The Most Common Problems with Flexible Screw Conveyors and How to Prevent Them
Flexible screw conveyors are renowned for their versatility and ability to move materials in any direction. They can be routed around obstacles and equipment, making them a preferred choice in many industries. However, like all mechanical systems, flexible screw conveyors are not immune to problems. Even well-maintained systems can experience issues such as wear, jamming, or inefficient material conveyance.
Here’s a look at the most common problems with flexible screw conveyors and how to prevent them.
1. Wear of Tube and Spirals
Problem: If you’re conveying abrasive materials, your tubes and spirals are likely to experience wear over time.
Prevention:
- Consider upgrading to double-wound spirals or those made from more durable materials.
- Ensure the tube is not too tight, as excessive tightness can cause premature wear on both the spiral and the tube.
2. Conveyor Locking or Jamming
Problem: If your conveyor is jamming or locking randomly, the issue may be related to the following:
Power Supply:
- Check if you can manually rotate the spiral. If you can, the issue could be with the electrical components, such as a thermal overload or a malfunctioning Variable Frequency Drive (VFD).
- Ensure the correct voltage is supplied to the conveyor. Consult the manufacturer’s manual for voltage specifications.
Spiral and Feed Restrictor:
- Inspect the spiral for damage and check the feed restrictor. Improperly set feed restrictors can cause material flow issues, leading to jams.
- Overloading the conveyor can also damage the motor and cause premature wear on the spiral.
3. Issues with Material Conveying
Problem: If the conveyor struggles to transport materials, there could be several causes.
Spiral Direction:
- Ensure that the spiral is rotating in the correct direction. Depending on the helix type, your conveyor may naturally rotate clockwise or counterclockwise.
- Verify if the spiral is turning as expected. If it’s not, you may need to contact your manufacturer.
Hopper Material Build-up:
- Excess material in the hopper can prevent the conveyor from operating effectively. Ensure the hopper is not overloaded, which could obstruct the flow of material.
Feed Restriction:
- Confirm that the spiral is receiving an adequate material feed. A malfunctioning feed restrictor can limit material flow, preventing the conveyor from achieving the desired conveyance rate.
4. Additional Common Issues and Solutions
If you’re still experiencing problems, consider these other factors:
- Motor: Ensure the motor is appropriately sized and compatible with your conveyor.
- Welding: Check the quality of the welding on the spiral to ensure it’s properly assembled.
- Environment: Extreme temperatures can strain conveyor performance. Ensure the working environment is suitable for the conveyor.
- Material Suitability: Ensure the materials being conveyed are appropriate for a flexible screw conveyor. Some materials may cause excessive wear or operational issues if they aren’t suitable for the system.
Conclusion
Flexible screw conveyors are highly efficient and versatile, but they are not without their challenges. By understanding the common problems and how to address them, you can keep your conveyor system running smoothly and extend its lifespan. Regular maintenance, proper setup, and selecting the right components are key to preventing these issues.
If you continue to face issues, don’t hesitate to consult with the manufacturer or a specialist to get your system back to optimal performance.