belts:

Ensure the conveyor belt has been run-in for a sufficient period of time.

If the conveyor belt has not been properly run-in, or if it is an old belt, cut off the stretched section and make a new splice.

4.Solution: Excessive counterweight

Recalculate the correct counterweight and adjust accordingly.

Reduce the tension to the critical point where slippage just begins to occur, then secure it.

If a winch tensioning device is used, loosen it slightly.

5.Solution: Insufficient counterweight

Recalculate the required counterweight and add it.

6.Solution: Damage caused by chemicals, acids, alkalis, heat, or abrasive materials

Select a conveyor belt specifically designed for these conditions.

Use sealed mechanical buckles or create vulcanized splices.

Implement protective measures for the conveyor system, such as rain and UV protection.

7.Solution: Asynchronous operation of dual drive drums

Adjust the two drive drums appropriately to synchronize their rotational speeds.

8.Solution: Insufficient conveyor belt strength

If the original conveyor belt becomes insufficient due to an increase in material volume at the loading point or a reduction in conveyor speed, recalculate the required tension and replace the belt with one of higher strength.

9.Solution: Conveyor belt edge wear

First, prevent the conveyor belt from drifting, then trim off the sections with severe edge wear.

10.Solution: Excessive idler spacing

Adjust the spacing between the idlers. Even under full load, the spacing should not exceed 10 millimeters.

11.Solution: Excessive impact on the conveyor belt or belt fasteners from material

Use material chutes and buffer plates correctly according to actual operating conditions.

Install idlers capable of absorbing impact.

If possible, load fine coal fines (or fine material) first.

If the side guards do not cause material jams, adjust the gap between the side guards and the conveyor belt as appropriate.

12.Solution: Misalignment of idlers, drums, and conveyor centerline
Perform realignment calibration.

Install limit switches to prevent severe misalignment.

Consult the conveyor’s user manual and make adjustments according to the instructions.

13.Solution: Improper loading, material spillage

The direction and speed of material feeding should match the direction and speed of the conveyor belt, and ensure the discharge point is centered on the belt.

Use appropriate feeders, chutes, and side guards to control material flow.

14.Solution: Insufficient friction between the conveyor belt and the drum

Use idler rollers to increase the contact angle (wrap angle) between the conveyor belt and the rollers.

Use rubber-covered rollers (with a rubber surface).

In humid environments, select rubber-covered rollers with grooved patterns.

Install appropriate cleaning devices on the conveyor belt to keep the roller surfaces clean.

Check whether the initial tension is sufficient.

15.Solution: Accumulation of debris on drums and idlers

Install cleaning devices such as scrapers or brushes.

Manually remove accumulated debris on a regular basis.

16.Solution: Foreign objects caught between the conveyor belt and the drum

Properly install and use side guards.

Remove debris and other foreign objects.

17.Solution: Wear on the drum rubber surface

Replace the worn rubber layer.

Use a grooved rubber surface in humid environments.

Tighten any loose screws protruding from the rubber surface.

18.Solution: Material loading speed is too high or too low

Adjust the feed chute or correct the conveyor belt’s running speed to match the material flow.

Consider using impact-resistant idlers and closely monitor operating conditions.

Conclusion: Proper Maintenance of Conveyor Belts to Extend Service Life
As shown above, conveyor belts may encounter various issues during operation, but most problems can be avoided through proper installation, reasonable operation, and regular inspections. Regardless of the type of belt conveyor you use, regularly clearing debris, maintaining the smooth operation of idlers and drums, ensuring proper tension, and selecting appropriate splices and belt fasteners are key to ensuring long-term, stable operation. We hope this easy-to-understand guide helps you better understand and manage your belt conveyor, making your material transport more efficient and safer.