Common Diverter Mistakes and Maintenance Tips for Warehouses

Diverters are workhorses in warehouses and fulfillment centers, but when they fail or underperform they can cause bottlenecks and increased manual labor. This friendly, beginner-oriented article covers common mistakes made with diverters, how to avoid them, and a practical maintenance checklist that keeps systems running smoothly.

Common mistakes and how to fix them

• Choosing the wrong diverter type: A common mistake is selecting a diverter without considering package diversity. For example, using a high-speed pusher on soft or irregular packages leads to jams and damage. Fix: Profile your items (dimensions, weight, rigidity) and select a diverter matching that profile. If items vary widely, choose a gentler and more adaptable option or segregate flows.
• Poor sensor placement and timing: Misplaced sensors cause diverters to trigger too early or too late, creating missed diverts or collisions. Fix: Calculate trigger distance using conveyor speed and actuator travel time. Validate with real items and adjust sensor positions accordingly.
• Ignoring environmental factors: Dust, humidity, low temperatures, or corrosive atmospheres can degrade components and sensors. Fix: Use ruggedized sensors and diverters rated for the environment. Apply appropriate sealing, materials, and maintenance schedules.
• Insufficient maintenance planning: Diverters with no preventive maintenance will fail more often. Fix: Implement a regular inspection and maintenance plan including lubrication, wear checks, and actuator testing.
• No fallback or manual bypass process: When a diverter fails, entire lanes can be blocked. Fix: Design manual bypass routes and establish documented procedures so staff can continue operations while repairs are made.
• Overlooking integration with control systems: Diverters that aren’t properly integrated with WMS/WCS or PLCs can result in incorrect routing. Fix: Ensure reliable communication protocols and test end-to-end flows during commissioning.

Maintenance checklist: daily, weekly, monthly

Daily

• Visual inspection for obvious damage or blockages.
• Verify sensors are clean and unobstructed; wipe lenses if needed.
• Listen for unusual noises that may indicate misalignment or failing bearings.

Weekly

• Inspect moving parts (paddles, belts, rollers) for wear and correct alignment.
• Check actuator performance—confirm full travel and responsiveness.
• Confirm access panels and safety interlocks are functional.

Monthly

• Lubricate bearings and pivot points as manufacturer recommends.
• Test control logic and failover routines—simulate sensor failures and ensure safe behavior.
• Review divert statistics and error logs to spot trends indicating impending issues.

Spare parts and lifecycle planning

Maintain a small inventory of common wear parts: actuators, sensors, rollers, belts, and control fuses. Track mean time between failures (MTBF) and plan replacements before components fail in service. For high-throughput systems, consider a hot-swap module strategy to minimize downtime.

Troubleshooting tips for beginners

• If items consistently miss the divert: Re-check sensor-to-diverter distance and account for variable conveyor speeds. Confirm actuator travel time in the control logic.
• If items are damaged during divert: Reduce push speed, switch to a gentler diverter type, or add soft contact surfaces to pusher heads.
• If diverter stalls or hesitates: Inspect for mechanical obstructions, worn bearings, or insufficient actuator power. Check electrical connections and fuses.
• If false triggers occur: Clean sensors and test for ambient light or dust interference. Consider moving sensor angles or adding shielding.

Operational best practices

• Train operators on quick checks and emergency procedures—first responders should be able to isolate and clear jams safely.
• Use data: Monitor divert accuracy, jam rates, and downtime to prioritize maintenance and adjustments.
• Standardize package presentation where possible—consistent orientation and spacing reduce divert complexity.
• Document change control for software or timing adjustments so you can revert if new settings perform worse.

Practical example

A mid-sized fulfillment center experienced a high rate of mis-diverts during peak season. Investigation revealed inconsistent placement of photoelectric sensors after a conveyor speed increase. By recalculating trigger points for the new speed, cleaning sensor lenses, and adding a short accumulation zone upstream, the center reduced mis-diverts from 3% to 0.5% and avoided significant manual rework.

Final thoughts

Diverters are simple in concept but demand careful attention in practice. Avoid common selection and integration mistakes, follow a consistent maintenance routine, and use performance data to drive improvements. With these steps, diverters will be reliable allies in keeping goods moving efficiently through your facility.