Objective: Solve belt mis-tracking and off center load issues

Challenge: A major cement processing facility in was experiencing severe belt tracking and alignment problems leading to regular costly repairs and maintenance. This plant was using traditional training idlers in an attempt to control the mis-tracking, however the nature of the aggregate material on the belt lead to continual build up around the pivot point, yielding it ineffective.  In addition, the rubber disk return idlers were preventing the belt from re-centering, defeating their purpose.

On several occasions, the belt became so severely mis-aligned, that it came in contact with the tail section of the
support structure, leading to catastrophic damage to the belt, and causing extended downtime for the
plant’s operations.  The problem persisted upon installation of a new belt, and within 12 months, it needed
to be completely replaced a second time.

Recommendations:

After ASGCO^®’s technicians performed a complete survey of the conveyor system, the problem issues were identified.
It was recommended that ASGCO^® Tru-Trainer^® was to be installed on the return side of the conveyor, 30 feet
before the tail pulley.  This position would allow the belt to run straight around the tail pulley and also be centered on
the conveyor in the load point, reducing spillage and costly material loss.  In addition, the rubber disk return idlers
were replaced with flat return idlers, eliminating resistance to centering.

Results:

After installing the ASGCO^® Tru-Trainer^® on return side of the conveyor, the belt is continually running straight
in the frame of the conveyor.  Due to the sealed design, interference from material buildup has been eliminated.
The plant’s output has greatly increased due to the greatly reduced maintenance and repair issues and productivity
is at an all time high.and reacts immediately if the belt begins to steer off center.  Because it does not rely on
contact with the belt edge in order to guide the belt, belt edge damage which frequently occurs with conventional
tracking systems, is avoided.

Tru-Trainer^® Flat Return Idler

The Tru-Trainer^® series of conveyor belt tracking idlers are a patented design that offers the most
reliable and re-active belt tracking idlers available today.

• Patented design does not rely on the conveyor belt to activate
• Heavy Duty Rolls use abrasive resistant hot-vulcanized rubber covers.
• Central Pivot with Two Individual Rollers
• Enhanced Sealing/Bearing System