Mining conveyors are marvels of modern engineering, built to endure the rigors of transporting thousands of tons of rock, sand, gravel, and aggregate. However, like all complex machinery, they require ongoing maintenance to ensure peak performance and minimize downtime.
Maintenance for mining conveyors falls into two main categories:
- Preventative Maintenance: This includes planned service, maintenance, and rebuilds before a failure occurs.
- Predictive Maintenance: This involves planned inspections to assess the overall health of system components and perform repairs when inspections indicate an imminent failure.
Three Main Conveyor Issues to Monitor
Regular maintenance can help prevent the following common conveyor issues:
- Belt Mistracking: Occurs when the conveyor belt veers off track, potentially damaging components, causing belt damage, and enabling material spillage.
- Belt Slippage: Requires precise tension; too much or too little tension can cause the belt to slip off the pulleys, leading to damage.
- Material Carry-Back: Happens when material does not discharge properly and is carried back on the return, potentially causing damage to other components.
Daily Maintenance
Conduct daily visual inspections of the entire conveyor system for:
- Lodged or stuck components
- Faulty electrical systems
- Structural damage due to accidents or weather
- Rocks
- Belt wear, nicks, or cuts
- Unusual noises
- Foreign objects (e.g., bolts and nuts on the belt)
Remote monitoring systems can help detect component failures and belt tracking issues proactively.
Additional daily tasks include:
- Greasing roller bearings to prevent lockup.
- Maintaining scrapers by cleaning, inspecting for damage, and adjusting tension.
- Removing dirt or debris (ensure the conveyor is tagged and locked out for safety).
Weekly/Monthly Maintenance
Focus on preventing the three most common issues:
- Belt Mistracking: Inspect idlers and rollers for alignment, dirt, lock-up, or freezing. Check for material overload, worn belt splices, and faulty chute structure skirting. Inspect weekly and monthly, and clean as needed.
- Belt Slippage: Check for worn lagging on the head drive pulley and ensure proper installation. Replace broken components or pulleys immediately.
- Material Carry-Back: Ensure scrapers are properly installed and of good quality. Clean up dust and consider investing in a dust containment system.
As-Needed Maintenance
Focus on quickly replacing worn or damaged equipment. Key areas include:
- Idlers and Rollers: Replace on an as-needed basis.
- Belt Repairs: Perform repairs immediately per manufacturer specifications. Avoid using mechanical fasteners as a long-term solution.
- Lagging: Replace every 3-5 years unless using ceramic lagging.
- Scrapers: Replace worn or malfunctioning scrapers with high-performance replacements.
- Dust Containment System: Replace, repair, or clean during weekly inspections.
- Power Module/Gearbox: After the initial break-in period, change the oil every 2,500 hours. Drain the reducer, flush with kerosene, clean the magnetic drain plug, and refill with recommended lubricant.
- Bearings and Motor Replacement: Track hours of operation and replace as per manufacturer recommendations.
By adhering to these maintenance practices, you can maximize the lifespan of your mining conveyors and ensure efficient, reliable operation.
