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Conveyor components

HM150 formed rollers

Conveyor technology

current situation
The bulk materials industry continuously strives for increased output and increasingly reliable conveyor systems. Suppliers have responded with a broad range of
rollers for regular or heavy-duty use. No doubt, we have
refined these products with incremental improvements.
Sandvik is committed to its full range of high quality traditional rollers. We have also identified the need to innovate, to provide additional value to our customers and
to do more than simply meet specifications and delivery.

NEEDED ROLLER IMPROVEMENTS


Rollers fail it is part of life when you operate or service
a conveyor system. And if the mean-time-to-failure translates into regular headaches, the traditional answer is to
make rollers heavier and stronger. Wear life is improved
with thicker shells; larger bearings are used; and the solid
shafts are also made heavier. These efforts can then be counteracted by
poor balancing or alignment which may still put unsustainable loads on
the bearings.
The costs go beyond purchase price as there is the effect of higher energy consumption as well as the additional demands on the pulleys and
drives. Then we consider the human aspect. There is an increased risk
from lifting heavy rollers in not-so-easy-to-reach places as well as the
environmental impact from increased conveyor noise affecting workers
and the surroundings.

TRADITIONAL ROLLER


1

Tube

Bearing supports machined


from solid

Solid through-shaft

Multiple labyrinth sealing


system

HIGH SPEED LIMITATIONS


In applications such as lignite mining or iron ore processing, speeds up
to 11 meters/second (36 feet/sec) and capacities up to 52,000 tonnes/
hour are common. For such speeds, traditionally welded heavy-duty rollers must be machined for roundness. To compensate for the metal loss,
the rollers are dynamically balanced and counterweights are applied
complicated indeed.

SANDVIK INTRODUCES TECHNOLOGY SHIFT


For traditional rollers, a series of simple manufacturing steps result in a complex product. With the new
HM150 formed rollers, an intelligent design and sophisticated manufacturing process gives a more straightforward product with superior characteristics. Great ideas are always simple and provide the greatest value, in
this case advancing your conveyors performance.

Formed shell

Formed bearing seats

Labyrinthabdichtung

Formed shaft

Formed rollers

advancing conveyor performance
Formed roller refers to both the manufacturing process and the end result. Through steps of both cold
and hot forming the tubular material becomes a roller with integral bearing seats. Extensive research by
Sandvik optimized the shapes, material properties and perfected the process. Using precision machinery
and tooling, formed rollers are produced with greater consistency and results than ever achieved before.

LONG LIFE
The forming process increases the steel wall
thickness by 50% for a length of 100 mm at the
center of the roller where the physical loads are
the greatest. 1 The rest of the tube wall thickness is reduced by approximately 20% which
removes unnecessary material to provide weight
reductions. The thicker wall, in combination
with a smooth surface finish and fine-grained,
work hardened steel, lead to dramatically
increased shell wear life at the high wear areas
of the roller.
With the bearing seats 2 formed as integral part
of the shell, the opposing bearings are tightly
aligned. Thanks to the increased steel thickness
in both the middle of the shell and the seats,
deflections are minimized under load. With an
excellent surface finish of 0,5 m (0.02 mil),
frictional corrosion is avoided.

QUIET ENVIRONMENT
Formed rollers are naturally balanced. This is
most critical at high speeds, but is beneficial in
any conveyor system. Measurements have confirmed noise reductions up to 20 dBA compared
with other heavy-duty rollers. Even compared
with dynamically balanced rollers, a reduction
of 10 dBA has been documented. That means a
significantly reduced noise for workers and the
surroundings.

EASY HANDLING
Compared with other heavy-duty rollers, total
weight is reduced by between 10 and 30%. For
maintenance personnel, that can make a huge
difference. Install rollers quickly with less risk
exposure.

A high quality labyrinth seal 3 effectively keeps


the bearing grease in place. The combined result
a much extended bearing life.

ENERGY SAVINGS
In formed rollers, a large diameter tubular shaft
4 can be used. In the process, the diameter is
decreased at the bearing ends and the wall
thickness increased. The overall impact is an
optimum strength-to-weight ratio. In addition
the graduated shell thickness provides a reduced
rolling mass. With less dead weight and smooth
turning, the power consumption is lowered by
up to 3 Watts per roller reduced operating
cost.

FORMED ROLLER

INCREASED CAPACITY
Short of major expansions, the most effective
ways to boost conveying capacity are to reduce
down-time and increase belt speeds. Sandviks
HM150 formed rollers let you do both within
existing infrastructure. Increased roller life, reliability and energy efficiency create new opportunities for raised tonnage conveyed per hour.

Traditional roller

Formed roller

Hands-off performance

under pressure
Bearings all too often the weak link in any roller perform best when installed with the optimum contact
pressure. With formed rollers, Finite Element Analysis confirms an averaged 25% reduced surface pressure
on the inner bearing ring than on traditional rollers, for an advantage right out of the box.
Under a loaded conveyor belt, the formed roller deforms on an average of 30% less. Inside the bearing
this lower deflection translates into substantially less misalignment of the bearing rings. These calculations
therefore support why formed rollers turn with less power and higher reliability.
But it is not all about theory. Field experience confirms the performance advantage. One lignite mine was
experiencing a roller life in an extremely arduous application of about 3 months. A trial of 500 Sandvik
HM150 formed rollers showed each and every roller was still in operation after 18 months.

HM150 formed roller



product assortment
Sandvik HM150 formed rollers are suitable for the high belt speeds and tonnages required in lignite
mining, iron ore processing and other demanding conveyor applications. Formed rollers are available
within these specified parameters.

Shaft diameter
mm/inch

Bearing size

Shell diameter
mm/inch

Bearing seats
mm/inch

51/1.97

6308

159.0/6.26
178.0/7.01
194.0/7.60

40/1.57

63,5/2.5

6310

159.0/6.26
178.0/7.01
194.0/7.60
219.0/8.62

50/1.97

82,5/3.25

6312*

194.0/7.60*
219.0/8.62

60/2.36

*special request
Roller length 380 - 1450mm (15 - 57 inches)

Sandvik is a high-technology engineering group with


world-leading positions in selected areas tools for metal
working, advanced materials technology, and mining and
construction. We are represented in 130 countries.
Sandvik Mining and Construction represents one third
of the overall Sandvik Group and serves a broad range of
customers in construction, mineral exploration, mining
and bulk materials handling. Our construction expertise
covers quarrying, tunneling, demolition and recycling, and
other civil engineering applications. Our mining products

SANDVIK MINING AND CONSTRUCTION www.sandvik.com

Sandvik is a registered trademark of the Sandvik Group. 2009 Sandvik. B6-081ENG

and services support customers on the surface and under


ground, in all mineral, coal and metal mining applications
from exploration to ore transportation.

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