Design and Optimization of Conveyor Belt Rollers

Abstract

Belt conveyor systems play a crucial role in the continuous transportation of bulk materials across varying distances. However, ensuring the reliability of these systems remains a significant concern for operators due to the potential financial losses incurred from system downtime, which not only impacts revenue from material conveying but also disrupts subsequent material processing facilities. The reliability of a belt conveyor system is contingent upon its main components, including the belt, pulleys, drive unit, and idler rolls.

This master's thesis addresses the persistent replacement challenges of conveyor rollers at LKAB's Narvik facility, crucial for the iron ore transportation system. Through a comprehensive approach integrating engineering solutions, operational considerations, and user-oriented factors, the thesis aims to extend roller lifespan while optimizing the roller structure within practical constraints. Emphasizing elevating performance, lifespan, and serviceability, the project is divided into two main sections structural study of the idler set, and investigates existing challenges and identifies factors contributing to frequent replacements, laying the groundwork for developing effective solutions.

Furthermore, in the process of considering parameters like regulatory compliance, load specifications, temperature constraints, and environmental factors, the main focus is to enhance the design of the roller idler. This optimization involves considerations such as weight optimization, ease of maintenance, and environmental compatibility. Through analytical calculations, FEM static and modal analysis, and material selection, HDPE material was proposed the structural behaviour of the roller was studied. Around 30% mass reduction was achieved between the existing and the proposed models. Moreover, other aspects of idlers was studied, including bearing lifespan, and factors that affect their performance, where a solution of shielded bearing was proposed as a solution to prevent the accumulation of contaminants on bearing race. Further work chapter, outlined aspects requiring further investigation, particularly elaborating on the introduction of an alternative solution to address both vibration and contamination concerns.