Conveyor Rollers, Idler Frames & Underground Structure · Idler loading geometry is based on the . Conveyor Equipment Manufacturers Association (CEMA) standard coupled with a numerical

Technical Overview

Conveyor Rollers, Idler Frames & Underground Structure

Fenner Dunlop design and manufacture a range of rollers to suit every application.

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Rol

lers

CLASSIC

The best engineered conveyor products for the materials handling industry.

Fenner Dunlop stock an extensive and ever growing range of rollers for both surface and underground applications. Our rollers are generally interchangeable with many existing conveyors in the Australian market. Fenner Dunlop design and quality assurance are of the highest standard to provide confidence to the client that the product is exactly fit for purpose. We stock steel rollers subject to specific requirements.Fenner Dunlop Rollers have become the preferred roller of choice for major projects within the Australian and International markets.

Rollers to suit every application;

Steel trough carry rollersSteel return rollersRubber impact rollersWeigh rollersSuspended rollersRubber disc return rollersRubber lagged rollers

Stock available and ready for useFenner Dunlop stock approximately 25,000 rollers in Brisbane with various satellite stores around Australia also stocking popular sizes. All our rollers are caged undercover and ready for immediate use.

CLASSIC HD

CLASSIC PLUS

CLASSIC

Optimising the component design Fenner Dunlop utilise custom developed idler design software to maximise the accuracy and speed of product design and manufacturing.

3D CAD software and Finite-Element Analysis (FEA) packages allow us to optimise the component design and selection process whilst maintaining flexibility.

R&D & TestingFenner Dunlops’ in-house testing facilities allow for continual product development and peace-of-mind operation, ensuring that our rollers perform to meet client’s requirements and expectations.

Loading geometryIdler loading geometry is based on the Conveyor Equipment Manufacturers Association (CEMA) standard coupled with a numerical analysis of the burden geometry for the highest accuracy loading distribution.

DesignFenner Dunlop Rollers apply a comprehensive approach to the roller design life factoring in bearing fatigue life, grease life and shell wear where possible to help predict a roller’s life.

BearingsDeflection criteria are monitored to ensure the design exceeds the minimum recommendations. Specific lubrication grease is selected to improve the life expectations and shielded bearings are always used to assist in the prevention of contaminant ingress.

ShaftBoth bearing deflection criteria under running conditions and yield strength under flooded conditions are considered during the design phase, using stepped shafts where appropriate to control both values.

ShellFenner Dunlop Rollers specify tight tolerancing on the raw shell materials to provide superior standard TIR and balance properties. Shell thicknesses are varied depending on the site and running conditions to meet client requirements.

HousingSeveral bearing housing options are available depending on the roller series requested ranging from light-medium duty pressed housings through to extra heavy duty solid housings.

ROLLER SERIES GUIDE

BEARING SIZE CLASSIC CLASSIC PLUS CLASSIC HD

6204 • •

6304 • •

6205 • •

6305 • •

6306 • • •

6307 • • •

6308 • •

6309 • •

6310 • •

6311 • •

6312 • •

Quality rollers built to last

CLASSIC CLASSIC PLUS CLASSIC HD

ROLLER SHELL

MaterialGB/T 13793 - Q235B(Grade PD.C, PT.B, PS.C)

GB/T 13793 – Q345B(Grade PD.C, PT.B, PS.C)

GB/T 13793 – Q345B(Grade PD.C, PT.B, PS.C)

Shell Thickness 4mm 4mm + 6mm +

TIR Avg Trough Roller = 0.50mm Avg Trough Roller = 0.50mm Avg Trough Roller = 0.15mm

ROLLER SHAFT

Material GB/T 905 – Q235 GB/T 905 – Q235 GB/T 905 – Q345

Type Plain Stepped Stepped

Bearing Seat Tolerance h8 h6 h6

ROLLER BEARING HOUSING

Material SPCC SPHE Q345

Type Pressed Pressed Cast/Machined

Fit Interference + Weld Interference + Weld Interference + Weld

BEARING

Manufacturer LYC, NSK NSK NSK, FAG, SKF

Sealing 2Z 2Z, 2RS 2Z, 2RS

TypeDeep Groove Ball Bearing, C3 Clearance

Deep Groove Ball Bearing, C3 Clearance

Deep Groove Ball Bearing, C3/C4 Clearance

Lubrication Sealed for Life, ENS equivalent Sealed for Life, ENS Sealed for Life, ENS

SEALING

Material Fire Resistant Nylon Fire Resistant Nylon Fire Resistant Nylon

Type Seal Cleaning LabyrinthSeal Cleaning Labyrinth inc rear seal

Seal Cleaning Labyrinth inc rear seal

Grease HP-R Blue HP-R Blue HP-R Blue

SURFACE PROTECTION

Type 2 Coat Paint System 2 Coat Paint System 2 Coat Paint System

Coating Thickness 40μm 40μm 70μm

PERFORMANCE CHARACTERISTICS

Running Friction 2N* 2N* 2N*

Balance Quality G40 G40 G16

Warranty** 12 months 18 months 24 months

*Based on 152 Dia Roller, 6306 NSK Bearing with Self Cleaning Labyrinth Seal running at 750rpm. Running Frictionmeasured at the face as per SANS1313-1. ** Subject to LECS Warranty Terms and Conditions

1 High accuracy Q235 ERW 4mm tube with internal seam burr removed to improve balance

2 SPCC deep drawn interference fit housing, matched machine to tube recess for high accuracy concentricity

3 Double Shielded C3 sealed for life deep groove ball bearing

4 Tertiary Multi Labyrinth FRAS main seal HP-R grease filled

5 Secondary Self draining centrifugal chamber + rear containment cavity

6 Primary ingress prevention cap

7 Rear seal to retain grease and keep contamination out

8 Class 8 precision ground cold drawn bar

Classic All-purpose economy roller

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CLASSICMATERIAL SPECIFICATIONS DESCRIPTION

ROLLER SHELL

MaterialGB/T 13793 - Q235B

(Grade PD.C, PT.B, PS.C)

The Classic Roller shell consists of a 4mm shell compared to the 3.5mm industry standard shell thickness. Unlike the A.S steel specifications we’re able to specify a tolerance for each parameter so the roller quality is matched to the client’s requirements. This shell uses:

• High Accuracy (PD.C) Diameter tolerance for consistent TIR• Medium/high accuracy (PT.B) shell thickness tolerance• High accuracy (PS.C) shell straightness tolerance.

All these tolerances meet or exceed AS1450 requirements. We believe by specifying each individual tolerance we can supply a more consistent roller and have better control over our quality. (refer material specifications comparison sheet)

Shell Thickness 4mm

TIR Avg Trough Roller = 0.50mm

ROLLER SHAFT

Material GB/T 905 – Q235 The Shaft material is of Grade 8 Q235 precision ground cold drawn bar to GB/T905

Type Plain

Bearing Seat Tol. h8


Material SPCC The bearing housing is SPCC pressed steel, 3.5mm in thickness. The housing has an interference fit into the shell to provide accurate concentricity, It’s then robotically fillet welded to completely seal and lock the housing in place. Welds are not in contact with the belt at any time, maximising belt life and roller fatigue life.

Type Pressed

Fit Interference + Weld

BEARING

Manufacturer LYC, NSK Have your choice of NSK or more economical LYC brand bearing in your roller. Both options consist of a double steel shield deep groove ball bearing with C3 clearance. Fenner Dunlop prefer ENS grease in our NSK bearings for the best performance under varying local temperatures especially in the hot Australian climate.

Sealing 2Z

Type Deep Groove Ball Bearing, C3 Clearance

Lubrication Sealed for Life, ENS equivalent

SEALING

Material Fire Resistant Nylon Our Rollers use fire resistant self-cleaning labyrinth seals. Our seals consist of a 4 part design comprising of:

• A primary steel outer seal that utilizes centrifugal force to expel containments at the face of the roller, this is extremely effective once the roller is at speed and can self-drain water at a 0-45 degree angle.

• A secondary steel containment chamber• A tertiary grease filled multi labyrinth seal chosen to minimise running friction

whilst still preventing the ingress of contaminants.• Finally there is a back seal on the opposite side of the bearing to stop reverse

contamination of the bearing.

Both the front and rear sealing are filled with HP-R type grease which provides a high drop point of 250 degrees whilst providing optimal viscosity for best ingress protection, low running friction and low energy consumption.

Type Self Cleaning Labyrinth

Grease HP-R Blue

SURFACE PROTECTION

Type 2 Coat Paint System The standard roller comes with a 2 coat paint system which is applied to the face, bearing housing and shaft ends providing storage protection and anti-rust properties whilst in service.Coating Thickness 40μm


Running Friction 2N*

Balance Quality G40

Warranty** 12 months

* Based on 152 Dia Roller, 6306 NSK Bearing with Self Cleaning Labyrinth Seal running at 750rpm. Running Friction measured at the face as per SANS1313-1 ** Subject to Warranty Terms and Conditions

1 High accuracy Q345 ERW 4mm + tube with internal seam burr removed to improve balance

2 SPHE deep drawn interference fit housing, matched machine to tube recess for high accuracy concentricity

3 Double Shielded (Steel or Rubber) NSK C3 sealed for life deep groove ball bearing




7 Precision machined bearing seat & shoulder for optimal bearing alignment and extended life



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Classic Plus High quality roller - built to last

CLASSIC PLUSMATERIAL SPECIFICATIONS DESCRIPTION

ROLLER SHELL

MaterialGB/T 13793 - Q345B


The Classic Plus Roller shell consists of a 4mm shell compared to the 3.5mm industry standard shell thickness. Unlike the A.S steel specifications we’re able to specify a tolerance for each parameter so the roller quality is matched to the client’s requirements. This shell uses:

• High Accuracy (PD.C) Diameter tolerance for consistent TIR• Medium/high accuracy (PT.B) shell thickness tolerance• High accuracy (PS.C) shell straightness tolerance.

All these tolerances meet or exceed AS1450 requirements. We believe by specifying each individual tolerance we can supply a more consistent roller and have better control over our quality. (refer material specifications comparison sheet)

Shell Thickness 4mm+


ROLLER SHAFT

Material GB/T 905 – Q235 The Shaft material is of Grade 8 Q235 precision ground cold drawn bar to GB/T905. The shaft is precision machined to house the bearing with a stepped shoulder for increased bearing support.

Type Plain



Material SPHE The bearing housing is SPHE pressed steel, 3.5mm in thickness. The housing has an interference fit into the shell to provide accurate concentricity, It’s then robotically fillet welded to completely seal and lock the housing in place.Welds are not in contact with the belt at any time, maximising belt life and roller fatigue life.

Type Pressed


BEARING

Manufacturer NSK NSK deep groove ball bearing with C3 clearance are used in all Classic Plus Rollers and utilize 2zz or 2rs sealing depending on the application. Fenner Dunlop exclusively use ENS grease in our NSK bearings for the best performance under varying local temperatures especially in the hot Australian climate.

Sealing 2Z

Type Deep Groove Ball Bearing, C3 Clearance

Lubrication Sealed for Life, ENS equivalent

SEALING

Material Fire Resistant Nylon Our Rollers use fire resistant self-cleaning labyrinth seals. Our seals consist of a 4 part design comprising of:• A primary steel outer seal that utilizes centrifugal force to expel containments at

the face of the roller, this is extremely effective once the roller is at speed and can self-drain water at a 0-45 degree angle.


whilst still preventing the ingress of contaminants.• Finally there is a back seal on the opposite side of the bearing to stop reversecontamination of the bearing caused by condensation.Both the front and rear sealing are filled with HP-R type grease which provides a high drop point of 250 degrees whilst providing optimal viscosity for best ingress protection, low running friction and low energy consumption.


Grease HP-R Blue

SURFACE PROTECTION

Type 2 Coat Paint System The standard roller comes with a 2 coat paint system which is applied to the face, bearing housing and shaft ends providing storage protection and anti-rust properties whilst in service.Coating Thickness 40μm


Running Friction 2N*

Balance Quality G40


* Based on 152 Dia Roller, 6306 NSK Bearing with Self Cleaning Labyrinth Seal running at 750rpm. Running Friction measured at the face as per SANS1313-1 ** Subject to Warranty Terms and Conditions

1 High accuracy Q345 ERW 6mm + tube with internal seam burr removed to improve balance

2 Precision machined Q345 billet housing withstands high loads and guarantees the tightest tolerances for optimal bearing clearances under extreme dynamic loading

3 Double Shielded (Steel or Rubber) NSK, FAG or SKF C3/C4 sealed for life deep groove ball bearing




7 Precision machined bearing seat & shoulder for optimal bearing alignment and extended life



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Classic HDHigh quality roller - built to last

CLASSIC HDMATERIAL SPECIFICATIONS DESCRIPTION

ROLLER SHELL

MaterialGB/T 13793 – Q345B


The Heavy Duty Roller shell consists of a 6mm shell compared to the 3.5mm industry standard shell thickness. Unlike the A.S steel specifications we’re able to specify a tolerance for each parameter so the roller quality is matched to the client’s requirements. This shell uses:• High Accuracy (PD.C) Diameter tolerance for consistent TIR• Medium/high accuracy (PT.B) shell thickness tolerance• High accuracy (PS.C) shell straightness tolerance.All these tolerances meet or exceed AS1450 requirements. We believe by specifying each individual tolerance we can supply a more consistent roller and have better control over our quality. (refer material specifications comparison sheet)

Shell Thickness 6mm +


ROLLER SHAFT

Material GB/T 905 – Q345 The Shaft material is of Grade 8 Q345 precision ground cold drawn bar to GB/T905. The shaft is precision machined to house the bearing with a stepped shoulder for increased bearing support.

Type Stepped



Material Q345 Bearing housings are made from cast Q345 and precision machined for best fit. Housings are specifically designed for each application to maximise roller life and durability whilst minimizing bearing deflection and fatigue. The housing has an interference fit into the shell to provide accurate concentricity, It’s then robotically fillet welded to completely seal and lock the housing in place. Welds are not in contact with the belt at any time, maximising belt life and roller fatigue life.

Type Cast/Machined


BEARING

Manufacturer NSK, FAG, SKF NSK deep groove ball bearing with C3 or C4 clearance are used in all Classic HD rollers and utilize 2zz or 2rs sealing depending on the application. FAG & SKF bearings are also available upon request. Fenner Dunlop exclusively use ENS grease in our NSK bearings for the best performance under varying local temperatures especially in the hot Australian climate.

Sealing 2Z, 2RS

TypeDeep Groove Ball Bearing,

C3/C4 Clearance

Lubrication Sealed for Life ENS

SEALING

Material Fire Resistant Nylon Our Rollers use fire resistant self-cleaning labyrinth seals. Our seals consist of a 4 part design comprising of:• A primary steel outer seal that utilizes centrifugal force to expel containments at

the face of the roller, this is extremely effective once the roller is at speed and can self-drain water at a 0-45 degree angle.


whilst still preventing the ingress of contaminants.• Finally there is a back seal on the opposite side of the bearing to stop reverse

contamination of the bearing caused by condensation.Both the front and rear sealing are filled with HP-R type grease which provides a high drop point of 250 degree’s whilst providing optimal viscosity for best ingress protection, low running friction and low energy consumption.


Grease HP-R Blue

SURFACE PROTECTION

Type 2 coat paint system The standard roller comes with a 2 coat paint system which is applied to the face, bearing housing and shaft ends providing storage protection and anti-rust properties whilst in service.Coating Thickness 70μm


Running Friction 2N* All premium HD Rollers come dynamically balanced to reduce noise and vibration and are 100% quality checked at final assembly to ensure reliable and optimal performance.Balance Quality G16


*Based on 152 Dia Roller, 6306 NSK Bearing with Self Cleaning Labyrinth Seal running at 750rpm. Running Friction measured at the face as per SANS1313-1** Subject to Warranty Terms and Conditions.

ROLLER TUBE MATERIAL COMPARISON:AS1450 vs GB/T 13793

AS1450Steel Tubes for

Mechanical Purposes

GB/T 13793Steel Tubes with a Longitudinal

Electric (Resistance) Weld(PD.C, PT.B, PS.C)

Document Scope Specification for carbon and carbon-manganese steel tubes (incl. round), hot and cold forming for mechanical applications

Specification for general-purposehigh frequency ERW tube withOD < 630mm

GEOMETRIC PROPERTIES

Straightness 1.67mm in 1000mm 0.5mm in 1000mm

Outer-Diameter Variation 100 to 125 OD : ± 0.5mm125 to 150 OD : ± 0.6mm150 to 175 OD: ± 0.7mm> 175 OD: ± 1%

80 to 114.3 OD : ± 0.4mm114.3 to 219.1 OD : ± 0.6mm

Wall Thickness ± 10% > 3.2 to 3.8mm : ± 0.2mm> 3.8 to 4.0mm : ± 0.22mm> 4.0 to 5.5mm : ± 7.5%> 5.5 : ± 10%

Roundness Not controlled/specified < 50 % of OD variation tolerance

ERW burr Not controlled/specified - 0.05 to + 0.20 mm

Mechanical Properties

Yield StrengthC250 or H250 : 250 MPaC350 or H350 : 350 MPa

Q235B : 235 MPaQ345B : 345 MPa

UTSC250 or H250 : 350 MPaC350 or H350 : 450 MPa

Q235B : 375 MPaQ345B : 470 MPa

Elongation before FractureC250 or H250 : 22 %C350 or H350 : 20 %

Q235B : 20 %Q345B : 18 %

ROLLER SHAFT MATERIAL COMPARISON:AS1443 vs GB/T 905

AS1443Carbon and carbon-manganese

steel – Cold finished bars

GB/T 905Dimension, shape, weight and

tolerance for cold-drawn round,square and hexagonal steels

Document Scope Specification for cold-finished carbon and carbon-manganese steel bars (incl. round) for general engineering purposes

Specification for the dimension,shape, weight and tolerance forcold-drawn round, square andhexagonal steels from 3 to 80mm

GEOMETRIC PROPERTIES

Straightness 2mm in 1000mm> 25 to 50mm : 0.75mm in 1000mm> 50 to 80mm : 0.5mm in 1000mm

Diameter Variation h8 h8

Roundness< 50 % of diametervariation tolerance

< 50 % of diametervariation tolerance

Mechanical Properties

Yield Strength M1020 : 340 MPaQ235B : 235 MPaQ345B : 345 MPa

UTS M1020 : 430 MPaQ235B : 375 MPaQ345B : 470 MPa

Elongation before Fracture M1020 : 13 %Q235B : 20 %Q345B : 18 %

Rollers life cycle Whilst the initial capital cost of a roller is often the only commercial consideration in a new product purchase, the total life-cycle cost is generally much more important.

Roller Life-Cycle

PurchaseCapital Cost

InstallationEase of installation, OH&S - manual feeding

OperationFriction, rim drag - Power Consumption

MaintenanceTime between maintenance, wash down etc.

ReplacementOperation life (L10, grease life, etc.), supply chain & leadtimes

RecyclingCost of disposal, recycling options

Each phase in a roller’s life has an associated cost, from the initial capital expenditure through to the running costs, downtime and cost of disposal and replacement.

Fenner Dunlop can work with site operations to synergise these processes and help reduce the total roller cost. We design specifically for site conditions so our Rollers are not over or under engineered, maximizing running efficiency ie power consumption.

Case Study:Using NSK’s ABLE bearing life forecaster to compare the bearing life of the Classic and Classic Plus Rollers.

This very basic example considers only the capital cost and life expectancy, ignoring other factors including revenue lost from system downtime (ie. the benefits could be greater).

The below is an illustrative example of the benefits of considering the life-cycle cost rather than simply just the upfront costs.

CLASSIC CLASSIC PLUS COMPARISON

Capital Cost $88.50 $97.50 10% increase

ISO L10 60,000 hrs 60,000 hrs -

ABLE L10 life 3.2 years 3.82 years 19% increase

Cost per year of operation $27.65 per year $25.52 per year 8% reduced cost

Note: 6306ZZ NSK bearings, 2200N @ 500RPM. ISO Life represents standard bearing life calculation methods. ABLE L10 represents overall design life calculation, incorporating fatigue, load, lubrication and contamination failure methods. Fenner Dunlop Whole-of-life design optimizes ABLE life, representing a far lower life cycle cost impact to the client’s maintenance costs.

Idle

r Fr

ames

Fenner Dunlop design and manufacture a wide variety of idler frames to suit every conveyor application.

Thinking Globally. Acting Locally.

Fenner Dunlop idler frames range from light-medium duty trough frames through to extra heavy duty pipe transom frames for the iron ore and coal industries.

All our frames are jig welded to ensure accuracy and consistency and are galvanized to AS4680 with typical coating thickness in excess of the Standard. We can also provide other surface treatments in accordance with the clients specifications.

Every production run of frames are subject to a vigorous quality assurance process inspecting the dimensional tolerances to ensure the product meets the engineering and client expectations.

Frames to suit every application;

Carry framesReturn framesVee-return framesRetractable impact framesExtra HD impact framesTransition framesTraining framesJack-down framesBelt saving framesRetractable return framesLow-profile frames

Fenner Dunlop stock a selection of smaller belt width frames (<1600mm belt) to enable rapid response times for emergency replacements.

However we can manufacture to any of our clients dimensional requirements.

Our standard preferred mounting centres are:

BELT WIDTH (mm) MOUNT CENTRES (mm)

≤ 1200 Belt Width + 250mm

1200 < BW ≤ 1500 Belt Width + 300mm

> 1500 Belt Width + 400mm

Con

veyo

r S

truc

ture

Fenner Dunlop specialise in the design and manufacture of innovative structures compatible with your existing assemblies.


Fenner Dunlop are always looking for ways to improve your operations and we work with our clients to improve your structure designs for added safety, serviceability, ergonomics and cost reduction.

Structure options;

• Surface/Overland• Drift• Trunk• Maingate• Development• Roof or floor mounted

Structure can be manufactured and packed into complete modules including frames, stringers, idlers and bolts/pins, ready to be assembled.All structure undergoes rigorous quality assurance both at the factory and in Fenner Dunlop distribution centres and is trial assembled to ensure functionality before it arrives on-site.

World-Class TechniciansUndoubtedly, our highly skilled engineers and technicians are what really set us apart. We take staff training seriously - so seriously in fact that Fenner Dunlop has its own registered training organisation to ensure all technicians reach the highest industry standards and qualification levels. Our technicians bring this knowledge to your operation, to support your business.

AccountabilityService is not just a word to Fenner Dunlop. It is in our culture, our training and our attitude. We take full accountability for the projects that you entrust to us. We always take a collaborative approach to solutions and this has been the key to our growth and success. Importantly, this growth and success have not changed our focus on highly customised and personal service.

We know that we are the only company in Australia that can provide a complete engineered conveyor solution, regardless of which OEM conveyor system you have. We take this responsibility very seriously, always ensuring that your needs are our objectives.

Remember - whether you need advice, an urgent repair, or the complete after sales service platform, one phone call is all it takes.

Thinking Globally. Acting Locally.With 4,800 employees and over 30 factories worldwide, we are always at the forefront of international research and development into conveyor systems and productivity. What matters to you most, of course, is that our regional service branches are conveniently located throughout Australia, which means that help is never far away.

Single Source ProviderFenner Dunlop offer complete conveyor solutions and components as a single-source provider.

Quality Systems and Components

Dependable Conveyor Services

Value Adding Diagnostic Services

Precise Engineering

State of the Art Facilities

Talk with us about our complete range of engineered conveyor solutions.

IdlersCleaners

IdlersDrives

IdlersCleaners

IdlersCleaners

IdlersCleaners

The expertise and support you need, fast.


Cairns

Townsville

Mackay

GladstoneBrisbane

SomersbySydney

Wollongong

Melbourne

AdelaideWhyalla

Burnie

Emerald

Mt Isa

Darwin

Port HedlandKarratha

Perth


It doesn’t matter what challenge you are facing with your conveyor or how small or large the problem, we have Fenner Dunlop service centres nationwide with fully trained technicians ready to take your call and provide the required support.

Phone 1800 Fenner (336 637) www.fennerdunlop.com.au

Manufacturing

MAP KEY

Service Centre

Documents

Conveyor Rollers, Idler Frames & Underground Structure · Idler loading geometry is based on the . Conveyor Equipment Manufacturers Association (CEMA) standard coupled with a numerical