Conveyor Care Part 2: Conveyor Components That Reduce Maintenance

This is part two of two in the Conveyor Care Series.

Conveyors are essential for a wide variety of industries, from food production to manufacturing, and they are responsible for moving materials and products from one point to another. A conveyor system that fails can cause significant downtime and production losses, resulting in delays and lost revenue.

At Dynamic Conveyor we take pride and regularly promote the minimal care requirements for our custom conveyor systems. We supplied some general guidelines for conveyor maintenance in part one of our conveyor care blog series. In this part two article, we capture and further describe the features and benefits of the components used in our conveyor systems that contribute to a minimal maintenance standard.  

DC Brushless Motors 

DC brushless motors offer several advantages in terms of maintenance compared to traditional brushed DC motors. Some of these advantages include: 

• Longer lifespan: DC brushless motors have a longer lifespan compared to brushed motors. This is because they do not have brushes that wear out over time, causing the motor to malfunction or fail. In addition, the lack of brushes means that there is less friction within the motor, reducing the amount of heat generated and prolonging its life. 
• Reduced maintenance: Brushless DC motors require less maintenance compared to brushed motors. Without brushes, there is no need for regular replacements or cleaning. This reduces the time and cost associated with maintenance and downtime. 
• Improved efficiency: DC brushless motors are more efficient than brushed motors. This is due to the lack of brushes and the resulting reduction in friction and heat. As a result, brushless motors can run at higher speeds and produce more torque, while consuming less power. 
• Higher power density: Brushless DC motors are more compact and can produce more power for their size compared to brushed motors. This makes them ideal for applications where space is limited, such as in robotics or drones. 

Non-Lubricated Bearings 

Non-lubricated bearings, also known as dry bearings, offer several advantages over traditional lubricated bearings. Some of these advantages include: 

• Maintenance-free: non-lubricated bearings require no maintenance or lubrication, which cuts the need for oiling, greasing or other lubrication-related tasks. This makes them a practical choice for applications where maintenance is difficult or costly. 
• No contamination: Lubricants can attract dust, dirt, and other contaminants, which can cause damage to the bearing and its components. Non-lubricated bearings, on the other hand, are free of lubricants, so they are less susceptible to contamination and can run in clean environments. 
• Reduced friction: Lubricated bearings can experience increased friction as the lubricant thins out over time or when the lubricant is not able to reach all parts of the bearing. Non-lubricated bearings have a lower coefficient of friction, which helps reduce energy consumption and wear. 
• Reduced cost: non-lubricated bearings can be less expensive than their lubricated counterparts due to the absence of lubricants and the reduced need for maintenance. In addition, non-lubricated bearings can also reduce the cost of waste disposal and environmental impact. 

Tensionless Conveyor Belting 

Tensionless conveyor belts, also known as positive drive conveyor belts, offer several advantages over traditional conveyor belts that use tension. Some of these advantages include: 

• Longer lifespan: Tensionless conveyor belts have a longer lifespan compared to traditional conveyor belts. This is because they do not experience the same amount of stress and wear and tear that tensioned belts do. As a result, they need less frequent replacements and maintenance. 

• Improved tracking: Tensionless conveyor belts are designed to keep consistent tracking and alignment, even under heavy loads or at high speeds. This helps reduce downtime and prevents damage to the belt and other components. 
• Reduced downtime: Tensionless conveyor belts require less maintenance and adjustments compared to traditional conveyor belts, which helps reduce downtime and increase productivity. In addition, tensionless belts can be quickly and easily replaced without the need for specialized tools or equipment. 

Other Belting Considerations 

Control of Belt Length

The principal function of our feed end take-up is to properly accommodate the change in belt length while running. Control of belt length is vital in keeping sufficient tension after the belt disengages from the drive shaft sprockets. A belt which increases in length can disengage from its drive sprockets if proper design criteria are not followed. A belt which contracts due to cold temperatures can cause over-tensioning and excessive shaft loads if some surplus belt is not provided. Belts either elongate or contract in operation because of three factors: temperature variations, elongation (strain) under load, and elongation due to break-in and wear. 

Belt Break-In 

New belts usually experience elongation in the first days of operation, as the hinge rods and modules seat themselves. This elongation presents itself in the way of a light dusting on the belt. This dusting can cause accelerated wear if not effectively managed, especially in the first few months of use.  

Routine Belt Wear 

All belts elongate overtime. In severe situations, where heavy loads exist, or abrasives are present, older belts experience elongation due to wear of the hinge rods and enlargement of the module link rod holes. The amount of elongation depends upon the belt series and style, the belt material, the amount of tension (belt pull) applied, and the operating temperature. Generally, on conventional conveyors where adjusted belt pull (ABP) is about 30% of allowable belt strength (ABS), this load-induced elongation is approximately 1% of the conveyor length. If ABP reaches the ABS, this strain should not exceed 2.5% of the conveyor length. 

Maintenance of Dynamic Conveyors can be boiled down to a few simple maintenance task – 1) develop a weekly maintenance schedule of cleaning that includes blowing the conveyor off remove debris, this will aid in reducing ware and keep proper belt length and 2) inspection of conveyor components to inspect and identify any wear or damage. 

Looking for a simple, minimal maintenance conveyor system to automate your manufacturing process? Contact us to share your application and for consultation.