New bearings are designed to support and tension rollers for conveyor belts operating under adverse operating conditions
ROLLER bearings are one of the most important parts of the conveyor belt supporting and tensioning rollers. In order to enable conveyor belt rollers to operate under extreme conditions, NKE Austria GmbH has developed single row deep groove ball bearings. Compared with standard bearings, these bearings have optimized performance and longer service life, thereby reducing the overall conveyor system Downtime.
The main purpose of the support roller and the tension roller in the conveyor belt is to shape the conveyor belt, serve as a support element for the material to be transported, and reduce movement resistance. When materials are transported with minimal friction, the total energy required for transport is reduced, which also reduces operating costs.
In a quarry or open-pit mining environment, conveyor belt drums may be exposed to harsh operating conditions and environments: heavy load, vibration and shaft deflection stress, high speed, increased load caused by external pollution, and severe weather conditions, such as High humidity, rain or snow.
In this environment, impurities can seep into the bearing points and cause premature equipment failure. This not only shortens the service life of the bearing, but also negatively affects the performance and reliability of other parts of the conveying system.
After extensive analysis, NKE has developed a single row deep groove ball bearing, which is especially suitable for conveyor belt drums that operate under harsh conditions. The company said that through a completely redesigned design, compared with standard bearings, it has successfully carried out targeted improvements to optimize performance and service life.
These bearings have a special cage structure made of low-friction synthetic materials, improved raceway geometry, adjusted radial internal clearance, special low-friction seals and selected lubricants, and can be used in a wide range of work Use within the temperature range.
According to NKE, the new design can meet the operating requirements of exposed conveyor rollers even when traditional bearings fail.
When contaminants penetrate into the bearing, standard bearings usually suffer a sudden, uncontrolled temperature rise, which can impair the active lubrication performance, damage the steel cage, and eventually cause the bearing to seize. When the bearings are stuck, they will block the drum, the conveyor belt will be damaged, and the risk of fire will increase significantly.
Although the pollution level is relatively high, it is said that the NKE roller bearings used for conveyor belt rollers can maintain their function even under heavy loads without increasing friction torque.
The new bearing concept is specifically designed to meet the requirements of conveyor belt rollers and has a series of advantages, including reducing fire risks, extending the life of roller bearings under the worst conditions, reducing energy consumption, improving conveyor system reliability and reducing overall operating costs .
"We have extensive expertise in mining applications," said Michael Rößl, NKE application engineer. 'This is an extremely complex engineering achievement that responds to the desire expressed by many customers to improve the functionality of the conveyor belt. Our new roller bearing system will help to drastically reduce the downtime of material transportation.
The new bearing design ensures that the rolling process is frictionless, which helps to minimize the friction of the entire system and makes the operation of the transportation system more cost-effective and reliable.
“In order to obtain the best results, it is necessary to start with the plant developer or plant operator who installs the external sealing system to prevent particulate contamination from penetrating into the bearing and the inside of the bearing as completely as possible,” added Mr. Rößl.
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