Development of rollers(idlers)

for conveyor-belt
systems

First recommended design

of7th August 2015

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1.Present state of knowledge on account of experimental tests

2. Qualitative comparison of the constructional versions(designs)

3.Variable technical factors that influence the manufacture

4.Summary and recommendation

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1
1. Present state of knowledge on account of
experimental tests

It can be basically recognized on account of the conducted tests that there is already a
divergence from the tubes straightness (curvature) in the delivered condition, which in turn
leads to diverging concentricity as well as to an imbalance. These properties mainly influence
the dynamic characteristics and the behaviour at high speed as a result. It is required to use a
qualitative better product (a tube with less divergence from straightness) for the idler shell in
order to reduce the diverging concentricity.The tube must have the lowest possible
variation of wall thickness in order to still achieve an improved balancing quality
simultaneously as well. Furthermore, the aforementioned properties and characteristics are
also influenced by the assembling process or the manufacturing process respectively: for
example, substance-to-substance bonds by welding, frictionally engaged joints or force-fitted
joints by means of axial presses or even radial forming.

2.Qualitative comparison of the constructional versions

(designs)

On the other hand, it is being sought to achieve a greater loading capacity or a higher
conveying volume (heavy-duty rollers) by means of constructions that use cast end discs,
larger bearings and larger axial diameters (refer to the table on page 3), while using the same
tube of the same qualityfor both of the new constructional versions(designaccording toType
1and Type 2).

One can assume that stiffness of the rollers entire sleeve (idler shell with inserted end discs)is
greater than when utilizing deep-drawn end discs because of the cast end discs inherent
stiffness (structural stiffness) as well as through a greater supporting effect on account of the
end discs longer cylindrical part too, which lies on the tubes inner walling. The use of an axle
with a larger diameter also contributes significantly to the rollers general resistance to
deformation. The resulting deformation therefore remains smaller on account of the external
loading and so the loading in the area of the roller bearings causes lesser deformation, which
could otherwise lead to tension or tilting (misalignment) of the inner and outer rings. Both the
Type 1 and Type 2 constructional versions ensure that there is continuous contact between the
end discs cylindrical part and the shells inner wall, which also applies in the non-cylindrical
section with the formed version according to Type 2.Whereas the welded version (Type 1)
only has a real connection in the welded seamsarea,the force-fitted and frictionally
engaged connections of Type 2are leading theoretically to a cross-pressed laminate over
the entire width at the end of the roller tube, which would basically result to a higher
general stiffness of the idler shell through increasing the momentary stiffnessat the transition
from the tube to the end disc.

2
Typ(Type)/ Bilddes Rollenboden / Tragrollenende/
Rollenendes /Picture Enddisc Endof rollertube
of rollerend

Typ1(Type1)

According
toCSD.I.1864
andCSD.I.1865.
D1=143.6 mm

Typ2 (Type2)

According to
CSD.I.1863 and
CSD.I.1866.

Typ3(Type3)

According to
CSD.I.1861 and
CSD.I.1862.

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3.Variable technical factors that influence the manufacture
A heat affected zone arises when welding the end disc onto the casings prepared end of the
roller tube but its expansion remains comparatively limited. A tight connection is also made by
means of the process reliable welding, besides a sufficiently strong and mechanically stiff
connection of the components on account of the substance-to-substance bond.

Axial pressing with a tool must create a radial plastic deformation in the area of the roller
casings end in order to make a frictionally engaged and force-fitted connection as well as
in specific areas of the end disc. The different resiliencies of both components should be noted
in particular while doing so because they also influence the resulting jointing pressure and the
connections tightness as a result.

The roller casing is compressively loaded during the process, which basically leads to a
resilient axial reflectionthat recovers its form completely after the jointing process. However,
this compressive loading also creates a so-called bucklingstress in addition, whichwill be
substantially influenced by the slenderness ratio, i.e., the ratio between the length and cross-
section or the tubular cross-sections secondary moment of inertia, as well as by the clamping
conditions.The susceptibility to buckling basically increases as typically happens in the
case of a cylindrical tube as the length increases and the diameter decreases
disproportionately which is why one must assume that the limits when using this
manufacturing process depend upon principles.

If an eccentrically input force additionally arises in relation to the tubes axis, which is caused
by aligning the tool with the components or by displacing it during the process, then this
negative effect can be increased. The processing forces that arise during the axial jointing can
spread in specific areas on account of different frictional conditions or (dimensional) tolerances
of the components.

Apart from that, one must assume in the case of end discs with formed joints that the roller
casings divergence from straightness remains uninfluenced in the best case but that it could
increase too. On the other hand, one should not expect such an influence to occur in the case
that the end discs joints are substance-to-substance bonded by means of arc welding.

However, noticeably reducing the cyclical time could be very advantageous when axial
pressing is used to create the formed joint; for example, when using several tools for
manufacturing several rollers in one pressing stroke too.

The misalignment that is caused by faulty welding or deformation during the pressing would
be eliminated in the case that the requisite fitting forthe bearing seat in the idler shell (tubular
casing with jointed end disc) is done after the welding or pressing with reducing tension, e.g.,
on a finishing machine. However, if such machining is not planned or available, then the
resulting divergences arise from adding up the (dimensional) tolerances of the
components(tubular casing and end disc)as well as those arising from the acting forces and
achievable precision.The welding apparatus that is already being used and working on
both sidesallows the end discs to be positioned by mandrelsfor example and the tube can

4
be positioned by means of chucks (i.e., clamps)within the framework of systematic precision.

The contact between the component and the tool is made on the front, while the roller casing is
aligned between them in the case of formed joints (manufacture of the Prototype 2).It would be
possible to support the roller casing centrally in this case if required, in order to prevent the
susceptibility of slenderer rollers to buckling.

4.Summary and recommendation

It can be recognized on the basis of the previously conducted and evaluated tests, as well as
by considering both the different constructional versions (designs) of the prototypes and the
manufacturing influences,that a idler shell with substance-to-substance bonded and jointed
end discs which provide a greater intrinsic stiffness than can be expected from a deep-
drawn component is an important developmental step.

The company is already welding on the end discs, which is why one can assume that
extensive experience is available regarding managing the process and ensuring its reliability,
which can be further optimized and adapted with reference to the new design of roller.

The cast end discs that are utilized in the Type 1 constructional version could be optimized
regarding its structural stiffness, as well as its material properties and jointing characteristics, in
order to be developed into a reasonable solution from the technical and commercial aspects.
The requisite balancing quality can be achieved if necessary by using a better quality of tube
with a slighter divergence from straightness, in order to increase the performance when the
conveyor belt is running at high speed. However, further constructional or technical processing
measures, or both, could be considered too, which have the objective of reducing the resulting
imbalance by means of fitting the end discs with defined imbalance in order to partly compensate
for the imbalance in the raw material.Such a constructional element can be comparatively easy
to integrate into the currently constructed form, whereas the tubes imbalanced condition and
the radial alignment of the end discs ought to be recorded in the technical process immediately
before the welding.

Further technical processing tests would then be practical for the rollers according to the Type
2 constructional forms, or they would be required whenever the estimated increase of
efficiency allows a corresponding potential to be recognized through the shorter expected
cyclical time of the formed jointing process.