Rotation Check: Verify smooth rotation of idlers without jamming or abnormal noise.
Material Buildup: Inspect helical blades for accumulated materials such as mud or debris, which may cause blockages.
Belt Alignment: Ensure the conveyor belt remains centered on the helical structure to maximize deviation correction.
Frequency: Apply high-temperature grease (e.g., lithium-based) every 3 months or as per the manufacturer’s schedule.
Method: Use a grease gun to inject lubricant into the sealed bearings, avoiding overfilling to prevent heat buildup.
Environment: In dusty conditions, select grease with anti-dust properties (e.g., NLGI Grade 2).
Self-Cleaning Function: Regularly activate the helical idlers at low speed to remove sticky materials (e.g., wet coal) via centrifugal force.
Manual Cleaning: Use a brush or compressed air to clear stubborn blockages in helical grooves. Avoid water flushing in electrical environments.
Blade Wear: Measure the thickness of helical blades. Replace if wear exceeds 1/3 of original thickness.
Bearing Condition: Check for bearing clearance or corrosion. Replace bearings if rotation resistance increases significantly.
Coating Integrity: Inspect rubber/urethane coatings for cracks or peeling, especially in corrosive environments.
Angle Alignment: Maintain the helical idler’s horizontal angle at 20° using the bracket’s elliptical holes.
Belt Tension: Adjust belt tension to prevent excessive sagging, which may reduce alignment efficiency.
| Issue | Possible Cause | Solution |
|---|
| Excessive Noise | Worn bearings or misalignment | Replace bearings or realign the idler. |
| Belt Deviation | Uneven helical blade wear | Rotate blades or replace the idler set. |
| Overheating | Lack of lubrication or overload | Lubricate bearings or reduce conveyor load. |
Full Set Replacement: Replace all helical idlers in a segment simultaneously to ensure uniform alignment force.
OEM Parts: Use original manufacturer’s replacement components to maintain compatibility and performance.
Note: For underground mining applications, ensure compliance with anti-static and flame-retardant standards (e.g., MT/T 990-2006).
