Quality	
  Assurance	
  Test	
  Methods	
  
Rela5ng	
  to	
  Conveyor	
  Idler	
  Rolls	
  and	
  
Prac5cal	
  Consequence...
Overview	
  
• 	
  Standard	
  Rolling	
  Resistance	
  and	
  extensions	
  
• 	
  Dust	
  and	
  Moisture	
  Ingress	
  ...
Idler	
  Rota5onal	
  Resistance	
  
• 	
  Represents	
  one	
  of	
  three	
  sta5c	
  mo5on	
  resistance	
  of	
  
conv...
Rim	
  Drag	
  Tes5ng	
  
• 	
  TBS	
  rim	
  drag	
  tes5ng	
  	
  
apparatus	
  
	
  
• 	
  Other	
  designs	
  exist.	
...
Rim	
  Drag	
  Tes5ng	
  
• 	
  Most	
  common	
  tes5ng	
  conducted	
  at	
  “standard	
  
condi5ons”	
  
• 25kg	
  Load...
Rim	
  Drag	
  Tes5ng	
  
• 	
  Important	
  to	
  consider	
  and	
  test	
  for	
  idler	
  behaviour	
  
under	
  all	
...
Rim	
  Drag	
  Tes5ng	
  
• 	
  Breakaway	
  Force	
  is	
  force	
  required	
  to	
  overcome	
  
sta5c	
  fric5on	
  in...
 Typical	
  Conveyor	
  Idler	
  Roll	
  Rota5onal	
  Resistance	
  
Profile	
  
• 	
  Force	
  as	
  measured	
  at	
  she...
Idler	
  Rota5onal	
  Resistance	
  –	
  Research	
  Data	
  
• 	
  Example	
  Data	
  Set	
  	
  
9
0	
  
50	
  
100	
  
...
Indenta5on	
  Rolling	
  Resistance	
  –	
  Idler	
  Diameter	
  
Influence	
  
• 	
  Generally	
  the	
  major	
  mo5on	
 ...
Indenta5on	
  Rolling	
  Resistance	
  –	
  Idler	
  Diameter	
  
Influence	
   11
Ø125 mm Idler Roll Ø150 mm Idler Roll
Ø1...
Dust	
  and	
  Moisture	
  Ingress	
  
• 	
  Standard	
  test	
  exists	
  as	
  South	
  African	
  standard.	
  
• Measu...
Dust	
  and	
  Moisture	
  Ingress	
  
• 	
  Dust	
  Ingress	
  rig	
  under	
  development	
  to	
  test	
  to	
  
SANS	
...
Total	
  Indicated	
  Run-­‐out	
  (TIR)	
  and	
  Maximum	
  
Indicated	
  Slope	
  (MIS)	
  
• 	
  TIR	
  is	
  a	
  mea...
TIR	
  and	
  MIS	
  
• 	
  Industry	
  specs	
  range	
  in	
  recommended	
  values.	
  
• 	
  Can	
  depend	
  on	
  id...
Conveyor	
  Idler	
  Roll	
  Noise	
  Tes5ng	
  
• 	
  Two	
  key	
  terms:	
  Self	
  Noise	
  and	
  Opera'ng	
  Noise	
...
Conveyor	
  Idler	
  Roll	
  Noise	
  Tes5ng	
  
• 	
  TBS	
  Opera5ng	
  Noise	
  rig.	
  As	
  close	
  to	
  realis5c	
...
Dynamic	
  Unbalance	
  
• 	
  A	
  test	
  to	
  determine	
  the	
  out-­‐of-­‐balance	
  mass	
  and	
  
loca5on	
  for...
Dynamic	
  Unbalance	
  
• 	
  Standard	
  test	
  speed	
  of	
  650rpm	
  however	
  other	
  
speeds	
  available	
  to...
Internal	
  Inspec5on	
  
• 	
  A	
  useful	
  tool	
  for	
  comparison	
  and	
  verifica5on	
  of	
  
internal	
  design...
Underground	
  Systems	
  –	
  FRAS	
  Tes5ng	
  
• 	
  Fire	
  Resistant	
  An5-­‐Sta5c	
  test	
  procedures	
  are	
  
...
Underground	
  Systems	
  –	
  FRAS	
  Tes5ng	
  
• 	
  Idler	
  related	
  current	
  test	
  range	
  
• Combus5on	
  Pr...
Conveyor	
  Idler	
  Roll	
  Selec5on	
  Criteria	
  
• 	
  Purpose	
  defines	
  selec5on	
  criteria.	
  
• 	
  Selec5on	...
New	
  Australian	
  Standard	
  
• 	
  Push	
  to	
  develop	
  a	
  standardised	
  ra5ng	
  system	
  for	
  
conveyor	...
QUESTIONS?	
  
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Daniel Ausling, TUNRA Bulk Solids, University of Newcastle, NSW, Quality Assurance Test Methods Relating to Conveyor Idler Rolls and Practical Consequences

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Daniel Ausling delivered the presentation at 2014 Bulk Materials Handling Conference.

The 11th annual Bulk Materials Handling Conference is an expert led forum focusing on the engineering behind the latest expansions and upgrades of bulk materials facilities. This conference will evaluate the latest engineering feats that are creating record levels of throughput whilst minimising downtime.

For more information about the event, please visit: http://www.informa.com.au/bulkmaterials14

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Daniel Ausling, TUNRA Bulk Solids, University of Newcastle, NSW, Quality Assurance Test Methods Relating to Conveyor Idler Rolls and Practical Consequences

  1. 1. Quality  Assurance  Test  Methods   Rela5ng  to  Conveyor  Idler  Rolls  and   Prac5cal  Consequences   Mr  Daniel  Ausling   Consul'ng  Engineer   TUNRA  Bulk  Solids in  associa5on  with   The  Centre  for  Bulk  Solids  &  Par5culate  Technologies   The  University  of  Newcastle      
  2. 2. Overview   •   Standard  Rolling  Resistance  and  extensions   •   Dust  and  Moisture  Ingress  Tes5ng   •   Total  Indicated  Run-­‐out  (TIR)   •   Maximum  Indicated  Slope  (MIS)   •   Noise  Tes5ng   •   Dynamic  Unbalance   •   Internal  inspec5on  for  comparison   •   Underground  Applica5ons  (FRAS  Tes5ng)   •   Changing  Selec5on  Criteria  for  varying  applica5ons   •   Push  for  a  new  Australian  Standard   2
  3. 3. Idler  Rota5onal  Resistance   •   Represents  one  of  three  sta5c  mo5on  resistance  of   conveyor  systems.   • Indenta5on  Rolling  Resistance   • Belt/Bulk  Material  Flexure   • Idler  Rota5onal  Resistance       •   Significance  in  total  mo5on  resistance  varies  from   minor  to  significant  depending  on  system  layout/ design.   •   Basic  measure  of  idler  rota5on  resistance  is   commonly  known  as  Rim  Drag  tes5ng.   3
  4. 4. Rim  Drag  Tes5ng   •   TBS  rim  drag  tes5ng     apparatus     •   Other  designs  exist.     4
  5. 5. Rim  Drag  Tes5ng   •   Most  common  tes5ng  conducted  at  “standard   condi5ons”   • 25kg  Load  (equivalent  to  no  load)   • 20-­‐25oC  Ambient  Temperature   • Variable  Speed  –  generally  tailored  for  specific  client   applica5on   •   Varia5on  in  behaviour  exists  as  test  condi5ons   change   • Varia5on  with  temperature   • Varia5on  with  rota5onal  speed   • Varia5on  with  load   5
  6. 6. Rim  Drag  Tes5ng   •   Important  to  consider  and  test  for  idler  behaviour   under  all  condi5ons  expected  to  be  experienced   during  idler  life5me.     •   Also  consider  transient  behaviour.   • Ini5al  behaviour  –  Breakaway  Force   • Ini5al  behaviour  –  Maximum  Start-­‐Up  Force   6
  7. 7. Rim  Drag  Tes5ng   •   Breakaway  Force  is  force  required  to  overcome   sta5c  fric5on  in  bearing  and  seal  arrangements  of   conveyor  idler  rolls.   •   Maximum  Start-­‐Up  Force  is  the  peak  rota5onal   resistance  during  the  transient  phase  of  the   conveyor  idler  roll.   7
  8. 8.  Typical  Conveyor  Idler  Roll  Rota5onal  Resistance   Profile   •   Force  as  measured  at  shell  radius   8
  9. 9. Idler  Rota5onal  Resistance  –  Research  Data   •   Example  Data  Set     9 0   50   100   150   200   250   300   350   G1   G2   G3   G4   Force  (%)   Idler  Group  Number   Rim  Drag   P1   Bh  
  10. 10. Indenta5on  Rolling  Resistance  –  Idler  Diameter   Influence   •   Generally  the  major  mo5on  resistance  component  in  a  conveyor   system.   •   Larger  diameter  idler  rolls  leads  to  a  lower  indenta5on  rolling   resistance.   •   In  appropriate  applica5ons  consider  use  of  larger  diameter  central  idler   in  a  troughing  configura5on  in  order  to  reduce  indenta5on  rolling   resistance  and  load  related  idler  component  fa5gue.   10 Approximate load distribution at the belt and idler roll interface Indentation rolling resistance distribution (bottom view)
  11. 11. Indenta5on  Rolling  Resistance  –  Idler  Diameter   Influence   11 Ø125 mm Idler Roll Ø150 mm Idler Roll Ø178 mm Idler Roll
  12. 12. Dust  and  Moisture  Ingress   •   Standard  test  exists  as  South  African  standard.   • Measure  of  how  much  and  how  quickly  fine  “dust”  and/ or  water  ingresses  into  a  seal  arrangement   •   Exis5ng  rig  provides  harder  test  for  idlers  by   inclining  the  idler  face  and  applying  a  normal  load.   12
  13. 13. Dust  and  Moisture  Ingress   •   Dust  Ingress  rig  under  development  to  test  to   SANS  and  harsher  condi5ons  as  required.   13
  14. 14. Total  Indicated  Run-­‐out  (TIR)  and  Maximum   Indicated  Slope  (MIS)   •   TIR  is  a  measure  of  the  concentricity  of  an  idler   shell   •   TIR  provides  a  general  indica5on  of  the   manufacturing  quality  of  a  conveyor  idler  roll   •   MIS  is  a  measure  of  concentricity  of  an  idler  shell   every  6  degrees.   •   MIS  has  been  shown  to  be  a  reliable  indicator  of   opera5ng  noise  of  a  conveyor  idler  roll.   •   Low  noise  idlers  are  generally  required  to  have  an   average  MIS  of  less  than  0.1mm.   14
  15. 15. TIR  and  MIS   •   Industry  specs  range  in  recommended  values.   •   Can  depend  on  idler  diameter,  length,  specifica5on   document  etc.   15 TIR MIS
  16. 16. Conveyor  Idler  Roll  Noise  Tes5ng   •   Two  key  terms:  Self  Noise  and  Opera'ng  Noise   • Self  Noise  is  a  measure  of  the  noise  created  by  the   interac5on  between  sealing  arrangement   components   •   Opera'ng  Noise  is  a  measure  of  self  noise  and  the   noise  created  due  to  idler  shell  and  conveyor  belt   interac5on.   •   Tes5ng  or  measures  for  self  noise  is  pointless  as  a   tool  for  predic5ng  noise  of  a  conveyor  system.   16
  17. 17. Conveyor  Idler  Roll  Noise  Tes5ng   •   TBS  Opera5ng  Noise  rig.  As  close  to  realis5c  tes5ng   as  possible.   •   Results  have  greater  relevance  however  are  only   directly  comparable  to  tes5ng  conducted  under   iden5cal  condi5ons.   •   Self  noise  tes5ng  can  be   useful  as  a  measure  of     incremental  improvement     of  successive  idler  designs.     17
  18. 18. Dynamic  Unbalance   •   A  test  to  determine  the  out-­‐of-­‐balance  mass  and   loca5on  for  each  end  of  the  conveyor  idler  roll.     18
  19. 19. Dynamic  Unbalance   •   Standard  test  speed  of  650rpm  however  other   speeds  available  to  suit  a  par5cular  conveyor  system   speed.   •   Another  general  indicator  of  manufacturing   quality.   •   Lower  out-­‐of-­‐balance  mass  will  reduce  stresses  on   idler  componentry  throughout  life  cycle.   •   Experience  suggests  out-­‐of-­‐balance  masses  of   <10g  represent  very  well  balanced  idlers.  With   masses  of  10g-­‐30g  represen5ng  a  well  balanced   general  purpose  conveyor  idler  roll.   19
  20. 20. Internal  Inspec5on   •   A  useful  tool  for  comparison  and  verifica5on  of   internal  design  specifica5ons.   •   Can  be  used  as  visual  aid  for  sealing  mechanism   comparison  for  a  supply  tender.   •   Can  be  used  as  idler  internal  componentry   verifica5on.   •   Can  be  used  as  inves5ga5ve  means  where  unusual   results  are  recorded  or  anomalies  are  found.   20
  21. 21. Underground  Systems  –  FRAS  Tes5ng   •   Fire  Resistant  An5-­‐Sta5c  test  procedures  are   required  for  any  non-­‐steel  idler  components   (MDG3608  –  NSW  Guideline).     •   Rag  of  tests  to  determine  opera5ng  performance   of  idlers  within  an  underground  coal  mining   environment.   21
  22. 22. Underground  Systems  –  FRAS  Tes5ng   •   Idler  related  current  test  range   • Combus5on  Propaga5on  Characteris5cs  (Gallery  Test)   • Ignitability  and  Maximum  Surface  Temperature  of  Idler   Subject  to  Fric5on.   • Ignitability  and  Flame  Propaga5on  Characteris5cs   (Finger  Burn  Test)   • Oxygen  Index   • Electrical  Resis5vity   • Toxicity  of  Products  of  Combus5on   22
  23. 23. Conveyor  Idler  Roll  Selec5on  Criteria   •   Purpose  defines  selec5on  criteria.   •   Selec5on  criteria  defines  scope  of  tes5ng.   •   Consider:   • Conveyor  system  layout   • Above  or  below  ground     • Environmental  extremes   • Noise  requirements   • Life5me  calcula5ons   • Costs   23
  24. 24. New  Australian  Standard   •   Push  to  develop  a  standardised  ra5ng  system  for   conveyor  idler  rolls.   •   Example  system  for  ranking  idlers  based  on   following  characteris5cs:   24   Very  High   High Good Standard Shell  and  Bearing   Fa>gue  Life A B C D Seal  Effec>veness A B C D Rim  Drag     A B C D Shell  Dimensional   Tolerance A B C D
  25. 25. QUESTIONS?  

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