Re: Flexible Idlers For Conveyor Belts
Fernando
A similar topic to this was discussed at length recently in ths formum. You can check the archives.
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Dear Mr. Croker
As I have indicated, I am not working at present, I have worked with this product for many years in the past, not now. It is not my interest to sell any product, but if someone is interested I can give information on various companies that manufacture similar this type of product or similar. Than you for your information, if in the future I am interested in selling, have not doubt I go in the way you have indicated.
Thanks and Regards.
Fernando Rubio ■
Re: Flexible Idlers For Conveyor Belts
Dear Sr. Rubio,
To be reputable, Your history of claims should be backed by testamonials of successful installations with accurate comparative data. Can you publish references on users who will back your claims?
1. increase belt life up to 2.8 times over conventional idler shapes with a similar covering - where?
2. larger(higher) conveyor belt carrying capacity - how much?
3. flexible idler usage in -35 deg C and +110 deg. C environment -where?
4. self aligning superiority - incline and decline belts say no since the flexible idler swings out of plane to the running axis of the belt thereby either increasing roll wear or mal-tracking the belt - in some cases the catenary idler had to be held by wires to keep the belt from mistracking - Obed Marsh Canada; Spring Creek Mine, Montana are good examples of catenary mistracking.
5. less spillage than conventional systems with same capacity, belt width, speed, trough angle, and ore density ( really same as point 2)
6. centers the load better than conventional idler assys - same as point 2 and 4.
7. resistant to abrasion or more so than conventinal idlers - not including point 4, how does the flexible idler either reduce abrasive action or use materials that are abrasiively superior
The flexible roller is similar to a multi-roll catenary idler. The catenary design does not support many of your claims. The catenary idler's chief benefit is derived by improving belt tracking when the structure is misaligned with the intended belt route. This consequence may appear to yield beltter belt centering and improved capacity. This only occurs when the structure deviates from its ideal route through earth settlement or when shiftable conveyors are used such as irregular terrain - this can be said for undergrounf coal mines.
THe flexible ilder roll assembly may have a niche in the scheme of conveyor design. I claim this niche is not as wide as you portray it. ■
Dear Mr. Nordel
First I beg your pardon as my English is not good.
All results I posted were obtained from the prestigious magazine: CANTERAS Y EXPLOTACIONES in March 1.979. As I have told, at present I am not working but I did with flexible idlers since 1.974.
In orer to effect a real, not a theoric work, tada have taken the following information from an important Spanish firm which had installed about 100 km. of conveyor belts. (It called EXPLOSIVOS RIO TINTO).
Since 1.971, and with qualified personnel, the above mentioned firm has been making different tests with wonderful results for the installation of a port ready to ore unload, in concret four conveyor belts: X-1, X2, X-3 and X-4
X-1: Flexible 296 Metallic 42 Total: 338
X-2: Flexible 64 Metallic 13 Total: 77
X-3: Flexible 20 Metallic 9 Total: 29
X-4: Flexible 45 Metallic 16 Total: 61
The installation started with the emplacement of 15 units of flexible idlers for belts of 1.000 mm mixed in transporter X-1 replacing the 17 conventional "metallic" stations and so on they reached the complet setting at the actual leevel of 87.5 by 100.
During this testing period, they appreciated the convenience of placing flexible idlers lightly separate a bit more than the conventional ones, so as to get a perfect close setting between the belt and rubber discs. Furthermore, it is convinient to place them from 1 to 1.5 centimeters higher.
By other way and to increase the belt capacity, the manufacturer advise to possibility of placing flexible idlers with different kneading through angle, therefore they moved the idlers with differente angles (25, 30, 35 and 40º) the did not reach the 45º angle, but the manufacturer says that in Europe people work with this kneading-dhrouhg perfectly well.
These are the advantages of the use of severan kneading-throug angle:
-Increase of transport capacity wighout chages in the structure and timbals. Sometimes this if factible also without chage the motor-reductor group which is ocassionali oversized.
-Speed drop with no lost of transport capacity, reducing damages and erosions.
On this installation chapter there are three points to take in consideration:
1.- It is possible to substitute partially, conventional rollers by flexible ones in installations already built, but it must be made in groups of 8 or 10 units as minimun.
2.- It is imperative to set the support in perpendicular to the belt as far as the idler working and belt centered in concerned.
3.- The supporting-box hook for ball bearings must be verified, it can turn freely into the roller support. That is to say, when connecting the reoller there must be a play enough and an appreciable oscilation when moving the roller by hand.
EXPENSES
As resume of all the above exposed, haben been extrapolated the test results and we habe applicated them to a belt of 100 m. wheel based type 4EP 160 1000/A. 60/30 with the following characteristics:
ROLLER DISTANCE BELT DURATION ROLLER DURATION
Metallic 1 m. 1.2 year 3 year
flexibles 1.2 m 3.3 year 5 year
ANALYSIS COMPARATIVE OF SOME POINTS:
COUNTENANCE CONVENTIONAL FLEXIBLE
IDLERS IDLERS
================ =========== ============
Roller by Station 6 2
Supports by Station 6 2
Stations of 100 m 100 88
Weigh by Station 60 kg 10.5 kg
(belt of 1000 mm)
Belt duration 1.5 year 4 years
Kind of rollers (as
per width of belt) many unic
Cleaning of belt To be done autocleaning
setting of idlers difficult easy and quick
line set of belt not centered autocenters
belt adaptability Poligonal uniformed
personal security detachments no detachments
belt performances expensives easiers
maintenance costs expensive cheap
saving in belts -------------- very important
RESISTANCE TO:
Bumps regular good
abrassion bad excellent
corrosion regular good
Their CONCLUSION:
In case of increasing of these prices, owing the energetic changes, we hope the same is absolutely covered by the following saving:
-Easy and quick installation
-Reducing in stock of spare parts
-reducing in watching personnel in installations
-Saving in cleaning personnel too
It seem to be a saving concept per TM. relating the transport in products such as:
- Chemical industries and fertilizers
- Siderurgical and founding
- Mining et.
All the above exposed shows a great expectations from manufacturers in all concerned with flexible rollers in actual markets.
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CANTERAS Y EXPLOTACIONES 30 MARCH 1.979
Dear Mr. Nordel I want to remember that I am not selling flexible idlers, I know more than 200 companies in Spain using this type of idlers as I worked in this market in the past.
There are more than 3 or 4 manufacturers in Europe, I am not talking aboun none.
I tried only to help, as I was helped in the past in this forum.
The use of flexible idlers is everyday higher in Europe, I worked in that way.
Best regards.
Fernando Rubio ■
Re: Flexible Idlers For Conveyor Belts
Dear Mr. Fernando Rubio,
Thanks for putting your opinion and information on the forum, about the flexible idlers. Presently, as per my observation, its use is quite less compared to conventional tubular idlers. The product can automatically become widespread, if it has numerous advantages as mentioned by you. It would have been better if you would have mentioned about the belt width & capacity for which it will have upper hand compared to the conventional idlers, as per your analysis.
Regards,
Ishwar G Mulani.
Author of Book : Engineering Science and Application Design for Belt Conveyors.
Advisor / Consultant for Bulk Material Handling System & Issues.
Email : parimul@pn2.vsnl.net.in
Tel.: 0091 (0)20 25882916 ■
Flexible Idlers
Dear Mr. Fernando Rubio,
Thanks for information about the flexible idlers.These idlers are seems to be very interesting Can you explain with the help of some sketchs working principle of these idlers.
A R SINGH ■
Re: Flexible Idlers
Originally posted by arsingh
Dear Mr. Fernando Rubio,
Thanks for information about the flexible idlers.These idlers are seems to be very interesting Can you explain with the help of some sketchs working principle of these idlers.
A R SINGH
■
Flexible Idlers
Dear Sirs,
Since 1996 I am not working this interesting product because personal problems. There are 2 manufacturers in Spain, I worked with CINTROL, S.L. in fact I am the owner of the trade mark, but I had problems with my associates.
They manufacture with a new system, but the results are not as good as in the past.
I can help you as I was the Commercial Director in the company, but I have some limitations as I hand phisical problems, now I am better, but I cannot dedicate full time to work. I try to help, economic matters are not important for me. Plese I beg your pardor for the retard in answering your post.
Best Regards.
Fernando Rubio ■
Flexible Idlers For Conveyor Belts
The application of conveyor belts in all kind of industries has reached in the last decades a considerable apogee, causing, by the way, the development and improvement of idlers, so long as their working is required.
So, different types of idlers have been created in function of their use.
In the line of short belts and width between r00 and 1400mm, flexible idlers are since 1966 in Spain. These cleverly rollers are made just to substitute the metallic roller triads as unic element, eliminating the lineshaft bearings.
The development of this product today is important, but will be very important in the next future. We base our afirmative opinion not only in the good quality of this material but inte fact that these idlers have been divulged in the american market mostly in the minning use, while in the european market quarry and chemical industries are their principal users. Threre will exists a lot of possibilities in both markets.
Flexible idlers are essentially consituted by an steel wire mandrel, made with 180 k/mm2 wires with a 6.600 kg. breaking strength.
This metallic core, proformed and wighout grease, gets vulcanised in hot with neopren, to addapt lately the rubber discs, with a 75 shore hardness, which are the adherent parts to the conveyor belt.
Belts are fixed to the supports through malleable cast iron hooks, where ball bearings are lodged. These are the results of the above mentioned characteristics:
1) Owing to its excellent flexibility, the idlers lays out by line itself forming a catenary, teherefore, this allows the material to converge just in the middle of the conveyor avoiding occasionally overflows.
2)The idlers lines the conveyor in all its length, avoiding as said before the overflows, very frequents for instance, because these rollers have a guide effect on the conveyor, owing to the adherance between this and the rubber wheels.
3)The belt addapts itself properly to the idlers, uniformily and without any fold.
4)Owing to its construction, rollers are resintaents to all kind of bumpings, abrassion, corrosion, heatiing and most of chemical agents, being recommended for delicate product transport installations.
PRACTICAL ADVANTAGES:
About a medium rate of5 effective years have been the result of controlled idlers. By the way, and following the notes from manufacturers, a permanent lubrucating is available for 8 years at about 20 working daily hours.
The employment of these idlers in the belt upside and downside, reduces the stok spares since there exist only a type of idlers for each belt width, in difference with those conventional ones with lot of varieties and classifications.
As the conveyor belts price/meter is very high, actually, any method to longer its life is very interesting. The use of flexible idlers is, therefore advisible owing to the following points:
- The idlers desing permits a perfect and uniform addaptation of the belt avoiding folds and frictions in the idler edges.
- Owing the great adherence between the belt and the rubber discs of flexible roller, the belt keeps perfectly centered, decreasing a great deal the working of the roller guides and autocentration stations which, generally are not in whishable condition.
-When a flexible idler does not work the broken part is quickly detected, just the contrary to the conventional ones. The can be "rasuring·" the downlet cover of the belt and even causing longitudinales outtings.
-The flexible idlers system does not hurt the conveyor belt since it absorbs its impacts, longing its life. For instance, it seems theorically justified the practical result gotten, referring to the reduce in the consumption of belts in a 1/3 medum in installations equiped eith flexible idlers, and always following with the above mentioned data, the lasting of belts have been increased in 2.8 times more.
SOME REASONS FOR INSTALLING FLEXIBLE IDLERS:
- Longer idler Life
- Larger conveying capacity
- Trough angles up to 45º
- Widths available form 400 to 1400 mm
- Withstands temperatures from -35 to 110ºC
- Self aligning
- No spillage
- Centers the load
- High resistance to shock, corrosion and abrassion.
I have been working with this product from 1974, there are various companies manufacturing this product, at present I am not working actively in the market, but due to the experience I am in disposition of helping you to find the best idlers at the best price. This forum allows me a few weeks ago to find interesting information, and it is an very interestin site to help, I would like to correspond to these friends that help me in the past.
Thanks and congratulations for this excellent forum.
Fernando Rubio
frykur@euskalnet.net ■