Janse van Rensburg, Barnard (2013) The development of a light weight composite conveyor belt idler roller. [USQ Project]
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Abstract
High incidence of injuries caused by the manual handling of heavy idler rollers is a major concern for the Australian mining industry. Consequently, major mining industry stakeholders called for the development of light weight idler rollers. As a result this project was designed to develop a light weight idler roller using pultruded continuous glass fibre, vinyl ester composite circular hollow section.
Current literature on the subject highlighted the need for non-ferrous light weight idler rollers but offers no real solution. A rigorous test regime, including physical static and dynamic testing in conjunction with finite element analysis, was used to analyse a designed light weight composite prototype idler roller.
The main empirical finding of the project was the possibility of producing shaftless lightweight composite idler rollers for use in the mining industry. The conceptual shaftless composite rollers are estimated to be 40-60% lighter than traditional steel rollers. The light weight of the concept idler roller, combined with the possibility of manufacturing idler rollers that are dimensionally suitable for mining, addressed the concerns of the Australian mining industry and answered the call to develop a light weight conveyor belt idler roller.
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