Frequent Idler Failures - What To Do?

Found this....

http://www.miningandconstruction.sandvik.com/sandvik/0120/Internet/global/S003713.nsf/Alldocs/Products*5CConveyors*and*conveyor*components*5CFrames*and*trackers*2AMetric*heavy*duty*frames/$FILE/HA200IdlerDesignManual.pdf

Have you looked at these...

http://www.martin-eng.com/sites/default/files/downloadable-files/press-releasenalc-saves-time-and-money/nacl-243-complex-news-release.pdf

http://www.martin-eng.com/products/belt-cleaners/martin-pv-cleaner.html

Problem points need easy access, in your case to keep the belt clean. As I see it, you are using a steel wire enforced rubber belt? Probably subject to damaged spots and sticky residue at the end roller.

The maintenance of the belt cleaning should be done on a roller. In your case the end roller before the idler gets involved.

I suggest you apply a rotating steel brush that counter rotates over the whole width of the end roller. It requires only a extra support and can be driven from the same shaft of the end roller (provided that the shaft turns and not the cylinder over a static shaft) At the end roller, the rubber is stretched in the good direction to clean the belt.

by 2 chain sprockets and a chain with a good cover protection and a exhaust for dirt, captured on the sprockets. If you want more details PM me please.

Thanks Guys for the help, I will look into details of Martin Engg as Im located in Australia.

Can you please provide more details of Steel brush which cleans right after the head pulley? Our head pulley is 1200mm and I assume you are saying we connect the wire brush to the shaft of Head Pulley for cleaning??

Cheers

Yes, put a sprocket on the shaft of the end roller and order a brush with a solid shaft and put a sprocket on there too.

Depending on the width and speed, use 3/4" bigger chain or bigger. You can work many ways:

1. Bigger diameter brush and e.g. same sprockets.

or

2. big diameter sprocket on belt shaft and smaller on brush

In both cases the brush will rotate faster (contact speed) than the belt = better cleaning. The brush will also rotate against the belt direction on the way back.

Provide the proper bearings for the shaft.

Check here for an idea- Australia will have providers too:

http://www.spiralbrushes.com/cylinder.html (copy and paste)

Best regards. D

I have worked with conveyor belts of all kind. The first idler is actually a placed there to get more contact surface between the belt and the roller. Because of its relatively small diameter and the pressure it has to take, this roller is the first to break down when deposits leftovers: or get stuck or adhere and make the diameter of this roller bigger and most of the time not equally.

A difficult product is sticky gum (mixture of kelrez, calcium, esters, water and emulsifiers) - and the brush works even for that.

Your ore is in no way more sticky, even mixed with clay. What brings us to clay quarries for clay bricks. They use these rollers too. It don't care what nut professor stripped the good answer(s). However I see no alternative brought here.

If you need more info PM me. I give non commercial advise. Regards. D.

Hi, I am at present doing an observation and solutions project for a number of clients who have cleaning issues and severe roll failure issues.

Please check our website http://www.ci-int.com and contact me on my email

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and I will discuss your issues and some possible solutions.

Contrary to what many think, the best exponents in the Bulk Materials Handling Systems are all failing to see the real issues due to pre-conceived outcome solutions.

My proprietary VitreSteel OneFits Rolls which have the greatest load carrying capacity and wear longevity for any particular diameter in the industry and are lasting 3 to 13 times longer than the best of all the other manufacturers' rolls. The OneFits Rolls still fail but Fail to Safe without becoming a 'Pizza Cutter', This has been estimated by the mine optimization engineer.

Hope this will give you some real solution to work with as I am prepared to assist and I will be putting this observation report to a white paper in the future.

Les

In my limited experience (sand and gravel) with belt conveyors the large head (drive) drum is too large to break the 'stiction' with the material. Two small rollers beneath, one below and one above the belt to put a gentle kink into the belt path will help considerably. That first roller (one the material side) should not be a simple tube, add bars to the O/D to put some vibration into the belt.

This generates another issue of course, all the shed material falls beneath the conveyor and reasonable access is required to clean up.

Hi, Whilst I know that you have a solution, remember that using a pulley or roller with too small a diameter will flex the belting beyond its limits and 'Break' the carcass and this will result in a larger issue to deal with and belting generally forms between 40% to 50% of the total cost of the conveyor. Small radius pulleys or rollers than the required terminal pulley's diameter must have less than 2% 'Angle of Wrap' to prevent carcass damage.

Just a small comment that can be found in the belt manufacturers recommendations and the best general guide being CEMA 'Belt Conveyors for Materials Handling'.

Sir, the area of the conveyor is tail pulley bearing or idler rollers which i doubt. The main cause which i doubt is failure of the tail pulley bearing or the failure of idler rollers, for both we have a solution. In the mines basically the problem is contamination ingression into the rolling or moving parts. if the issue is that i can definitely help you out. If possible please provide some application facing problem site pics, so that it would be more clear at my end.

Thanks & Regards,

Debjyoti Bhattacharjee.