Analysis and solution of the cause of Conveyor roller failure (Part 1)

The belt conveyor idler is a simple structure. Because it is in use in the speed is not high, the load is not big, no impact, if manufacturing precision meet the design requirements, bearing is not contaminated, the long-term work under good lubrication condition, material also have no serious wear and tear or corrosion, should be up to 10, 150000 hours service life. However, in the actual working environment, due to work needs and other inevitable damage to the roller, the normal work production and working life of the roller are affected.

Case:

For example, a belt conveyor on a belt conveyor in Jidong Cement Mine has been used for 15 years and is still working. The belt conveyor in the mud cement mine, which began operation in 1997, has been produced two shifts a day, and 80 percent of the roller is still in operation. But, in many other occasions, roller damage phenomenon is very serious, life is only about 1 year, half year damaged roller is very common, even less than one thousand hours to be ground off, or from a hole, because scratch and even serious consequences of the tear tape.

Damage cause analysis:

So, what are the causes of roller damage? Is there a solution? From the technical quality level of the roller, we analyze the environment one by one, and provide some solutions for the reference and discussion:

The sealing performance of the roller is poor, and the bearing is polluted by water or dust: in order to minimize the rotation resistance of the roller, the labyrinth seal structure is basically adopted. At present, all of the labyrinth seal structures in China and abroad are designed with the design of the forehead, without the basis of principle, can't prevent the water and dust pollution to the bearing. It is well known that the sealing effect is not good when the gap between the labyrinth seals is large. So, people racking their brains, as far as possible the clearance of labyrinth seal design is small, the number of deep embedment (or number), or the circular arc form, etc., in order to achieve the ideal sealing effect, do you not know that this is a big mistake. The gap between the labyrinth seals is small and can only reduce the pollution rate of water and dust, far from achieving the desired effect. Moreover, the grease in the labyrinth cavity is filled with grease, which greatly increases the rotation resistance of the roller. Therefore, all the roller at home and abroad, in harsh environments, such as spray water or dust, the longest do not exceed 10000 hours service life, only 2000 hours, the shortest bearing failure cycle of contaminated couldn't expected.

There are two types of damage:

1. When the rotation resistance increases, the tubular circumference is rapidly sharpened.

2. The bearing card has been ground to a hole.

There is only one solution: you must ensure that the bearings are never contaminated.

To be continued...