Risks and Recurring Challenges
When materials become trapped between the belt and a pulley, both components can suffer significant damage. These issues aren't limited to the amount of material trapped; multiple types of failures can occur:
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Degradation of Fugitive Material
Any material that falls between the conveyor belt and the pulley poses a danger if it breaks down into small particles that fit between these components. Material stuck in this area can cause the belt to slip against the pulley, leading to wear on the non-carrying underside of the belt. Unlike the load-bearing side, the underside lacks a durable top cover, making it susceptible to damage even from small particles over time. Over time, the buildup of materials in a tail pulley can lead to belt wander, potentially causing damage to the edge of the belt or conveyor structure itself.
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Belt Failure
While fines and degraded materials can gradually wear down the belt through abrasion, there's also the risk of sudden and more severe damage. Any material trapped between the pulley and the belt can potentially force its way through the belt's top cover, especially if it's a sharp-edged lump. These actions can create gouges and tears that may extend along the length or width of the belt, depending on the nature of the damage.
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Pulley Failure
While conveyor belts are typically more prone to abrasion and wear, pulleys can also be damaged by stray materials. This damage can lead to pulley misalignment and slippage, both of which can further harm the belt.
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Recurring Issues
One of the most serious problems caused by material getting trapped between the belt and the tail pulley is its tendency to recur. If material becomes pinched and pulled around the pulley, it may fall back onto the returning belt at the tail pulley. This cycle can continue, potentially causing repeated attempts to break something or causing failure until the material lump is removed from the belt.