The main factors affecting the service life of conveyor idlers

The main factors affecting the service life of conveyor conveyor idlers

The conveyor idler operation needs to be flexible, reducing the friction between the conveyor belt and the conveyor idler plays a key role in the life of the conveyor belt, which accounts for more than 25% of the total cost of the conveyor. Although the conveyor idler is a small part in the belt conveyor and the structure is not complicated, it is not easy to manufacture a good quality conveyor idler.Carrying conveyor idlers are an important part of belt conveyors, with many types and large quantities. It accounts for 35% of the total cost of a belt conveyor and bears more than 70% of the resistance, so the quality of the conveyor idler is particularly important.

Factors affecting the service life of conveyor conveyor idlers
(1) Poor coaxiality of the conveyor idler shaft: Because the dimensional accuracy of the cold-drawn optical shaft is unstable due to factors such as the wear of the tire during production, and it is easy to form bending during transportation, the coaxiality of the conveyor idler shaft is poor. , the bearing gap installed at both ends of the conveyor idler shaft is uneven, and then the rotation resistance of the conveyor idler increases, which affects the service life of the conveyor belt conveyor idler.

(2) The source of affecting the service life of the conveyor idler is its internal structure, because the conveyor idler is generally used in poor conditions, with a reasonable structure and the service life of the sealed conveyor idler is usually only about 15,000 hours.

(3) When stamping, the bearing house is not round or the end face at the junction with the shell is unequal, etc., it is easy to form different axes of the two bearing house after welding with the shell, resulting in the reduction of the conveyor idler bearing clearance and the increase of the rotation resistance, and  conveyor idler rotating is insensitive.

(4) Poor quality of the conveyor idler bearing: The quality of the bearing used in the conveyor idler greatly affects its service life. Poor quality bearings have lower load-carrying capacity and are more prone to failure, resulting in frequent replacements and increased maintenance costs. In contrast, high-quality bearings have a longer service life and can withstand heavy loads, reducing the need for frequent replacements.

(5) Environmental factors: Conveyor idlers are often used in harsh environments such as dusty, wet, and corrosive conditions, which can cause damage to the conveyor idler and affect its service life. Dust and moisture can cause corrosion, wear, and tear on the conveyor idler, leading to a reduction in its lifespan.

(6) Installation quality: Proper installation of the conveyor idler is essential for its optimal performance and extended service life. Poor installation, such as misalignment or over-tightening, can cause premature wear and tear, leading to early failure.

According to industry standards, the average service life of a conveyor idler is typically around 30,000 hours. However, the actual service life can vary significantly depending on the factors mentioned above. For instance, a study conducted by a Chinese mining company found that the service life of conveyor idlers installed in harsh environments was only 15,000 hours, while those installed in less severe conditions had a service life of up to 60,000 hours. Similarly, a study conducted in Australia found that conveyor idlers using high-quality bearings had a service life of up to 100,000 hours, while those with lower quality bearings had a service life of around 50,000 hours.