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5-Roll Idler Design Considerations

For CEMA Technical Meeting 21-24 June 2015
Based on a paper by Mark Elliott , Gary James, Gus McLennan, and Peter Molden presented at ContiTech State of the Art Technical Conference,
Melbourne, Australia March 9-11, 2015

Robin Steven
www.contitech.de
Benefits of 5-Roll Idlers

For wide belts => 1800 mm:

Shorter roll lengths

Easier handling underground

Less maintenance downtime

More capacity (up to 40%)

Improved loading at load point

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Issues with 5-Roll Idlers

Mis-tracking due to poor belt contact

Belt pinching due to wide gaps and high loads

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Proposed Categorization of Types

Basic types In-Line

Offset

Type 1 (proposed)
5 equal rolls

Type 2 (proposed)
3 short center, 2 long wing

Type 3 (proposed)
1 long center, 4 short wing

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Comparative Capacities of Proposed Types

Geometry CEMA Min Calculated CEMA %

Type 1 Type Edge Edge Loading
(mm) (mm) (%)
3-Roll -35Deg 122 159 89.90%
5-Roll -Type 1 122 162 87.80%
5-Roll - Type 2 122 182 83.40%
5-Roll - Type 3 122 148 91.40%
Based on:

1800mm wide structure

5500tph load capacity,

800kg/m3 material density ,

25 degree surcharge angle

5.2 m/s belt speed

2045mm equal idler length

22.5 degree inner wing angle

45.0 degree outer wing angle

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Natural Trough Shape of Conveyor Belts

› PN1260/4 4 mm x 4 mm

1500mm 1000mm 800mm

› ST7000 16 mm x 9 mm

900mm 2400mm

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Relative Idler to Belt Contact
Types 2 and 3
Contact Contact Contact Total
Geometry Length Length Length Contact
Type Center Inner Wing Outer Wing Length
(mm) (mm) (%) (%)
Type 2 140 80 250 44.00%
Type 3 50 25 155 23.00%

High Contact Length Type 2 Geometry Low Contact Length Type 3 Geometry

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Load Distribution

Most of material load is in center third of horizontal width.

Type 1 Type 2

Load focused on center roll bearings Load distributed on three roll bearings

Type 2 offers better load distribution, bearing life balance, and shaft sizing.

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Proposal for CEMA

1. CEMA consider a 3 Type classification for 5-roll idlers

based on arrangements of different idler roll lengths. I.e.
› Type 1 - 5 equal rolls
› Type 2 - 3 short center, 2 long wing rolls
› Type 3 - 1 long center, 4 short wing rolls
2. A preference for Type 2 as better capacity, belt contact,
tracking, and idler loads (based on lab & field experience).
3. Develop a recommendation for short roll to long roll length
ratios. Current experience suggests 0.60 to 0.70 for Type 2.

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Thank you
for your attention!

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