A conveyor belt is a vital component of any manufacturing process, as it transports materials and products from one stage to another. However, if the belt is not properly tensioned, it can cause problems such as slippage, misalignment, premature wear, and reduced efficiency. In this article, you will learn how to properly tension a conveyor belt in six easy steps.
Before you start tensioning the belt, you need to inspect its condition and make sure it is clean, undamaged, and free of debris. Look for any signs of cracks, cuts, fraying, or abrasion on the belt surface and edges. Also, check the pulleys, rollers, and splices for any damage or wear. If you find any issues, you need to repair or replace the belt or the affected parts before proceeding.
The next step is to measure the amount of slack in the belt, which is the distance that the belt can be lifted from its normal position. To do this, you need a tension measuring device, such as a spring scale or a belt tension gauge. You also need to mark a point on the belt halfway between two pulleys, where you will apply the measuring device. Then, you need to lift the belt at the marked point until it is parallel to the pulley shafts and read the force required to do so. This is the slack force, which indicates how loose or tight the belt is.
Once you have the slack force, you need to calculate the optimal tension for the belt, which is the force that will ensure optimal performance and longevity of the belt and the conveyor system. The optimal tension depends on various factors, such as the belt type, width, length, speed, load, and environmental conditions. You can use a formula, a chart, or a software tool provided by the belt manufacturer or supplier to determine the optimal tension for your specific belt and application.
The take-up device is the mechanism that allows you to adjust the tension of the belt by moving the pulleys closer or farther apart. There are different types of take-up devices, such as screw, hydraulic, gravity, or pneumatic. Depending on the type of take-up device, you need to either turn a screw, apply a hydraulic pressure, adjust a counterweight, or regulate an air pressure to change the position of the pulleys and the tension of the belt. You need to adjust the take-up device until you reach the optimal tension calculated in the previous step.
Measuring tension of a belt has always been previously something of a skill or competency for Engineers and Mechanical minded people alike, however, during the digital era we have everything from apps to dedicated equipment able to check tension rapidly through reading decibels. I would also strongly emphasise not to over tension out of worry. Over tensioned belts cause huge side load to shafts and equipment as a whole which limits the lifespan of the belt as well as the application it is driving.
After you have adjusted the take-up device, you need to verify that the tension of the belt is correct and consistent. To do this, you need to measure the slack force again at the same point and compare it with the optimal tension. If the slack force is equal to or close to the optimal tension, then you have successfully tensioned the belt. If not, you need to repeat the adjustment process until you achieve the desired tension.
The final step is to test the conveyor operation and observe how the belt behaves under normal working conditions. You need to run the conveyor for a few minutes and check for any signs of slippage, misalignment, vibration, noise, or overheating. You also need to monitor the belt speed, load, and alignment and make sure they are within the recommended ranges. If you notice any problems, you need to troubleshoot the cause and make the necessary corrections. If everything is working well, then you have completed the tensioning process.