Belt drives
| SUBJECT OUTCOME |
| 4.5 Perform quality checks and job completion procedures |
| When new belt installation was done or any maintenance was conducted on a belt dive, the following must be performed to ensure proper commissioning of the belt drive: |
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| Conduct quality checks |
After any maintenance or
installation was done on a belt drive the following should
be observed to ensure that the belt drive is ruining to
specifications:
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| The following tables can assist as a guide: Synchronous-Failure-poster Additional information Additional website |
| Premature V Belt Drive Failure |
|
Symptoms |
Probable Cause |
Corrective Action |
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Broken belt(s) |
1. Under-designed drive 2. Belt rolled or pried onto sheave 3. Object falling into drive 4. Severe shock load |
1. Redesign the drive 2. Use drive take-up when installing 3. Provide adequate guards or drive protection methods 4. Redesign the drive to accommodate shock load |
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Belts fail to carry a load No visible reason shown |
1. Under-designed drive 2. There is a damaged tensile member 3. There are worn sheave grooves present 4. Centre distance movement |
1. Redesign the drive 2. Follow the correct installation procedures 3. Check for groove wear – Replace as needed 4. Check the drive for centre distance movement while running |
|
Edge cord failure |
1. There is Pulley misalignment 2. Damaged tensile member |
1. Check the pulley alignment and correct 2. Follow the correct installation procedure |
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Belt De-lamination OR under cord separation |
1. Too small sheaves 2. Use of too small of a backside idler |
1. Check Drive Design > Replace with larger sheaves 2. Increase the backside idler to an acceptable diameter |
Severe or Abnormal V-Belt Wear
|
Symptoms |
Probable Cause |
Corrective Action |
|
Wear is found on the top surface of the belt |
1. Rubbing against the drive guard 2. Idler malfunction |
1. Repair or replace the dive belt guard 2. Replace the faulty idler |
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There is wear on the top corners of the belt |
1. Belt-to-sheave fit is incorrect – belt too small for the groove |
1. Use the correct belt to sheave combination |
|
Wear was found on the belt sidewalls |
1. Belt Slip 2. Misalignment 3. Worn sheaves 4. incorrect Belt |
1. Retention until the slipping stops 2. Realign the sheaves 3. Replace the sheaves 4. Replace with the correct belt size |
|
There is wear on the bottom corner of the belt |
1. Belt to sheave combination fit is incorrect 2. Worn sheaves |
1. Use the correct belt-to-sheave combination for the drive 2. Replace sheaves |
|
There is wear on the bottom surface of the belt |
1. Belt bottoming out on the sheave groove 2. Worn sheaves 3. debris in the sheaves |
1. Use the correct belt to sheave match for your system 2. Replace the sheaves 3. Clean the sheaves |
|
Under cord Cracking can be detected |
1. The sheave is diameter too small 2. Belt Slip 3. Backside idler too small 4. Improper storage of the belts |
1. Use larger diameter sheaves 2. Re-tension the belt and system 3. Use a larger diameter backside idler 4. Do not coil the belt too tightly, kink or bend – Avoid heat and direct sunlight |
|
Under-cord or sidewall burn or hardening |
1. Belt slipping 2. Worn sheaves 3. Under-designed Drive 4. Shaft movement |
1. Re-tension until the slipping stops 2. Replace sheaves 3. Redesign the drive to accomplish task 4. Check for centre distance changes |
|
Belt surface hard or still |
1. Hot drive environment |
1. Improve ventilation to the drive belt |
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Belt surface flaking, sticky or swollen |
1. Oil or chemical contamination |
1. Do not use belt dressing -Eliminate sources of oil, grease, or chemical contamination |
| Measure and test replacement parts and evaluate performance |
| After doing any maintenance on mechanical drives it is important to monitor for any abnormalities during start up and running in. This is also applicable to belt drives. After replacing belts on a drive, let it run under load for period of time and observe for any abnormalities. Recheck tension and adjust correctly. This must be repeated after a run-in period of 24-48 hours. |
| Record information accurately on the completed job |
When maintenance have been completed it
will be necessary to complete a report on the work that was done on
drive. This report will include the following information:
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| Open a new file and name it or use an existing file and store information in a safe place |
| It is important that maintenance records
must be kept for future reference. This will assist for planning
and evaluation effectiveness of plant and equipment. Can also
assist engineers to make improvements on designs to increase reliability
of the plant and equipment. It is also used for budgeting purposes
to determine profits and loss. The records are normally hard copies that will be filed after it been captured electronically in a database. Most large companies will use programs such SAP. SAP Plant Maintenance (SAP PM) is a software product that manages all maintenance activities in an organization. Plant Maintenance module consists of key activities to include inspection, notifications, corrective and preventive maintenance, repairs, and other measures to maintain an ideal technical system. Other CMMS (Computerized Maintenance Management) programs are:
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| Clean and maintain equipment and tools |
| After maintenance was done on belt drive, it is important to apply good housekeeping principles. Clean work are around drive. Remove all consumables and packaging material and dispose of it responsible. Clean tools and return to toolbox. Special equipment such as gauges and lifting equipment must be cleaned and returned to tools store. |
| Report on defective tools and equipment and facilitate discard procedures or repair |
| Inspect tools such as lifting equipment and measuring tools and gauges for defects. Report such defects for repairs or depose of it. This will prevent damage tools and equipment to be used again that can lead to injuries or damage to plant equipment. |
| Store equipment and tools in an authorised place |
Tools must be stored in the following
manner:
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