Calculating L10 Idler Life: The definition of L10 for belt conveyor idlers: The basic rated life

(number of operating hours at 500 RPM) based on a 90 percent statistical model which is expressed as the total number of revolutions. 90 percent of the bearings in an apparently identical group of bearings subjected to identical operating conditions will attain or exceed before a defined area of material fatigue (flaking, spalling) occurs on one of its rings or rolling elements. The L10 life is also associated with 90 percent reliability for a single bearing under a certain load. The tables below show load ratings for series B, C, D, and E idlers. These load ratings are based on the following: Series B load rating based on minimum L,, of 30,000 hours at 500 RPM. Series BC (Ball Bearing) load rating based on minimum L,, of 30,000 hours at 500 RPM. Series C (Tapered Roller Bearing) load rating based on minimum L,, of 60,000 hours at 500 RPM. Series D load rating based on minimum L,, of 60,000 hours at 500 RPM. Series E load rating based on minimum L,, of 60,000 hours at 500 RPM.
Idler Class Belt Width (Inches) 18 24 CEMA B Idlers 30 36 42 48 18 24 30 36 CEMA C Idlers 42 48 54 60 66 Trough Angle 20 410 410 410 410 390 380 900 900 900 900 850 800 750 700 35 410 410 410 410 363 353 900 900 900 837 791 744 698 650 45 410 410 410 396 351 342 900 900 900 810 765 720 675 630 Single Roll Return 220 190 165 155 140 125 475 325 250 200 150 125 * * * 500 500 500 500 500 500 500 Two Roll Vee NOTES FOR TABLE: 1. TROUGHING IDLER LOAD RATINGS ARE FOR THREE EQUAL LENGTH ROLLS. 2. LOAD RATINGS ALSO APPLY FOR IMPACT ROLLS. 3. TROUGHING IDLER LOAD RATINGS ARE BASED ON A LOAD DISTRIBUTION OF 70% ON CENTER ROLL AND 15% ON EACH END ROLL FOR ALL TROUGH ANGLES.

Ratings Based on Min L10 of 30,000 Hours at 500 RPM

Ratings Based on Min L10 of 30,000 Hours at 500 RPM * Use CEMA D Return Idlers CEMA D Idlers 24 30 36 42 48 54 60 66 1,200 1,200 1,200 1,200 1,200 1,200 1,200 1,200 1,200 1,200 1,200 1,200 1,200 1,200 1,200 1,200 1,116 1,080 1,150 1,070 1,035 600 600 600 500 425 375 280 215 850 850 850 850 850 850

72 78 36 42 48 54 60 CEMA E Idlers (see note # 4) 66 72 78 84 90 96 102

1,050

977

945

155 125

850 850 1,300 1,300 1,300 1,300 1,300 1,300 1,300 1,300 1,300 1,300 1,300 1,300

Ratings Based on Min L10 of 30,000 Hours at 500 RPM 1,800 1,800 1,800 1,800 1,800 1,800 1,800 1,800 1,800 1,800 1,800 1,800 1,800 1,800 1,800 1,800 1,800 1,800 1,674 1,674 1,650 1,750 1,628 1,575 1,000 1,000 1,000 925 850 775 700 625 550 475 400 250

Ratings Based on Min L10 of 30,000 Hours at 500 RPM Rigid Frame and Catenary Where Applicable 60 72 CEMA F Idlers (see note # 4) 84 96 3,000 3,000 3,000 3,000 3,000 3,000 2,800 2,800 1,500 1,200 900 600 ** ** ** **

Ratings Based on Min L10 of 30,000 Hours at 500 RPM Rigid Frame and Catenary Where Applicable ** For Vee Returns Consider Using CEMA E Series

Picking Idler Load Ratings (Lbs.)

Belt Width 24 30 36 42 48 54 60 72 84 96 CEMA C 475 475 325 250 200 150 125 CEMA D 600 600 600 600 530 440 400 280 1,260 1,200 1,000 1,000 1,000 925 775 625 CEMA E

Live Shaft Idler Load Capacities (Lbs.)

Belt Width 18 24 30 36 42 CEMA C 1,200 1,200 1,200 1,200 1,100 1,400 1,400 1,400 1,400 2,100 2,100 2,100 2,100 CEMA D CEMA E

48 54 60 72 84

1,000 875 780

1,275 1,150 1,000 850

2,100 2,100 2,100 2,100 1,825

Determine Troughing (Carrying) ldler Load and Spacing: Calculated ldler Load (lbs) = CIL = [(WB + (WM x KI))x SI] + IML Where:

WB = Belt weight (Ibs./ft.) use actual or estimate from Table 8 WM = Material weight (Ibs./ft.) =I(TPH x 2000) l(60 x FPM)~ TPH = Quantity of material conveyed (Tons per hour) FPM = Design belt speed (Feet per minute) SI = Spacing of idlers (ft.) see below and Table 9 K1 = Lump adjustment factor (see Table 11) Note: Actual weight of lump should be compared with WM value. In situations, it may be necessary to use actual lump weight as WM. IML = ldler misalignment load (lbs) due to idler height deviation and belt tension = [(D x T) / (6 x SI)] : Where: D = Misalignment (inches) T = Belt tension (Ibs.) SI = ldler spacing (feet)

When an idler is higher than adjacent idler, a component of belt tension will add load to that idler. The amount of height deviation can vary with the installation and type of idler, especially when training idlers are used. CEMA publication on conveyor installation standarts (Appendix D, Belt Convevors for Bulk Material, fifth edition or later) list recommendations on structure misalignment). Determine idler bearing L10 life correction: L10 (CORRECTED) = L10 (RATING) x K2 x K3A x K3B (IF APPLICABLE) Where:
K2 = Effect of Load on Predicted Bearing L10 Life K3A = Effect of belt speed on predicted bearing L10 life K3B = Effect of roll diameter on predicted bearing L10 life

K2 Factor: When calculated idler load (CIL) is less than load rating of series idler selected, the bearing L10 life will increase. Figure 1 shows this relationship for either a tapered roller bearing or a ball bearing idler design. This chart can be used in conjunction with the type of service or life expectancy of the conveyor system. If the specified design life of the conveyor system exceeds the L10 life rating at rated load it may still meet specification based on percent of rated idler load vs calculated idler load (CIL).

K3A Factor: Goodman L10 life ratings are based on 500 RPM. Slower speeds increase life and faster speeds decrease life. Figure 2 shows this relationship.

K3B Factor: Larger roll diameter will increase idler L10 life, due to lower rpm.

For ASI Job #5648 Tatum/Liberty Mine, 48 wide belt, 1500 TPH, 700 FPM, Tcarry=15,420 lb , Treturn = 16,123 lb, 1/8 idler misalignment, Series D idlers, ball bearings: Carrying idler load, 4 ft spacing: CIL = (WB + (WM x KI)) x SI + IML = (14 lb/ft + 71.4 lb/ft x 1.0) x 4 + 15,420 lb x .125 in /(6x4 ft) = 342 lb + 80 lb = 422 lb Return idler load, 10 ft spacing: RIL = 14 lb/ft x 10ft + 16,123 lb x .125 in /(6x10ft) = 140 lb + 33 lb = 173 lb L10 Load rating for Series D idlers: Carrying idlers: 48 inch, 35 degree, 3 roll = 1200 lb Return idlers: 48 inch, single flat roll = 425 lb 7Carrying idler L10 life: L10 (CORRECTED) = L10 (RATING) x K2 x K3A x K3B 77777
77777777

Where:

L10 (RATING) = 30,000 hours

422 lb/1200 lb = 0.35 ; K2 = (1/0.35)**3 = 23 for 5in dia rolls: 535 rpm vs 500 rpm ; K3A = 0.97 using 5 in dia rolls: K3B = 1.0 L10 (CORRECTED) = L10 (RATING) x K2 x K3A x K3B
888 = 30,000 hrs x 23 x 0.97 x 1.0 = 1,338,600 hrs

Return idler L10 life: L10 (CORRECTED) = L10 (RATING) x K2 x K3A x K3B 88888
88888888

Where:

L10 (RATING) = 30,000 hours 173 lb/425 lb = 0.40 ; K2 = (1/0.40)**3 = 14.8 for 5 in dia rolls: 535 rpm vs 500 rpm ; K3A = 0.97 using 5 in dia rolls: K3B = 1.0

888

L10 (CORRECTED) = L10 (RATING) x K2 x K3A x K3B

= 30,000 hrs x 14.8 x 0.97 x 1.0 = 882,880 hrs

9999999999 999999999999999