5 Ball Bearings Used In Conveyor Rollers

Mobility in engineering is a vital element, and many manufacturing businesses and industrial processes require movement of inventory, materials, finished goods, and other objects within parameters. Conveyor rollers have around for quite some time, and they provide tremendous utility to such ventures.

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Furthermore, with their open-ended trays that can be joined to create any pathway along with the ability to be customized to fit any floor plan, conveyor rollers have limitless potential to be adapted to your requirements.

According to a recent study by Fortune Business Insights, the global conveyor systems market size was around $5.23 billion in and is projected to reach $7.43 billion in . This brings the growth rate of 4.5% CAGR during the forecasted period.

The driving forces behind this increase are the transformations in the e-commerce industry and traditional supply chains. This is compelling for companies to change the way they move, track, and store materials using automation and other advanced technologies.

With that out of the way, let’s take a quick look at some of the best ball bearings used in conveyor rollers around the globe.   

Angular Contact Ball Bearings

The angular contact ball bearings are designed and developed to have an inner and outer ring raceway that is positioned relative to each other in the direction of the bearing axis. This allows them to accommodate combined loads while simultaneously acting axial and radial loads.

The angular contact ball bearings are used to support conveyor belt rolling shafts. These are long cylindrical structures that form the main section of the conveyor belt and have the ability to roll and manage weight of the workload.

As the contact angel increase the axial load capacity of angular contact ball bearings also increases. There are several variations available including single row angular contact ball bearings, double row angular contact ball bearings, and four-point contact ball bearings, with each of them offering their own benefits. 

Deep Groove Ball Bearing

Widely considered as one of the most commonly used and conventional types of ball bearings, deep groove ball bearings are used for a variety of applications. One popular variation is the single-row deep groove ball bearings that have steel shields and rubber seals installed on one or both sides while requiring prepublication with grease. 

These bearings can be used in multiple quantities to create conveyor belt systems as shown in the picture.

Snap rings are sometimes used on the periphery whereas for big deep groove ball bearings. Machined brass cages are used since machined cages are adequate for high-speed applications.

These types of bearings are also quite versatile due to their low friction and are optimized low noise and low vibration as well as requiring less maintenance than other bearing types. 

Pillow Block Bearing

Also known as plummer block, pillow block bearing is a pedestal that can be used to provide support for a rotating shaft with the help of various accessories and compatible bearings.

The assembly consists of a mounting block which houses a bearing. The insert bearing mounted in the housing can be bolted to a support surface.

Pillow block bearings are housing bearings that act like a pedestal which is used to support the rotating shaft of conveyor belts with other compatible bearings.

These bearing types are commonly used in the most demanding food and beverage related environments. The inside of the bearing is typically 0.025 mm larger than the shaft to ensure a tight fit. Housing material for pillow block bearings is mostly made from cast iron or cast steel.

Self-Aligning Ball Bearings

Self-aligning ball bearings are made available either open or sealed. They have two rows of balls along with a common sphered raceway in the outer right and two deep uninterrupted raceway grooves in the inner ring.

This allows the axis of the inner ring, balls and cage to deflect around the bearing center to automatically correct misalignment caused by housing and shaft machining or installation error.

Hence this makes these types of bearings to be insensitive to angular misalignment of the shaft relative to the housing, which can be caused by shaft deflection.  

These bearings are used in similar fashion as the angular contact bearings. However the only difference is that they can only be used in light axial load applications due to the small axial capacity.

Tapered Roller Bearing

They are commonly used for heavy-duty applications with moderate speed and where durability is required. They are rolling element bearings that can support axial forces as well as radial forces making them good thrust bearings.

The inner and outer ring raceways are segments f cones, and the rollers are tapered so that the conical surfaces of the raceways and roller axes would meet at a common point on the main axis of the bearing.

Due to the overall geometry, the motions of the cones remain coaxial with no sliding motion between raceways and the OD of the rollers. Engineering students often request for a personal statement help when dealing with topic involving tapered roller bearings and other types of bearings.  

Tapered roller bearings can substitute for other types of bearings mentioned in this list apart from Pillow Block Bearings. They are usually implemented to support for moderate speed but heavy duty applications where durability is priority.

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Conclusion 

Conveyor systems are one of the best when it comes to handling equipment that transports materials from one pace to another. Their usefulness comes with the ability to move and feed the system making the process convenient, easier, and faster with the ability to withstand large workloads and even extreme weather conditions. 

Powering these systems are the ball bearings which offer relatively easy replacement with increase motor performance through less motor friction and the ability to withstand a wide range of temperatures from -40 to 180 degrees.

However, bearing selection is often done, keeping in mind the load and the working environment. 

Author Bio 

Choosing the right roller for your conveyor belt system is critical to maximise your productivity and reduce unplanned downtime on your site. To achieve maximum longevity and performance of the roller in your conveyor system all aspects of the rollers operation need to be considered.

At PROK, our team of product specialists considers these the most important factors when it comes to selecting the right roller for your conveyor belt system:

• Roller operating life
• Operator and environmental impact including
  • Weight of the roller
  • Noise generation
• Exposure to wet or corrosive conditions

How long should a roller last?

Bearing life expectancy is an important factor to consider when selecting a roller. This is affected by many factors, such as the speed at which your conveyor belt moves, how much weight is on it, or if there are vertical curves.

Failure analysis of mining conveyor rollers has shown that most failures can be attributed to three primary reasons:

• Bearing failure due to inadequate sealing system
• Bearing housing to shell bond
• Wear and abrasion on the shell

Seal designs and bearings go hand in hand, seals protect the bearing by preventing contaminants and moisture from entering. Corrosion has been found to be the largest contributing factor to roller failure; this can be minimized with a premium seal arrangement such as a grease-filled labyrinth with a contact seal which provides a barrier from contaminants reaching the bearing.

In addition to the seals in the end cap, shielded ball bearings add an additional sealing layer to give a 3-barrier solution which will provide a protective barrier in preventing bearing failure when operating in a mining environment.

Shell thickness is also a significant factor to consider when selecting the conveyor roller. As the shell begins to wear down it will reach a thickness that can no longer support the load which will result in shell failure.

PROK HDPE utilises a world-first visual wear indicator. The shell is constructed with an outer yellow wear layer and inner green layer which allows mine operators to visually check rollers for shell wear while in operation. When the green layer prevails, the roller can be scheduled for changeout during planned maintenance rather than an unplanned event and conveyor downtime.

How much can a roller weigh?

The weight of a conveyor roller has a significant impact on the manual handling exposure of your maintenance crew. Incorporating a lightweight conveyor roller is important for the ease of change-outs and can greatly reduce the health and safety risks that are associated with heavy steel rollers.

The weight of a roller is dependent on the type of material it is made from and the application it is being used for. Historically, in heavy applications, traditional steel conveyor rollers can weigh up to 45 kg. During roller change-outs, steel rollers can be an operator risk due to their heavy weight and awkward location resulting in worker fatigue and a higher risk of back or hand injuries.

With advancements in technology and innovation, composite rollers have become a dominant choice for major mining companies due to their unique lightweight properties. Incorporating a lightweight conveyor roller is important for ease of change-outs, significantly reducing the health and safety risks associated with steel rollers. PROK HDPE is 40% lighter than traditional steel rollers of the same duty, meaning roller changeouts can be performed safer and quicker, boosting productivity at your site.

Can noise affect your operations?

Many conveyor systems operate 24/7, with rollers being a contributing factor to the level of noise produced. Contact between the rollers and the belt, along with any damage to the belt will generate increase noise levels when operating.

Depending on the location of your conveyor system, such as close to residential areas, you need to be aware of the regional laws and policies in place for environmental noise. Disturbances to residents during certain hours can incur a hefty fine.

Noise can also impact the safety of your workers, exposure to elevated noise levels over long periods of time can lead to permanent hearing loss.

Testing of PROK composite rollers has demonstrated they produce less noise than steel rollers, with the PROK HDPE roller being 50% quieter than traditional steel rollers.

How can corrosion affect your rollers?

With corrosion being one of the main causes of roller failure, it is important to consider the environmental factors in which the roller is operating. The roller’s construction along with a seal design is critical to prevent contaminants and moisture from entering the bearing and achieving the desired longevity of the roller.

Steel rollers when exposed to wet environments are more vulnerable to rust and corrosion as compared to HDPE rollers. PROK HDPE rollers are designed to reduce the risk of failure when operating in harsh conditions with superior features such as;

Shell and end cap manufactured from composite materials with properties that makes them resistant to corrosion.
Multi-labyrinth sealing system with shielded bearings providing a barrier from water and contamination ingress.

Conclusion

Selecting the right roller for your conveyor belt system is not always straightforward. The key factors that should be considered are;

• The operating environment and loading application the roller
• Roller construction and materials used
• Bearing and sealing system
• Noise generation from the roller belt interface

The factors above will all influence which roller is right for your conveyor system and how well it will perform.

PROK rollers are designed and engineered to withstand the 3 most common modes of failure, being bearing failure due to poor sealing, bearing housing connection and wear and abrasion on the shell.

Are you interested in learning more about Industrial Conveyor Rollers? Contact us today to secure an expert consultation!