SALIENT FEATURES OF ROLLWELL IDLERS

How will Rollwell Idlers Benefit You?

1. Longer Life - minimum expected life of 40,000 hours for well designed idler.
2. Reduced down time for the conveyors, due to longer life of Idlers
3. Reduction in power consumption due to one of the lowest friction factor ( as low
as 0.01)
4. Reduced maintenance costs
5. Increased belt life.

What are the Salient features of Rollwell Idlers ?

 Idlers are manufactured from ERW pipes as per IS: 9295, which are specially
made for Idlers application. These pipes are specially made with tight tolerances
related to straightness and ovality.
 Pipes are bored at both ends simultaneously using a special purpose Double
Headed Boring machine. This will maintain concentricity of shaft at both ends
of idlers and will limit the run out of the idlers.
 The bearing housings are manufactured from Extra Deep Drawn CRCA sheets.
 The Bearing seating, flange diameter and back facing of the bearing housing are
machined in a single setting on a Special Purpose Machine to ensure absolute
concentricity.
 All bearing housing are manufactured in house to ensure right quality opf
material and manufacturing excellence.
 Bearing Housings are welded to the pipe at both ends simultaneously by
CO2 welding. The bore diameter in the pipe and the flange diameter of housings
are maintained in such a way that the housings press fit in to pipe and
concentricity is maintained.
 Welding is done in a Special Purpose Machine, where the idler is rotated
slowly at the required RPM depending on the diameter of idler and automatic and
simultaneous welding is done at both ends by SPMs.
 Idler shafts are made of bright bar.
 Idler shaft is machined and fine ground with closest tolerance for proper fitment
of the bearing. End details of shaft act as a tie for idler fixing brackets.
 We use only genuine bearings from SKF/FAG and they are sourced directly
from the manufacturer.
 Vertical labyrinth type sealing system is provided for the bearings. The sealing
system consists of Double Labyrinth Seal, made of CRCA sheet. Glass beaded
Nylon seal is provided at back of the bearing to avoid grease entering in side the
pipe. A neoprene rubber seal is provided on top of the outer labyrinth seal to
prevent any water and dust from entering inside the idler.
 After the idlers are assembled each idler is continuously rotated for a
minimum period of 15 minutes for both freeing of the idler as well as testing for
any heating of the bearing.
 As per the Quality Assurance Plan, idlers are tested for Water and Dust
Penetration in specially built Jigs.
 In Water Ingress Test, water is sprayed at both ends of the idler at constant
pressure and idler is rotated continuously. The test is done for a minimum period
of 02 Hours.
 In Dust Ingress Test, the idler is rotated continuously in a Dust Chamber, where
the dust is circulated using a blower. The test is conducted for a minimum period
of 02 Hours.
 The rolling resistance of Rollwell idlers is as low as 0.01 as against
allowable value of 0.02 and design value of 0.03. The co – efficient of friction is
tested in specially built Jig