Abstract
Improving the performance of idlers is paramount to the performance of the conveyor system in various industries since belt conveyors can be many kilometers in length and consequently there are a huge number of rollers in use. The key intention of this work is the development of a light-weight composite idler roller. Critical design considerations are strength-to-weight ratio and performance. Most importantly, the design must reduce the weight of the roller as compared to standard steel rollers. The final design provides a significant reduction in weight of about 47 % over that of traditional steel rollers of a similar size.
Highlights
The most commonly used material handling conveyor system is the belt conveyor [1]
Finite Element Analysis (FEA) has shown how the rollers will perform under the identified operational conditions; producing deformation, stress, and strain predictions
It was decided that the stub axle is to be made out of grade 431 stainless steel, this is because it provides a level corrosion resistance whilst having a reasonable tensile strength required for a shaft
Summary
The most commonly used material handling conveyor system is the belt conveyor [1]. The popularity of belt conveyors is owed to their capability of handling a wide variety of materials and their status as the least expensive powered conveyor. There are two types of idler rollers; carrier idlers that bear the load of the belt and material in the direction of transport, and the return idlers that support the 'empty' belt as it travels toward the tail pulley [2] The inclusion of these rollers increases the length of the conveyor and the weight of a product that a particular drive can handle [1]. The stub axle diameter could be decreased by using a different material, this would limit the rollers applications as grade 431 stainless steel provides a high tensile corrosion resistant option.
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