Properly designed and manufactured conveyors are reliable machines with components that require minimal maintenance.
Only a few simple winter shutdown tasks and checks of pulleys, idlers and take-ups are recommended to assure a troublefree spring start-up. This includes the cleaning of carryback or spillage, lubricating bearings with compatible grease, and inspecting for worn or broken components.
Many idlers are sealed for life and are maintenance free. Regreasable designs exist, and these should be greased at shutdown.
Idler rolls and frames should be visually inspected for poor rotation, wear or physical damage, and those with issues should be replaced. Self-aligning idlers and their frames should be checked for proper motion. Some designs require pivot-point lubrication, even when the main rolls are sealed for life.
Pulleys and shafts should be visually inspected for physical damage, excessive corrosion or excessive wear. Surfaces in contact with the belt, such as lagging and contact bars, will wear over time.
Excessive wear will affect pulley life and adversely impact belt tracking. Pulley assemblies can often be scheduled for refurbishment or replacement during the winter shutdown. Bearings should be regreased at shutdown and inspected for seal damage or misalignment.
Cleaning and inspecting take-ups are often the forgotten part of the fall shutdown. Manual take-ups should be cleaned and screws checked for the ability to turn properly. Each spring, we commonly get rush requests for replacement take-ups that are seized.
Gravity and other automatic take-ups should be cleaned and inspected for free motion over the full range of travel. Wire ropes should be inspected for damage, and sheaves should be lubricated and inspected for free rotation.
In most cases, these simple fall shutdown tasks will assure a trouble-free start-up in the spring. At times, it may point out a problem area that could use additional attention. In those cases, having a field or product engineer review may be warranted.
Implementing corrective action during the shutdown could improve performance and lower costs for the following season.
Related: Analyzing bearing power consumption costs
Tim Wolf is vice president of engineering at PPI.