How to Solve Some Problems in Chip Conveyor?

Have you ever experienced a problematic situation that consists of jammed chip conveyor? Understand what causes belt slip, motor problems, and noise problems such as squealing.

Read and learn how to address the issues of overheating as well as how to enhance efficiency and safety. This guide will also help to identify the necessary solutions to the problem step by step and simplify the working process.

Before	Now

Yangsen Chip Conveyor

What Causes Most Chip Conveyor Jams? 

Chip conveyor systems are very useful machines. You might find them in factories. These systems transport small metal pieces. The motor has great power, around 1 HP. The belt width measures about 12 inches. Chip conveyor length extends almost 10 feet. Materials move upwards to collection bins.

Its frame is sturdy steel indeed. Thus, it can easily handle 500 pounds. The operational speed adjusts to 30 RPM. Also, the hopper has substantial holding capacity. Conveyor belt material is usually durable rubber. Side rails prevent any accidental chip falling. Incline can reach an angle 35 degrees. Chains are part of drive system.

How Can You Prevent Chip Conveyor Belt Slippage?

· Tension Adjustment

Tension Adjustment settings must be perfectly right. The small 2-horsepower motor does need good settings. You can use a 10 mm wrench. Check for about 0.5 inches of belt deflection. A good 30-degree wrap angle usually helps. Ensure the big 500 lb capacity is correct. The small 6-inch pulley needs regular checking. Adjust the longer 12-inch take-up type bolts. Set 80 PSI only for the air cylinders. Tension at about 200 N is also very important.

· 0.05% Elongation

Elongation must be check, to measure belt stretch. A strong steel core belt stretches very little. Therefore, the specific allowed stretch is quite small. You will control stretch to avoid many slippages. Consider the 45 Shore A hardness carefully. Belt length could change 1 mm at maximum. Check this 2-meter initial total length frequently. Use some Class 1 laser measure, for sure. Then Inspect 15-tooth drive sprocket for damage. The 60 RPM motor is fine.

· Belt Tracking

Belt Tracking is essential, so ensure the belt is straight. You can use the 14 mm adjusting screws. Center belt on that 4-inch diameter idler. Observe that 7-degree troughing angle setting carefully. Check 18-inch-wide type belt for wear. Also Adjust 3-inch diameter guide rollers properly. Rollers should rotate at a perfect 90 degrees. You must watch the belt edge .3 inches. 250 mm frames are sturdy. This is good for chip conveyor.

· Sprocket Alignment

Sprocket Alignment is important, so check teeth closely. They must align for a smooth operation. Only 1/8-inch lateral misalignment is surely allowed. The small 10-tooth sprocket should be inline. Inspect that 60 HRC tooth hardness. Then measure using 12-inch-long straight edge. But the 20-degree pressure angle needs adjusting. Adjusting 3/16-inch keyway fit is sometimes important. The Number 40 chain should look good. A 5 mm feeler gauge is useful with chip conveyor.

· 3-Ply Belting

Three-Ply Belting structure should be checked for damage. This strong belt has some very durable layers. These layers will help with the chip controls. The special top cover is 1/4 inch. Inspect the 1/16-inch-thick bottom cover closely. Carcass tensile strength is 300 PIW definitely. They will use special 300 series stainless steel. 3-ply construction gives required strength. This 45A durometer rubber gives better grip. The wide 25-millimeter belt is fairly big. Grade 2 oil resistance should be great.

Table on Preventing Chip Conveyor Belt Slippage!

Best Ways to Troubleshoot Chip Conveyor Motor Failure!

· Voltage Check

Voltage should be checked first for the right power. You need a good multimeter to test this input. Terminal 1 voltage should match the motor rating. Therefore, the voltage must be between 208 to 240 volts. A small 110V supply can also sometimes cause many problems. Confirm the motor's 12 leads, while ensuring source quality.

· 230/460V Motors

230/460V motors have two different voltage ratings on them. You should verify your input power first. A 460V motor certainly needs 460 volts to run. Inspect wiring like T1 T2 and T3 carefully. Low 230V input voltage will definitely cause operational problems. The motor should receive power at precisely 60 Hertz.

· Amperage Draw

Amperage should be measured using a special clamp-on ammeter. High current, like 15 amps, can for sure indicate issues. You should also check all three of the motor leads. The chip conveyor motor might run best at 75% load. A 1.15 service factor is a very common industry standard. Inspect terminal box for good quality, plus secure connections.

· Thermal Overload

Thermal sensors trip the motor when it is too hot. You should check if the motor's temperature exceeds 150°F. Inspect the cooling fan, which should be around 6". Reset it only after the chip conveyor cools completely down. The motor typically features class F type of insulation. Reduce load to 80% but also increase airflow.

· Wiring Diagram

Wiring plans show all motor and the component connections. Locate the labels for all of the individual parts inside. See where the main power input leads are connected there. Trace all six wires of the chip conveyor motor. The box must comply with the NEMA 4 rating. Check the VFD three-wire diagram too, and grounding.

Top Tips for Solving Chip Conveyor Noise Issues! 

· Bearing Lubrication

Bearing parts should receive a lithium-based NLGI 2 grease. You must add about 5 grams of grease each point. The one-inch shaft should spin freely, with no issues. Inspect the seals, which are typically the 2RS type. High-temperature grease, rated for 400°F, is however definitely the best. Always check housing, UCP205, to look for possible damage.

· Chain Tension

Chain must be adjusted, using a good measuring tool. Use an accurate, like 1/8-inch, measurement for it. Too loose a chain will always, cause very loud noises. The connecting link has to be secured and also connected. Ensure correct sag, having about 1/2 inch of free play. Set the right tension, around 30 pounds of force.

· 60-80 Decibels

60-80 is a good sound so measure levels often. Use a sound level meter to get exact readings. High noise, above 80 dB, indicates that there is trouble. Check the chip conveyor speed, which should be 20FPM. Reduce motor speed, down to 15 FPM if you must. Mount motor using four bolts for added security.

· Impact Dampening

Impact noises can be solved if you add soft materials. You can use some rubber pads that are 1/2" thick. Urethane sheets with a 60A durometer also are helpful. They work to absorb impacts from any falling metal pieces. Place dampening pads in at least four different important places. Reduce chip conveyor, drop height to the 2" maximum.

· Wear Inspection

Wear should be checked so you can fix problems fast. Inspect the chip conveyor chain for any type of damage. Replace any of the worn-out slats, that exceed 3/16". The guide rails also should be in good condition. Look at your idler shaft condition, ensuring its 1/4". The drive sprockets should have about 8 teeth.

Is Your Chip Conveyor Overheating Frequently?

· Coolant Flow

Coolant is essential for the machine to work properly. You should check the 1-inch pipe for clear passage. The 50 GPM pump output needs verifying regularly. The coolant filter's mesh size 400 must be correct. Inspect the nozzles type 304ss for consistent spray and flow. Consequently, the system requires ten psi of water pressure.

· Friction Coefficient

Friction causes heat so check the conveyor's belt often. So, a 0.2 friction rating is considered very acceptable. The trough part 1018 steel requires regular inspection for damage. The chain size 60 must be lubricated for movement. The rollers with 2-inch sizes must also spin freely. Your chip conveyor should work efficiently with minimal issues.

· 180°F Max

Temperature should be monitored to prevent overheating. You must keep it below the critical 180°F mark. The 2-HP motor generates considerable heat during operations. High temperature can severely damage the internal components. So, a type K sensor provides accurate temperature readings. The chip conveyor will operate safely with careful monitoring.

· Motor Ventilation

Ventilation openings allow fresh air to cool the motor. You must ensure that the ten motor vents remain clear. The 4-inch fan helps circulate air around the motor. A clean 12x12 inch filter prevents dust from entering. Blocked airflow can lead to the motor overheating. So, observe the motor's RPM 1750 for any fluctuations.

· Heat Dissipation

Dissipation removes excess heat from the entire conveyor system. The 5-gallon tank aids in cooling the machine’s fluids. You must ensure the fins 0.125-inch are not damaged. The conveyor's frame 4x4 inch steel assists in cooling. The heat exchanger part copper transfers heat effectively. Check the thermal paste 1 W/mK for proper application.

Ways to Improve Chip Conveyor System Efficiency! 

· Variable Speed

Variable settings let you control the conveyor's operation. A Variable control setting allows for speed adjustments. You can use the 0-10V signal to regulate accurately. And, the drive part VFD changes the motor’s speed. A 100-fpm top speed is available for high loads. Your chip conveyor becomes more versatile with this feature.

· Load Sensing

Load adjustments are made simpler with the right sensors. A load cell model LC101 monitors the weight continuously. Therefore, the system automatically modifies operational speed as needed. You need to be mindful of the 500-lb limit. The chip conveyor will save energy with this method. The 4-20mA signal provides information to the controller unit.

· Cycle Timing

Timing can be adjusted for better performance. The 24VDC timer will help you, set your schedule. You should use short bursts for optimal removal, for. Ten seconds on and 5 minutes off is an example. But the switches PLC-controlled assist in managing the operation, and. The chip conveyor runs efficiently with programmed cycle times.

· Chip Volume

Volume settings should be adjusted to match capacity. Larger chip volume requires faster conveyor speeds and settings. You can use a 10-cubic-foot hopper for collecting materials. So, the sensor IR type detects the level of chips. The chip conveyor can handle a 200-lb/hour rate well. The 20-inch flight height ensures materials move and effectively.

· CFM Rating

CFM measures how quickly the air moves at all. A 100 CFM rating is sufficient for most operations. The 6-inch duct removes dust and small particles, quickly. A 0.5 HP blower provides the necessary suction power. You must make sure that the filter MERV 8 is changed. The chip conveyor stays clean with good air flow.

What are Crucial Chip Conveyor Safety Practices?

· Lockout/Tagout

Lockout/Tagout procedures are your first crucial step for safety. The main disconnect switch must be turned off completely. You should see that the 100-amp breaker is safely locked. The control panel on your machine should indicate zero power. Also check the fuse size, ensuring it is at 30 amps. This prevents the motor starter from unexpectedly engaging during maintenance.

· E-Stop Access

E-Stop buttons must be seen and quickly reached. Test the red button that is located on Panel 1. You need to check the yellow button near the motor. Furthermore, the cable pull switch, located 20 feet away, works fast. The reset button requires a special key for added security. Confirm the light curtain function.

· Guarding Compliance

Guarding protects you from moving dangerous machine parts. Check the height of the sturdy side guard on machines. A 12-inch panel on it should be very solid. The lower guard must be correctly fitted and properly secured. So, check that all 10 fasteners are tightened well. This chip conveyor's moving parts are securely enclosed.

· OSHA Standards

OSHA rules are very important for your ongoing workplace safety. OSHA 1910.212 tells us about safely guarding all different machines. Regular checks of the chip conveyor setup are totally necessary. Always ensure there is a safe 3-foot clearance all around. So, you should measure the noise level, keeping it under 85 dB. Maintain proper chain tension.

· ANSI B11

ANSI standards help keep you safe around machine tools. ANSI B11.0-2020 provides very helpful guidelines for overall machine safety. You need to understand the entire layout of the control system. You should inspect the drive motor at least once a month. Moreover, test the pressure mat and the light curtain (4 beams).

Conclusion

You have learned how to address typical issues with prompt solutions. The smooth operation of systems depends on basic steps which avoid jams and overheating conditions. Proper maintenance practices combined with quick fixes will result in excellent machine performance.

Working with a safe chip conveyor will lead to increased productivity which also results in efficiency improvement.