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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.
TRADITIONAL ROLLER
1
Tube
Solid through-shaft
Formed shell
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.
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.
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)