Don’t drop the ball at the critical moment: do you know the wear of the conveyor belt of the milling machine?

The performance of a Wirtgen milling machine is largely determined by the performance of the feed system. It is conceivable that if on a busy construction site, especially a large milling machine that is rushing for work and output, the receiving capacity will decrease due to the serious wear of the conveyor belt, the output of the milling machine will not increase, or even the conveyor belt will break, and the milling If the machine can’t work normally, it’s really what the saying goes “the chain falls at the critical moment”, it’s too bad.

So to avoid this passive situation, especially in the peak construction season, it is very necessary to carry out self-inspection on the wear of the conveyor belt of the milling machine in advance, and make a plan according to the degree of wear. Xiaowei is here to introduce you some knowledge about the wear of the conveyor belt of the milling machine, I believe it will be very helpful to you.

Original Wirtgen conveyor belts have the advantage of high performance and long service life, which is determined by the construction and design characteristics of the conveyor belt. Click the video below to learn more.

Example of normal wear of conveyor belts
WIRTGEN
During the normal operation of the milling machine, friction will occur between the milling material and the upper layer of the conveyor belt, and the contact between the idler and other components of the conveyor system and the lower layer of the belt will also cause friction, which will affect the conveyor belt. Form wear. The degree of wear and tear gradually accumulates with the number of working hours and the output of the milling machine, so how to judge the wear and tear? The most intuitive way is to visually inspect the different positions of the belt.

Example of wear on the upper layer of the conveyor belt and how to check it yourself

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Figure 1: It can be seen that the conveyor belt has appeared and the top of the belt edge has been partially ground. The tool in the picture is Wirtgen’s special tool for checking belt wear, which can measure the belt edge after wear

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Figure 2: If you compare it with Figure 1, it is very intuitive to find that the entire size of the belt edge has become smaller

Suggestion: If your milling machine has been used for a long time (large milling machine: about 1000 hours), and the wear can be clearly observed, it is recommended that you directly contact the local Wirtgen agent in China for the wear and tear of your belt. Check the situation and give targeted advice on when to replace the conveyor belt.

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Figures 3 & 4: Severe wear: The underlying fabric layer has been exposed after the rubber layer has worn away

Recommendation: In addition to the wear of the belt edges, the condition of the upper layer between the belt edges can also be observed. In such a situation that the rubber layer has been completely worn away, it is recommended to replace the conveyor belt as soon as possible, otherwise there is a risk that the belt will be overwhelmed and broken during the high-strength construction process.

Example of wear on the lower layer of the conveyor belt and how to check it yourself
Dynamically varying loads can cause the bottom layer of the belt to detach from the underlying fabric due to a variety of reasons, such as material damage to the rubber, or reduction in Shore hardness, or dilution and spillage of grease on the idlers. Therefore, it is necessary to observe the state of the lower layer of the belt. The following picture example is a relatively serious wear condition.

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Figure 5: Observe whether the underlying fiber fabric layer is exposed after the rubber layer is worn

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Figure 6: After the rubber layer is worn, the lower fiber fabric layer has been exposed in a large area

Suggestion: As shown in Figure 6, it is necessary to consider the serious wear of the conveyor belt.

Example of abnormal wear of conveyor belt
WIRTGEN
In addition to the feeding belt, the feeding system of the Wirtgen milling machine also includes four parts: guide wheel, lower idler, drive drum and return drum.

Wirtgen original guide rollers are durable and have very good directional stability in some challenging construction sites; highly wear-resistant idler rollers are made of special polyurethane compounds, which can provide reliable support when the belt is revolving; drive rollers The inner special rubber synthetic material is thicker, the power transmission is safe, and the permanent bond between the metal and rubber of the outer ring ensures a long service life of the driving drum; the strong and open design of the return drum allows the entire conveying system to withstand extreme conditions. Prevent asphalt from sticking. All of these high-performance components work together so that the conveyor system works efficiently.

During the use of the milling machine, if the entire conveying system is not properly cleaned, maintained and maintained, such as the surface of the idler is dirty, the belt tension is not set correctly and other factors will cause abnormal wear on the conveying belt. So what are the common abnormal wear conditions and how to observe them?

Abnormal wear caused by belt tension setting problems

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Figure 7: Belt rib cracks usually caused by excessive belt tension

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Figure 8: Longitudinal and slight transverse cracks at the edges, usually also due to excessive belt tension

Recommendation: If the function is not seriously affected, the crack repair kit can be used to quickly repair the crack at the construction site as an emergency measure. However, if the belt is at risk of being permanently damaged, the matching belt should be replaced to prevent downtime on the jobsite.

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Figure 9: Abnormal wear caused by belt deviation due to unbalanced left and right tension of the belt, the conveyor belt does not run centered on the drive roller

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Figure 10: Excessive belt tension causes wear on one side of the idler

 

 

Recommendation: Abnormal wear of idlers due to long-term uneven loading of the milled material. It is recommended to replace the idler to avoid more serious wear of the belt and other components in the later stage, which may lead to downtime.

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Figure 11: Because the belt tension is too large, the working hours are only 250 hours, and the abnormal wear of the belt is heated and decomposed.

Suggestion: In the case of the above picture, the rubber has fallen off in a large area, and the conveyor belt needs to be replaced.

Dirty rollers cause abnormal wear

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Figure 12: The idler is not cleaned regularly, and the uneven surface will cause great abnormal wear on the belt

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Figure 13: The gap between the drive roller and the belt is not well adjusted, and foreign objects such as stones are caught between the belt and the drive roller, causing the belt to be damaged, as shown in the picture with potholes

Recommendation: The diamond pattern on the drive drum should be no less than 1 mm thick. Belt damage can result if worn belt edge material remains stuck to the rollers. Therefore, timely cleaning is required.

Unusual wear and tear caused by accident on site

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Figure 14: Stone breakdown leading to hole

Recommendation: The belt is no longer in normal use and needs to be replaced.

 

The above is some knowledge about the wear of the conveyor belt. You can refer to these pictures and examples to carry out self-inspection of the conveyor belt of your equipment. According to the wear condition of self-inspection, if the regular wear is severe, or abnormal wear is found, it is in the peak construction season, it is recommended that you consider putting the replacement of the conveyor belt on the equipment maintenance schedule. Especially in the spring promotion of  milling machine conveyor belt quality service, the conveyor belt quality guarantee and discounts, don’t miss it!

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Post time: Mar-15-2022