In the process of using the conveyor belt, apart from the deviation fault, it is also prone to tear damage.

The common ways of tearing include longitudinal and transverse tearing. Transverse tearing is generally caused by quality problems of the conveyor belt itself. 

Aimai will introduce the conveyor belt longitudinal tearing causes and solutions for you as following.

Longitudinal tearing of conveyor belt mainly occurs at the loading point of the tail of the machine, the main reason is that the material falling from the blanking mouth often carries foreign objects, which usually have sharp edges and are easy to tie the conveyor belt. When these foreign bodies are stuck on the blanking mouth, shelf or roller, the top pressure and continuous scratching will be formed on the surface layer of the conveyor belt. If found in time, immediately brake the belt, but also reduce the loss. If not detected in time, it will have serious consequences.

1. Causes for conveyor belt tearing

/1/.Belt tearing caused by impurities in conveying materials

Foreign objects, such as iron, wooden rod and other objects, are mixed in the conveying materials, which cause partial damage to the belt when falling and even directly penetrates the conveyor belt when serious and is stuck on the funnel, chute, rack or idler, and the conveyor belt runs forward at high speed, causing longitudinal tear of the conveyor belt.

There are large blocks of transmission materials in the conveyor belt, which are stuck between the cleats and the buffer roller, or between the roller frame and the returning routine of conveyor belt . After long time scratching and clamping conveyor belt, once the surface of the conveyor belt is punctured and scratched, the wound will be rapidly deepened, and finally the belt will be cut through, forming a tear belt. The rubber conveyor belt consists of three parts: covering layer, carcass and bottom cover. The covering layer is the key part to determine its performance and application. According to the different materials used in the covering layer, the conveyor belt industry can be divided into two categories: heavy conveyor belt and light conveyor belt. the former is rubber including natural rubber and synthetic rubber are apply for heavy industry and foundation industry. The latter mainly use polymer materials, mainly used in food, electronics and other light industrial fields. Therefore, the removal of bulk materials and foreign matters is the key to prevent conveyor belt tearing.

/2/. Belt tearing caused by improper installation of conveyor auxiliary equipment

In addition the threat from the material itself, the objects of the conveyor belt fall off or drop itself is also a major cause of tearing during transportation. Rubber conveyor belt with heat-resistant, wear-resistant, burning-resistant, oil-resistant, alkali-resistant, resistance to tropical, cold-resistant and other characteristics which are apply for mines, metallurgy, iron and steel, coal, building materials, chemical, grain and other enterprises for solid material transportation, such as vibrator liner, pulverization hammer head, blanking mouth adjustment and other shedding may cause conveyor belt tear.

/3/. Belt tearing caused by imperfect conveyor structure

The design of the belt conveyor is not reasonable, the falling height from machine ending is too high (the maximum falling height is about 10 meters), resulting in falling force is too large to insert the conveyor belt at the falling point, causing the belt to tear.

/4/. Conveyor belt tear caused by blocking material

Transfer chute is small, which easy to block materials and impurities through the conveyor belt caused by tearing.

 /5/. Tear caused by drop of middle idler wheel 

The conveyor belt is directly pressed on the support in the middle wheel. The heavy load makes the conveyor belt press the support tightly, and the support cuts through the belt like a knife, result in tearing.

/6/. Belt tearing caused by blocked material in the machine head or ending

Because the machine head is full of materials, the materials are inserted into the drum and the connecting beam on both sides of the machine head to cause tear. Or the machine head sweeper scraper center block the metal wire and so on the sharp objects causes the tearing.

/7/. Belt tearing caused by failure of conveyor parts

If the end cover of the supporting roller is not welded well, the rotate end cover cuts the conveyor belt like a rotating blade. When the fracture of the steel wire rope in the conveyor belt occurs, the fractured head of the steel wire rope will emerge from the joint of the conveyor belt, the adhesive mouth or the more severe wear (a basic type of component failure) to the outside of the rubber cap. When the exposed steel wire rope reaches a certain length, it may be twisted into the drum, roller, etc. With the conveyor belt operation, the steel wire rope break away from the cover glue of conveyor belt, resulting in core pulling tear.

(2)Measures to prevent conveyor belt from tearing

/1/. Strengthen the control from the source of materials, clean up the bulk materials, increase the impurity removal equipment, and reduce the threat of other objects and bulk materials to the conveyor belt.

/2/. Strengthen routine inspection and professional spot inspection, and timely find and deal with problems. 

/3/. Improve the conveyor structure, by reducing the falling height, increase the buffer baffle, fine material before the large material falling, lower the material running speed, reduce the possibility of impurities inserted into the conveyor belt.

 /4/. Add tear detection device, to find and inspected tearing condition in the shortest time as soon as possible with alarm signal and stop running, to reduce the tear length and reduce the loss. But there are various factors caused the tearing, and it is difficult to avoid tearing problem  at present. The current application of conveyor belt tear-proof device and detection device is mainly tear detection device, generally installed at the drop point, composed of sensors and controllers. The sensor is installed under the conveyor belt or beside the chute, and the controller is installed on the machine side or indoor. When tears caused in the conveyor belt, the objects penetrate the conveyor belt then touched sensor. Sensors signal to the controller,  The controller sends out an alarm signal and stops.　

/5/. Choose anti-tear conveyor belt. The anti-tearing conveyor belt made by steel wire rope as the longitudinal carcass, and the belt body is added with the transverse enhancement material as the anti-tearing layer. The structure is divided into two types: one is the adhesive mesh cloth (steel mesh fabric or chemical fiber mesh); The other is use horizontal rope (steel wire or chemical fiber rope). The covering layer adopts high strength, high elasticity and good abrasion resistance rubber.

 /6/. Choose conveyor belt with detectable tearing detective device. A sensor coil is added into the conveyor belt. The detector is installed in the easily cracked part of the belt conveyor. The detector is connected to the control device.When the conveyor belt runs normally, the sensor passes through the detector, and the detector sends a pulse. When the conveyor belt is tearing, or cutting, The sensor coil is truncated. When the sensor passes through the detector, the detector stops sending pulses.  After the controller accepts the detector, it sends an alarm signal and stops.

/7/. To prevent conveyor belt tearing from management. Through the analysis of the above situation, the anti-tearing of the conveyor belt should be control from material quality control, strengthen the management of equipment and carry out the control of impurity material.

/8/. In addition, we can take the following measures from the technical:

    ① Strengthen daily maintenance, reduce faults and incorrect operation. Ensure all operations is correct, any abnormal operation is strictly prohibited.

    ② Enhance the conveyor belt quality to improve the wear resistance of the top cover of belt.

    ③Belt tear detection the detection effect of the device and the belt tear record are introduced into the computer management.

    ④Set up the conveyor belt detection means and system, build the long-term tracking record analysis, compare costs and benefits, etc., draw out correct conclusions.