FEATURE BEARINGS, SEALS & GASKETS


To withstand the harsh conditions faced within the mining industry, NKE Austria has


developed a new range of single-row deep


groove ball bearings that enhance the


Conveying the benefits of roller bearings


I


n applications such as those found in the mining industry, the components


specified need to not only withstand extreme conditions - ranging from vibration, to dust, weather extremes and more – but they need to offer the highest reliability. Conveyor belts, for example, are an essential piece of equipment within this industry; and roller bearings are some of the most important components for support and tensioning rollers in these conveyor belts. In order to meet the demands of this


industry, NKE Austria developed a range of single-row deep groove ball bearings. Designed to enable conveyor belt rollers to operate in extreme conditions such as transporting sand or rock in the mining industry, these bearings reduce downtime for the entire conveyor system, helping to ensure higher levels of productivity. Roberto Elgorriaga, director of


engineering for NKE in Latin America, works closely with OEMs in the mining industry. He explained: “Based on NKE’s extensive knowledge in mining applications and our collaboration with our customers to solve conveyor operating issues, we have developed a solution that helps reduce the failure problems inherent to the material transport process. The special NKE bearings for conveyor rollers allow a freer running-belt which reduces friction, thereby enabling the conveyor to operate with lower costs and greater reliability.”


A NEW DESIGN Support and tensioning rollers in a conveyor belt are used to shape the belt, serve as a support element for the material that is to be transported, and reduce resistance to movement. When the material is transported with minimal friction, the overall energy required for transportation is reduced, thereby also reducing the operating costs.


8 SEPTEMBER 2020 | DESIGN SOLUTIONS In an open-cast mining environment the


conveyor belt rollers are exposed to harsh operating conditions and environments: heavy loads, vibration and shaft deflection stresses, high rotating speeds, increasing load from external contamination, and demanding weather conditions such as high humidity, rain or snow. Furthermore, the tremendous pollution in the mining environment creates conditions for impurities to infiltrate the bearing point and can lead to premature equipment failure. This not only shortens the service life of the bearing, but it also has negative consequences for the performance and reliability of the other components of the conveyor system. The new bearings therefore have a


completely re-engineered design. To improve performance and withstand the harsh conditions faced, they have a special cage construction manufactured in a low-friction synthetic material, improved raceway geometry, adjusted radial internal clearance, special low friction seals and a lubricant suitable for use in a wide operating temperature range. Thanks to the design, the bearings are


capable of sustaining operating demands under which conventional bearings may fail. When contaminants infiltrate the interior of bearings, standard versions often suffer from a sudden, uncontrolled, rise in temperature. This increased temperature impairs the positive lubricant properties, destroys the steel cages and ultimately causes bearings to seize up. When bearings seize, they then block the rollers, the conveyor belt is damaged, and the risk of fire increases significantly. NKE roller bearings for conveyor belt


rollers maintain their function even under heavy loads and without increased frictional torque. Capable of withstanding the requirements faced by conveyor belt rollers helps to reduce the risk of fire, prolongs the service life of the


Conveyor belts transporting rock in mining applications have to withstand the harshest of conditions


performance of conveyor belt rollers


roller bearings in the harshest conditions, reduces energy consumption, increases the conveyor system’s reliability and lowers overall operating costs. Commenting on the development of


these bearings, Michael Rössl, applications engineer with NKE in Steyr, said: “NKE has tremendous expertise in mining applications. This is an extremely complex engineering achievement in response to the wish expressed by many customers for improving the functional capability of conveyor belts. Our new roller bearing system will help to substantially lower outage times in material transportation.” The new bearing design ensures


frictionless rolling processes, thus helping to minimise friction throughout the entire system, and makes it possible to run the transport system more cost-efficiently and more reliably, the company explains. Rössl added: “In order to achieve the


best possible results, measures to prevent particulate contaminants from penetrating the bearing and the bearing interior as completely as possible must begin with the plant developer or the plant operator installing external sealing systems.”


NKE Austria


Right: NKE’s bearing concept for conveyor belt rollers


www.nke.at


Conveyor belt rollers in a conveyor belt system


/ DESIGNSOLUTIONS


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