English (UK) 
简体中文 Do you know what is the most expensive part of the conveyor line? Not the motor is not the belt, but those densely packed rollers! They can eat up the cost of the whole machine 30%. today we nag understand: how to use the scientific arrangement of the rollers to ensure that the belt running stable, but also to cut down the cost of a large section.
First, the golden rule of the arrangement of the rollers
The rollers aren't just loaded, the spacing is wrong and you're straight up burned! Here's a foolproof formula for you:
- carrier section(Upper level of cargo): 1.0 to 1.2 metres for ordinary materials, and 0.8 metres for heavy goods such as ores.
- return leg(Lower level of empty belt): Easy, 2.4~3.0 metres is enough, with V-type rollers can also be pulled to 3.5 metres
- Extra meals at special locations::
- Splices must be onBuffer rollersThe distance between them is pressed to 0.3~0.5 metres, otherwise the material will not be able to top the belt when it is smashed down.
- The turn (convex arc section) rollers are encrypted to 0.6 metres to prevent the belt from flying out.
A mine has suffered a loss: the original return section according to the 3-metre swing, and later replaced with V-type rollers + 3.5 metres spacing, the total number of rollers directly cut down 18%, a year of maintenance costs save 120,000 --Put the spacing right and you can really pick up the money!
Second, the divine operation of quantity optimisation
Don't think that more rollers are better! I'll do the maths for you:
- One size up in diameter, one down in quantity::
Belt width ≥ 1400mm, 89mm small rollers replaced by 159mm big, the pitch can be relaxed from 1.2m to 1.5m, the rollers used to reduce 15%. large rollers more expensive? But life doubled ah! - Focused protection of abrasion-resistant areas::
High wear areas like coal mines, withCeramic RollerAlthough the unit price is higher 30%, the life expectancy is 3 times that of the regular rollers. Other places with ordinary models, the overall cost is rather lower. - Intelligent alignment to prevent runaway::
Insert 1 set for every 10 sets of plain rollersSelf-aligning rollers(slot angle of 35 ° kind), the probability of running straight down 40%. less a downtime to adjust, save time enough to buy dozens of rollers!
III. The wild card of cost control
Saving money is something that teachers can be too good at! Check out the real life examples:
- good old methods of repairing old buildings and making good use of new ones:: A fertiliser plant refurbished and reused the rollers removed from an old belt conveyor, replacing 150 in three months, with the cost of spare parts going from an average of 20,000 per month to almost zero -Don't throw away the scrapped bearings! A bit of used oil will last you half a year..
- Preventive Maintenance Trio::
- Monthly to the rollers to do a "physical examination": the rotation is not smooth immediately change, to avoid collateral damage to the belt
- For dusty areasLabyrinth sealing rollersLubrication intervals increased from 500 hours to 2000 hours.
- Buy RollerQuick Release StructureThe new model can be replaced in 30 minutes, saving 2 hours of labour time compared to traditional models.
- Standardisation of spare parts::
Roller type Diameter (mm) Applicable Scenarios Grooved forward tilting rollers 89/108 Primary Carrier Segment V-Comb Roller 133 Anti runout in return section Spring loaded buffer rollers 159 Dropout impact resistance Purchase price cut by 20% after harmonisation of models, stock types halved
IV. A guide for novices to avoid the pitfalls
You lose a year by stepping on one of these minefields:
⚠️Blind volume reductionA factory pulled the spacing of the bearing section to 1.5 metres, as a result, the belt drooped over the limit, the material fell off, and it cost 80,000 yuan more to make up the belt in three months.Remember the formula: droop ≤ 2% of bandwidth!
⚠️Neglect of dynamic loadsTransporting large ores without multiplying 1.2 times the impact factor, the roller bearings were scrapped in half a year, and the labour cost was doubled when re-purchasing...
⚠️environmental mismatch: Fertiliser plant with ordinary rollers, ammonia corrosion caused by the monthly damage rate of 15%, replace with304 stainless steel bearing housingDirectly doubling the life expectancy after
A final heartfelt word.Roller arrangement is like playing chess, sticking to the standard is not as good as being flexible. The engineer of the mine who made the return section 0.5 metres wide relied not only on calculation, but also on the site to grasp the characteristics of the material. Next time before the adjustment, go to the conveyor line squatting half an hour - to observe the belt shaking amplitude, listen to the bearing noise, feel the temperature of the rollers, these earthly methods than computer simulation is more reliable! After all, the savings can be real money ah.
