A Systematic Approach to Conveyor Belt Alignment and Tracking
Achieving proper belt tracking within a conveyor’s structure and components involves adjusting idlers and managing loading conditions to prevent the belt from veering off its intended path. The initial step is aligning the structure with the belt’s theoretical centerline, as determined during the system survey. Once alignment is achieved, it's crucial to ensure that all pulleys and idlers are level and square to this centerline before addressing the belt’s tracking accuracy.
During belt training, it's recommended that a single person oversee the procedure. Simultaneous adjustments by multiple individuals can lead to conflicting corrections that complicate the path correction process. Maintaining detailed records of the conveyor’s issues and the steps taken to rectify them is essential. This practice helps prevent or identify problems stemming from corrective actions, re-corrections, over-corrections, and counter-corrections in specific areas. 
Belt tension is usually highest as the belt enters the drive pulley; areas of low tension will vary depending on the location of the snub and take-up pulleys. To train a belt, start inspection for mistracking directly behind the highest tension area (where the belt leaves the drive pulley).
Procedure for Training
The following steps outline how to train the belt to correct alignment and loading issues:
1. Identify Belt Tension Areas
Start by pinpointing and adjusting components in low-tension zones as these adjustments have the most significant impact on correcting the belt’s path. High-tension areas, especially around the drive pulley, require careful attention due to the substantial tension present. The location of the lowest tension varies depending on the positions of snub and take-up pulleys, unique to each conveyor setup. For detailed guidance, consult resources like the Conveyor Equipment Manufacturers Association’s (CEMA) "BELT CONVEYORS for BULK MATERIALS, Sixth Edition," or seek advice from experienced conveyor engineers.
Ensure the take-up pulley applies the correct tension specified by the belt’s current specifications and capacity ratings. Inadequate tensioning can cause significant deviations in the belt’s path.
2. Identify Mistracking Locations
Begin inspecting for belt mistracking immediately after the highest-tension area, typically where the belt departs from the drive pulley. Track the belt’s path until you visually identify where it deviates off track.
Remember, the condition of the belt at any point is primarily influenced by upstream idlers and components rather than downstream ones. Therefore, corrective actions should focus on points the belt has already passed, before the visible mistracking area.
Adjustments made to an idler typically have the most significant corrective impact within a 5 to 8 meter (15 to 25 ft) downstream range.