Important factors to consider when choosing the right roller ...

Selecting the proper roller for your conveyor belt system is essential for optimizing productivity and minimizing unplanned downtimes at your location. To guarantee the maximum lifespan and efficiency of the roller in your conveyor mechanism, you need to consider all relevant operational aspects of the roller.

Please visit our website for more insights on this topic.

At PROK, our team of specialists believes the following to be the most significant factors when it comes to choosing the right roller for your conveyor belt system:

• Roller lifespan
• Operator and environmental considerations including
  • Roller weight
  • Noise levels
• Exposure to wet or corrosive conditions

Determining the Lifespan of a Roller

The expected bearing life is paramount when selecting a roller. This can be influenced by multiple factors such as conveyor belt speed, load weight, or the presence of vertical curves.

Studies into mining conveyor roller failures have pinpointed three principal reasons for most failures:

• Bearing failure due to poor sealing systems
• Bond failure between the bearing housing and shell
• Wear and tear on the shell

Seals and bearings operate in tandem—seals prevent contaminants and moisture from entering and thereby protect the bearings. Corrosion is a leading cause of roller failure but can be mitigated with high-quality seals like a grease-filled labyrinth combined with a contact seal to block contaminants.

Beside end cap seals, shielded ball bearings provide an extra sealing layer, creating a three-barrier solution that prevents bearing failure in mining environments.

Shell thickness also plays a crucial role. As it wears down, it reaches a point where it can't support the load, resulting in shell failure.

PROK HDPE utilizes an innovative visual wear indicator. The shell features an outer yellow wear layer and an inner green layer, enabling mine operators to visually inspect the rollers for shell wear during operation. When the green layer becomes visible, the roller can be replaced during scheduled maintenance, avoiding unplanned downtime.

Assessing Roller Weight

The weight of a roller greatly influences the manual handling exposure for your maintenance crew. Opting for lightweight conveyor roller alternatives is crucial for easier changeouts and significantly reduces health and safety risks associated with heavy steel rollers.

The material and application determine a roller's weight. Traditional steel rollers in heavy applications can weigh up to 45 kg, posing safety risks during changeouts due to their weight and awkward positioning.

Technological advancements have brought composite rollers to the forefront, especially in major mining operations, because of their lightweight properties. Using a light conveyor roller, like the PROK HDPE, which is 40% lighter than conventional steel rollers, results in safer and quicker changes, thereby enhancing site productivity.

Impact of Noise on Operations

Many conveyor systems function around the clock, and rollers contribute to the overall noise level. Contact between the rollers and the belt, as well as any damage to the belt, can raise noise levels.

Location matters: systems near residential areas must comply with local environmental noise regulations to avoid penalties.

Noise also affects worker safety. Long-term exposure to high noise levels can cause permanent hearing loss.

PROK composite roller tests have shown they produce less noise than steel rollers, with the PROK HDPE roller being 50% quieter.

Combating Roller Corrosion

Corrosion is a significant cause of roller failure, making it vital to consider the environmental conditions where the roller operates. Proper construction and seal design can prevent moisture and contaminants from entering the bearing, ensuring desired roller longevity.

Steel rollers are more prone to rust and corrosion in wet environments compared to HDPE rollers. PROK HDPE rollers are designed to reduce failure risks in harsh conditions with superior features such as:

Shell and end cap made from composite materials resistant to corrosion.
A multi-labyrinth sealing system with shielded bearings that prevent water and contaminants from entering.

Conclusion

Choosing the appropriate roller for your conveyor belt system can be complex. Key factors include:

• Operating environment and loading application
• Materials and construction of the roller
• Bearing and sealing system
• Noise generated by roller and belt contact

These factors will determine the most suitable roller for your conveyor system and its performance.

PROK rollers are designed to withstand the three most common failure modes: bearing failure from poor sealing, weak bearing housing connections, and shell wear and abrasion.

Explore the range of PROK products at Joyroll.

For more information on our conveyor roller selection, please visit our contact page.

Critical Questions to Consider:

1. What is the Belt Strength?

One of the most crucial factors when choosing a conveyor belt is its strength, which relies on understanding the load it will bear. This involves considering aspects like tons per hour (t/h), conveyor length, motor power, and pitch angle.

You can quickly determine belt strength from its product designation.

Example:

A belt labeled &#;EP400/3 &#; 4+2&#;, denotes various elements:

• The numbers represent strength in newtons per millimeter (n/mm)
• The number after the slash indicates the number of layers
• The figures &#;4+2&#; specify the amount of rubber on each side;
• The letters denote the material type of the belt. Here, &#;EP&#; indicates a common polyester-polyamide construction.

The actual strength is documented in the test certificate, revealing the force needed before the belt breaks.

2. How Wear-Resistant is the Belt?

Another vital quality indicator is the belt's wear and tear resistance, reflected as &#;abrasion&#; in test specifications. This measures cubic millimeters (mm3) lost in a fixed test cycle—lower numbers suggest greater wear resistance.

Standard DIN norm for Y-quality tapes is 150 mm3. Top belts in this category typically range between 110 and 120 mm3.

3. Compatibility with Drum Diameter

It's essential to consider the drive and turn drum diameters when choosing a conveyor belt. If the drums are small, avoid thick belts with many layers as bending may cause layer separation.

Example: Heavy loads will require a multi-layer strong belt, yet this combination with small drum diameters leads to layer separation and loss of strength.

4. Is a Special Belt Required?

Specific scenarios might demand specially constructed belts. High-load situations can benefit from superior quality rubber options, significantly extending belt life.

If handling massive falls or lengthy conveyors, consider a belt with stronger rubber, multiple layers, and thick cores.

Read more:
Avoid conveyor belt misalignment in 10 simple steps

Check the &#;tensile strength&#; in the inspection certificate for a good idea of the belt's capacity to handle shocks and heavy loads.

5. Manufacturer's Quality Standards

Conveyor belts from European manufacturers often exceed standard DIN norms, ensuring consistent quality through rigorous testing and production routines.

High-quality belts come with test certificates guaranteeing their durability and performance as promised.

We're Here to Help You Find the Right Product

When ordering, you typically specify quality, width, and thickness of the belt.

It's also helpful to provide additional details such as:

• Quantity (tons per hour)
• Type of material transported
• Specific usage scenario

Asking the questions and considering the points above will help you make an informed decision when purchasing conveyor belts. Keep in mind that the initial purchase cost isn't paramount. Instead, focus on selecting a belt that meets your needs for the best durability per ton produced.

Want more information on Conveyor Rollers For Sale? Feel free to contact us.