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Thread: Side Rollers Load

  1. #1
    Graneisa Guest

    Side Rollers Load

    We've supplied thousands of idlers for a conveyor manufacturer, and they're running just fine for 3 years. Except for the side rollers of the carrying idlers in a specific conveyor. They're failing after a few months of use. The central rollers are all perfect, the only problem is with the side rollers, and that repels the first impression of material overload.

    We believe the causes could be:
    - Excessive counterweight
    - Belt too rigid. It's a steel cable belt.
    - Belt uneven tension (caused by a broken steel cable).

    We had thought of seal failing, because the 45 side rollers are more exposed to the iron ore dust atmosphere, but we've opened some rollers after 2 months running and the seals were perfect.

    Does anybody has faced a situation like this ?

  2. What is the failure?
    Is the problem related to the failure of ball bearings?

    Regards,

    Antonio Reis
    Vitrom Mfg Consultants
    Your Process and Manufacturing Solutions
    Phone: 209.834.1900
    Fax: 209.834.1039
    www.vitrom.com

  3. #3
    Graneisa Guest
    Yes, Mr. Reis.

    The rolls start making that typical damaged roller noise, then the roller breaks and with it, the seals.

    Regards

  4. Please be sure the selected belt is capable of troughing at a 45 degree angle with the belt width used. A common mistake in the conveyor industry is to force a belt into a trough that it was not designed for. This will cause undue stress on the outer (wing rolls) and coulkd also make the belt cup.

    Another thing to check is the speed of the roller. Is the belt speed sufficient to exceed the rated bearing speed of the roller.

    Hopes this gives you some help.
    Larry J. Goldbeck
    Martin Engineering

  5. #5
    Are the rollers failing in all areas of the belt or are they isolated?

    Please provide the following info if available.

    Width of Belt -
    Rating of Iders -
    Max belt capacity -
    Speed of belt -
    Spec on belt -

    We can then determine if there is a problem in the system.


    Gary Blenkhorn

  6. #6
    Graneisa Guest
    Originally posted by larryg
    Please be sure the selected belt is capable of troughing at a 45 degree angle with the belt width used. A common mistake in the conveyor industry is to force a belt into a trough that it was not designed for. This will cause undue stress on the outer (wing rolls) and coulkd also make the belt cup.

    Another thing to check is the speed of the roller. Is the belt speed sufficient to exceed the rated bearing speed of the roller.

    Hopes this gives you some help.
    The belt is a ST-1000 with 10 mm x 5 mm covers, 1400 mm width, 45 throughing. Belt speed is 4.4 m/s. Rolls are 165 mm. Roll rating is 13723 N.

    Belt throughing is not a problem, according to its manufacturer. Belt speed is also withing design limits.

  7. #7
    Graneisa Guest
    Originally posted by Gary Blenkhorn
    Are the rollers failing in all areas of the belt or are they isolated?

    Please provide the following info if available.

    Width of Belt -
    Rating of Iders -
    Max belt capacity -
    Speed of belt -
    Spec on belt -

    We can then determine if there is a problem in the system.


    Gary Blenkhorn
    The rolls are failing along the conveyor length, which is about 650 meters.

    Width of Belt is 1400 mm
    Rating of idlers is 13723 N
    Conveyor design capacity is 8500 ton/h
    Belt speed is 4.4 m/s
    The belt is a ST-1000 with 10 mm x 5 mm covers, 1400 mm width, 45 throughing.

  8. Fernando,
    My personal opinion, and note that I don't have much information on the system, you may have unfavorable distance between idler assemblies and the belt deflect enough that it loads the bearings axially above the bearings rating.
    Maybe you have the capabilities of measuring the axial force by using a simple load cell.

    Good luck.


    Antonio Reis
    Vitrom Mfg Consultants
    Your Process and Manufacturing Solutions
    Phone: 209.834.1900
    Fax: 209.834.1039
    www.vitrom.com

  9. #9
    I am assuming an idler spacing of approx 1.2 M, my calculations come up with the belt being loaded approx 95%.

    Calculated load on idlers is approx 8000 N.

    For a 2% sag counterweight should be approx 9000 kg.

    Accel tension 175 kN.

    Running tension 85 kN.

    Hope this info is helpfull.

    Gary Blenkhorn

  10. #10
    Graneisa Guest
    Originally posted by Antonio Reis
    Fernando,
    My personal opinion, and note that I don't have much information on the system, you may have unfavorable distance between idler assemblies and the belt deflect enough that it loads the bearings axially above the bearings rating.
    Maybe you have the capabilities of measuring the axial force by using a simple load cell.

    Good luck.


    Antonio Reis
    Vitrom Mfg Consultants
    Your Process and Manufacturing Solutions
    Phone: 209.834.1900
    Fax: 209.834.1039
    www.vitrom.com
    Antonio,

    It's a good idea. Even if the idler spacing is not the problem, measuring the axial (and radial) forces on the side roller is a must in this situation.

    Thanks

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