Understanding Conveyor Belt Vulnerabilities: The Impact of Junction-Joint Failures
In general, structures and machines tend to be most vulnerable at seams or points of transition, where stresses do not act consistently on a single surface.
Conveyor belts illustrate this vulnerability through various types of damage at their edges or where layers are joined. Many conveyor systems suffer from junction-joint failure, particularly as belts transition from a flatbed to a trough.
These junctions are critical in various conveyor designs, but issues arise when the transition space is either too narrow or too wide. A small gap between idlers can cause the belt to crease abruptly, while a large gap can stretch the belt under the weight of conveyed materials, as they fill the gap. The optimal gap size between idlers and the design of these junctions depends significantly on the belt material, its thickness, and the desired belt shape. Early signs of junction-joint failure often manifest as a 'W' or 'M' shape on the belt over flat idlers, accompanied by wear along the edges where outer idlers tilt upwards.