TECHNICAL INFORMATION

FAG Bearings India Limited Page 1 / 4

TECHNICAL INFORMATION

Conveyor Belt Idlers

In many branches of industry, belt conveyors are used for the transport of bulk materials. The
endless belts run on idlers. The conveyor lines can extend over several kilometers, so
considerable importance is attached to economic construction, including the bearing
arrangements (see figure below).

The idlers for an idler station of a belt conveyor for bulk material are arranged to provide a
troughed belt profile, as shown below.

Rigid arrangement Garland arrangement

The outer idlers are mounted at a defined trough angle in the framework. Rigid arrangement is
used for smaller, rigidly troughed belt conveyors. The garland arrangements are preferred for the
large conveying plants in brown coal opencast mines. The idlers of a garland are linked to each
other by flexible joints. A chain link (flat or round) or a similar component may be used as a joint
between idlers. Due to their flexibility the garlands absorb shocks caused by transportation of
coarse materials. Garlands with a damaged or seized idler can be lowered without the need for
closing down the entire conveyor belt.
The following data is given for the design of idler arrangements in a belt conveyor used for open-
air transportation of bulk materials. The idlers are arranged as garlands.
Capacity Im = 2800 t/h
Belt speed v = 3.7 m/s
Belt width B = 1000 mm
Trough angle g= 20º
Idler diameter D = 108 mm
Axle diameter d = 20 mm
Idler length l = 380 mm
Distance between two idler lR= 1.2 m
Belt mass GG= 25kg/m
Mass of rotating parts of one idler GR = 11kg

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TECHNICAL INFORMATION

The bearing supporting the idlers are usually arranged as an internal or hub mounting, i.e. hubs
and outer rings rotate about the stationary axle, see figure below.

The idler axle diameter is determined by strength considerations. Care must be taken that the
axle inclination at the bearing locations due to the axle deflection under load does not exceed a
certain amount. This inclination produces an angular misalignment between the inner ring and
the outer ring of the bearing.
Bearing arrangement and fits
Since the inner rings are under point load, they can be loose fit on the axle. The axle is
machined to h6 or js6. Loose fits may lead to inner ring creep on the axle, especially at high belt
speeds. A small axle shoulder and the labyrinth ring secured on the axle by a snap ring limit the
axial displacement of the inner rings on their seats. Since the outer rings are under
circumferential load, they are tightly fitted in the idler hub (machined to M7).
Bearing loads
To determine the bearing loads the idler load FR is calculated according to VDI recommendation
2341 from the given data. For the trough angle of 20º, the horizontal center idler carries
approximately 60% of the load of an idler station. The load on this center idler FR = 1.76kN. Each
bearing therefore carries a radial load FR = 0.88 kN. The idler speed n = 650 min-1 is obtained
from the idler diameter D and the belt speed v. According to the rolling bearing catalogue the
relevant speed factor fn = 0.372, so fL value can be calculated;
fL = fn C/P = 0.372 x 13.6 / 0.88 = 5.37 corresponding to Lh = 90,000 hrs (for FAG 548816A)
Since from the bearing catalogue fL stipulated value for conveyor idler of 2.5 to 3.5, the bearing
arrangement is amply dimensioned.
Attainable life
At the beginning of their life, idler bearings have the highest cleanliness standards. During the
course of operation, contaminants collect in the lubricant.
In belt conveyor idlers, the attainable life and the lubricant service life are mainly reduced by
contamination of the grease during operation, so particular importance is attributed to the
sealing.
Sealing
As a rule, conveyor belt idlers operate under very unfavorable environmental conditions.
Conveyors are subjected to severe contamination. In opencast mines, the belt conveyors are
additionally exposed to the influences of the weather. Operating conditions are more favorable

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TECHNICAL INFORMATION

under cover, or when there are tolerable levels of moisture and contamination during material
transport.
Idler bearing are usually loaded moderately. Experience has shown that bearings fail from
wear and not fatigue, because even under relatively favorable environmental conditions, dirt
enters the bearing in the course of time. Deep groove ball bearings are normally used these
days.
The service life of the idler bearings depends mainly on the sealing. The sealing of idlers must
prevent the ingress of contamination and moisture into the bearing space and retain the lubricant
in the bearings. So the sealing of the idlers must be adapted to the operating and environmental
conditions of the conveyor belts.
Lubrication
As a rule sealing spaces are lubricated with lithium soap base grease of consistency class 2 or 2
with anticorrosion additives.
FAG Seize Resistance Bearing
FAG India seize resistance bearing are made from ball bearing steel with special internal design
having larger ball size to allow the balls to roll over the contaminants, crushing them in the
process and throwing them out. Thus, enabling the bearings to function even under moderate
speeds. With larger ball size enveloped in internationally established inner ring bores and
outside diameters, the bearing capacity is increased and hence the actual life expectancy
improves. Also, land width on either side of the raceway is reduced ensuring no build up of
abrasives take place around the ball set.
A flexible plastic cage with prong type extension acts like wipers between each pockets, which
prevent build-up of contaminants around the ball set.
FAG India has the following seize resistance bearing under their production program,

Dynamic Static
Bore Outer
Bearing Width Load Load
size Diameter
Number (mm) Rating Rating
(mm) (mm)
(kN) (kN)

548816A 20.00 47.00 12.00 13.60 6.50

536064 25.00 52.00 12.00 15.30 8.00

808325 30.00 62.00 14.00 20.70 11.20

548429 25.00 62.00 15.00 22.40 11.40

548817 30.00 72.00 17.00 29.00 15.30

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