What are the key factors that determine the quality of conveyor idlers?

As a manufacturer or purchaser, it is very important to understand the quality factors of conveyor idlers to ensure the smooth operation of the production line. This article will introduce you to the key factors that affect the quality of conveyor idlers, so as to help you choose high-quality idlers, improve production efficiency and reduce maintenance costs.

1. Bearing quality

The service life of the conveyor idler mainly depends on the performance of the bearing and sealing. If the bearing and sealing performance of the conveyor idler is good, the service life of the conveyor idler will be greatly extended. The test results show that the friction resistance of the bearing accounts for about 1/4~1/8 of the rotation resistance of the conveyor idler. At present, the bearing models adopted by the idler are 6204KA, 6205KA, 6305KA, 6306KA and other rolling bearings.

The quality of the bearing determines the operating life. At present, a considerable number of manufacturers choose low-priced, low-quality bearings to assemble conveyor idlers, whose inner and outer diameter dimensional accuracy, hardness and clearance are not up to the technical standard requirements. Therefore, bearing brands with high precision and stable quality must be selected, such as SKF, FAG, NSK, etc.

2. Bearing housing quality

Poor machining accuracy of the inner hole of the bearing housing causes the bearing to move axially in the bearing housing, which is one of the reasons for damaging the idler conveyor idler.

For stamping bearing housings, 3 sets of stamping dies are used to complete the finished product. The quality of the stamping die determines the quality of the bearing housing, and also determines the life of the bearing, which is ultimately related to the life of the idler. Therefore, the conveyor idler manufacturer must strictly inspect the purchased bearing housings in accordance with the inspection procedures.

3. Welding accuracy of bearing housing and conveyor idler tube body

The welding quality between the bearing housing and the tube body is poor, causing axial separation or dust and water infiltration into the conveyor idler bearing, causing the conveyor idler to be damaged. Therefore, the welding accuracy and quality of the bearing housing and the tube body must be very important, and argon or CO2 gas shielded welding should be selected for welding. During the welding process, there are strict requirements for welding voltage, welding current, air flow, wire feeding speed, and tube body selection line speed. Verification and calibration are required for welding equipment, welding wire materials and welding operators.

4. Selection of grease

Improper selection of grease will cause bearing damage, which in turn will cause damage to the conveyor idler. The MT821-2006 coal industry standard clearly requires the selection of 3# lithium base grease, and all manufacturers must comply with it. Otherwise, the conveyor idler will be damaged after a few hours of operation.

The emphasis here is: For conveyor idler bearings operating at -25°C, a special type of low-temperature resistant aviation grease must be selected.

5. Conveyor idler assembly

Conveyor idler assembly must not only produce special process equipment, but also must be completed on the conveyor idler press. Only in this way can the axial specified assembly pressure of the bearing, seal assembly and retaining ring be controlled. It is also required that the constructor must pass the technical training examination and pass the assembly fitter to operate

As one of the core components of the conveyor system, the quality of the conveyor idler roller directly affects the stability and efficiency of the production line. By understanding the key quality factors of idlers, you can choose high-quality conveyor idlers with more confidence, ensure efficient and stable operation of the production line, and reduce maintenance costs. We hope this article has provided you with valuable information to help you make informed roller purchasing decisions.