T - SU553 IDLER LIFE

Technical Paper T - SU553

BELT CONVEYOR IDLER LIFE;

FACTORS AND CONDITIONS
By Bob Domnick, P.E.

CONTENTS ABSTRACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 IDLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 IDLER LIFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 THEORETICAL LIFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 FACTORS THAT AFFECT IDLER LIFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Bearing Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Bearing Style - Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Bearing Style - Impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Bearing Style - Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Bearing Style - Misalignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Bearing style - Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 SEAL EFFECTIVENESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 ROLL CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 IDLER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 MAINTENANCE AND ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 CONCLUSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

ABSTRACT
Transporting bulk material from one point to another is an age-old process with methods that have evolved from primitive and costly to advanced and economical. Today, modern belt conveyors can continuously transport material through the toughest terrain, in the most severe environments, and at rates that cannot be attained via a batch process. By transferring material from one conveyor to another, the length of transport is unlimited. As such, the number of required conveyor components is also unlimited. Continuous material flow is much like an assembly line. As any manufacturer knows, just one small process on the line can delay the final product. Similarly, the malfunction of just one conveyor component can delay all material production. The reliability of each conveyor component is vital. The idler (a roll or series of rolls that support the belt) is one such component, and as idlers are present along the entire length of the conveyor, they demand close scrutiny. How long can an idler support and protect a belt? That can only be estimated after a careful examination of just what factors affect idler life and how these factors apply to a producer's application. Pertinent factors include: idler class, bearing style, seal type, lubrication, roll construction, maintenance and environment. A detailed look at each is required to maximize idler life and to choose the best idler type for a given application.

IDLERS
An idler is a roll or series of rolls that supports and protects the conveyor belt. A troughing idler, which is the most common idler on high capacity belt conveyors, is mounted on the material carrying side of the conveyor and generally consists of three equal length rolls. The two outer rolls are inclined upward while the center roll is horizontal Figure 1. The rolls are mounted to a framework that attaches directly to the conveyor frame. The belt follows this geometry and an effective profile for conveying bulk material is formed. Typical conveyed materials include but are not limited to sand and grav-

el, coal, limestone, crushed stone, grain, fertilizer, salt, and wood chips. There are four classifications of idlers defined by the Conveyor Equipment Manufacturer's Association (CEMA). They are classes B, C, D, and E Table 1. The classes are defined by envelope dimensions, loads, roll diameters, belt widths, and L10 requirements (defined later). The roll is the heart of an idler. In its most basic form the roll consists of a cylindrical shell that rotates concentric to a shaft Figure 2. The shaft is supported on either end by the idler frame. A housing is attached to each end of the roll that accommodates a bearing and seal arrangement. This housing is called an enddisc. As the conveyor belt moves across the idler, the roll and outer bearing race turn while the shaft and the inner race remain stationary. Typically there is a portion of the seal that rotates and a portion that remains stationary. It is the roll or its components that usually fail first.

IDLER LIFE
Idler life is defined as the length of time during operation in which an idler effectively supports and protects the conveyor belt. It can also be stated as the amount of time operating between idler installation and idler failure. An idler has failed if any one of the following conditions has occurred Figure 3: a roll has stopped turning a roll has a hole worn through its shell the enddisc has separated from the shell the bearings are squeaking at an unacceptable decibel level any portion of the frame has failed the deflection of any frame component is so great that it limits the idler's usefulness. This paper will describe the conditions and factors that influence idler life.

THEORETICAL LIFE
Idler life is affected by many variables. However, bearing rating is the only variable for which laboratory tests have provided standard values. Therefore CEMA uses bearing L10 life as a guide for establishing idler ratings. The CEMA idler selection procedure does provide charted guides that can be used to modify the L10 life into a more practical estimate of idler life. L10 life for an idler is defined as 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 identical group of bearings subjected to identical operating conditions will attain or exceed before a defined area of material fatigue 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. Spalling, or material fatigue, is the chipping or flaking of the contact surface of either the bearing race or the rolling elements. Fatigue develops gradually over the life of the idler bearing as its parts repeatedly exert pressure on each other during rotation. Eventually small, subsurface cracks form and grow in size until spalling occurs. This is considered the full life of the bearing and is equivalent to "dying of natural causes." The L10 formula comprises the dynamic load rating of the bearing, the radial load, the rpm, and the bearing style. The allowable load and rpm are specified by CEMA. Bearing style correlates

to the formula only by essence of the elements being either ball or roller. The bearing dynamic load rating is the constant radial load a bearing can endure for one million revolutions and is published by the bearing manufacturer. In many cases these ratings were based on tests performed many years ago. Bearing advancements include improvements in alloys, material processing techniques, manufacturing, design and tribology (interaction between bearing surface topography with lubricants and debris). In response to these advancements, many manufacturers have contrived increased life factors to be applied to the published dynamic load ratings. L10 life is most useful in bearing selection for a relative comparison between different bearings. Actual idler life may have very little correlation to the L10 life. Very seldom does an idler fail due strictly to bearing fatigue. Therefore it is so important to look beyond theoretical life and consider the other factors that affect idler life. After all, actual idler life is all that interests the customer.

FACTORS THAT AFFECT IDLER LIFE

Bearing Style
There are primarily two styles of bearings used in an idler: tapered roller and ball bearings. It is not sufficient to state that one is better than the other since the considerable difference in design produces advantages or disadvantages based on application. The tapered roller bearing is made up of a cup, a cone, rolling elements, and a cage Figure 4. The cone is inserted into the cup in a way that sets the axial clearance, or end play, of the bearing. The extensions of the raceway and rollers converge at a common point on the axis of rotation resulting in true rolling motion Figure 5. The angled raceways allow the tapered roller bearing to carry both radial and thrust loads. The tapered configuration also ensures roller alignment by generating a seating force Figure 6. The cage provides proper spacing of the rollers. Deep groove ball bearings are made up of an inner ring, an outer ring, rolling elements, a cage, and seals Figure 7. This bearing is suitable for moderate radial loads. It is also suitable for moderate thrust loads because the inner and outer rings are manufactured with a deep groove raceway. The bearing is factory assembled with inseparable rings that fix the radial clearance. The cage provides proper spacing of the balls.

It is important to further describe internal clearance. Bearing internal clearance is the total displacement of the inner ring to the outer ring under no load conditions. Internal clearance permits interference fits on the bearing rings without causing preload, allows unequal thermal expansion of the rings, and accommodates misalignment resulting from shaft deflection. It is called radial clearance when the displacement is in the radial direction and axial clearance when the displacement is in the axial direction. It is essential that an internal clearance remain during operation. An interference fit between the rolling elements and the rings will produce excessive heat that will reduce the life of the bearing. Ball bearings are produced with different classes of radial clearances per bearing size with a guaranteed minimum and maximum clearance. Axial clearance in a tapered roller bearing is set by the idler manufacturer when the cup and cone are assembled. The consistency of this setting is subject to the manufacturing capabilities of the idler manufacturer.

Bearing Style - Load

The idler load consists of the material weight, belt weight, roll weight, impact from lumps or transfer points, and belt tension due to vertical misalignment of the idlers Figure 8. The majority of the load, approximately 70%, is supported by the center roll of the troughing idler. This load is used to select the idler class in addition to calculating the L10 life of the bearings.

The tapered roller bearing has rolling elements that result in uniform load distribution along a line of contact created by the roller and the raceway Figure 9. Long line contact gives the tapered roller bearing a high load carrying capacity for both radial and thrust loads. The line contact also allows the roller to bridge raceway defects. The ball bearing has components that result in point contact Figure 10. Because of the point contact the load capacity is lower than a tapered roller bearing of the same size. All other conditions being equal this results in the ball bearing having a lower L10 life than the tapered roller bearing. CEMA idlers meet the minimum L10 life requirement regardless of bearing style. Since less than five percent of bearings fail by fatigue it is no surprise that the benefit of added L10 life for the tapered roller bearing is often disregarded. Load carrying capacity is significant but must not overshadow the other factors affecting idler life. Light idler loads can present a problem. The load must be large enough to turn the rolling elements and overcome seal friction. The combination of a small diameter roll, an empty belt, and a roll with high rolling resistance may result in a roll that will not turn. The point contact of ball bearings results in low frictional forces for the load to overcome. A tapered roller bearing with its line contact results in high frictional forces. Additional grease retaining seals used in a tapered roller bearing idler add to the force needed to turn the roll.

Bearing Style - Impact

Because of the line contact tapered roller bearings are more suitable for impact loading. The point contact of ball bearings has more of a tendency to damage the raceway or the balls when impacted. The geometry of the tapered roller bearing ensures that the impact load is distributed evenly across the face of the roller or raceway. Therefore, tapered roller bearing idlers are often recommended under crushers and transfer points.

Bearing Style - Speed

Conveyor belts move in a speed range of zero to in excess of one thousand feet per minute. Therefore it is prudent to consider the effect of speed on the idler bearing. There is a limit to the speed at which a bearing may be operated. Generally, it is the operating temperature that can be permitted with respect to the lubricant being used or to the material of the bearing components that sets the limit. Friction, which generates heat, is the resistance to

movement. The total resistance to rolling is made up of the rolling and sliding friction in the rolling contacts between rolling elements and cage, as well as the guiding surfaces for the rolling elements or the cage, the friction in the lubricant and of the sliding friction of rubbing seals if present. The speed at which the limiting temperature is reached depends on this frictional heat and the amount of heat that can be transferred away from the bearing. Lubrication type, lubrication amount, bearing style, level of maintenance, environmental conditions, shaft to bearing fit, radial or axial clearance, and style of seals all have a significant impact on the total rolling resistance. There are low temperature and high temperature greases available. Bearings may be over-greased and force the rolling elements to push through excess grease leading to sharp temperature rises. Poor maintenance can lead to over-greasing or insufficient lubrication. Some environmental conditions such as high ambient temperatures or presence of water can lead to premature grease breakdown. A loose fit can cause creep or slip which leads to a temperature rise. A tight fit may cause a damaging radial clearance or preload. Tight seals can cause unnecessary temperature rises. The allowable bearing speed is determined by these factors. The highest speeds can be achieved by deep groove ball bearings. The point contact of the rolling elements, the controlled grease fill, and the inde-

pendence of varying maintenance practices aid in making ball bearings a consistent highspeed performer. The tapered roller bearing can also operate at these speeds, but the higher operating temperature requires close attention to maintenance, idler seal design, grease quantity, and grease type.

Bearing Style - Misalignment

Angular misalignment between the shaft and enddisc occurs when the shaft deflects under the operating load Figure 11. Misalignment can also occur if the bearing seat of the enddisc is not level. If the enddiscs are not welded in parallel to each other, misalignment is introduced. Good manufacturing processes will reduce this risk. The shaft slope is typically determined in radians or inches of deflection divided by inches of length. There are two variables (other than load) that affect the shaft slope; the shaft moment of inertia and the moment arm. The moment of inertia is a cross sectional property that quantifies stiffness. The moment arm is the distance from the shaft support to the effective load center of the bearing. For the same bearing location the moment arm for a tapered roller bearing Figure 12 is smaller than the moment arm for the ball bearing Figure 13 due to the line of action of the force. This moment arm should be minimized to avoid loss in L10 life. The most successful means to achieve the short moment arm is a shallow enddisc with a compact seal configuration.

Ball bearings are praised for their ability to tolerate up to 16 minutes or .005 in/in of misalignment while maintaining normal contact Figure 14. Misalignment causes edge contact in tapered roller bearings severely reducing bearing life Figure 15. Early designs of tapered roller bearings could only tolerate 3 minutes or .0009 in/in. The flat tapered roller and flat raceways gave way to modern designs utilizing edge crowning. If the cup and cone are misaligned on a flat tapered roller the stress is concentrated on one end of the roller Figure 16. When the tapered roller and raceway are crowned the stress will be evenly distributed along the length of the roller Figure 17. Edge crowning allows up to 7 minutes or .002 in/in of misalignment. Misalignment beyond the aforementioned values derates the L10 life similar to the curve shown Table 2. Each bearing has a unique curve, but the relationship between tapered roller bearings and ball bearings is consistent.

Bearing Style - Cost

Power consumption is an important cost consideration when selecting idlers. The friction caused by rolling resistance increases the amount of power required to move the conveyor belt. The CEMA Kx factor designates the overall drag force and is comprised of the sliding friction between the belt and the idler rolls and the frictional rolling resistance of the roll. The CEMA Ai value is the force required to overcome frictional resistance and rotate idlers. Ball bearing idlers have a significantly lower Ai value than tapered roller bearing idlers. On long horizontal conveyors this can represent noteworthy savings in power consumption as well as increased life of associated drive components. The bearing price tag is an obvious cost consideration. Typically a ball bearing can be purchased at a lower cost than a tapered roller bearing. It is easy to assemble requiring less labor than a tapered roller bearing. A sealed for life ball bearing can provide an excellent cost saving by eliminating maintenance labor, grease expenditure, and grease piping for single point lubrication. Tapered roller bearings are usually more cost effective in terms of dollars per L10 hour. This measure becomes less meaningful considering less than five percent of bearings reach theoretical life. However, designers often specify increased idler spacing for tapered roller bearing idlers, thereby reducing capital costs. The idler can withstand the increased load and still have an L10 life equal to a ball bearing idler. Therefore the entire system must be explored to determine which idler will provide the greatest cost advantage.

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SEAL EFFECTIVENESS
Idler roll seals are responsible for retaining grease in the bearing cavity, excluding contaminants, maintaining low roll resistance, and maximizing wear life. Ball bearing idlers rely on the seal attached to the bearing itself as well as the seal configuration provided by the idler manufacturer. Tapered roller bearing idlers rely only on the idler manufacturer's seal. It is necessary to understand the importance of excluding contaminants. Despite advances in sealing and lubrication methods, enough contaminants still enter the bearing cavity to cause fifty percent of all bearing failures typically at a fraction of the calculated L10 life. If dust and dirt reaches the bearing, it will mix with the lubricant to form an abrasive compound that causes wear on the bearing. If water contacts the metal parts of the bearing, an iron oxide is produced that forms a grinding compound that also causes wear on the bearing. Contaminants can be large enough to make dents in the contact surfaces of the raceways and rolling elements. This significantly reduces the life of the bearing. Idler manufacturers have developed an assortment of labyrinth seals to aid in excluding contaminants. The labyrinth combines a tortuous path with centrifugal forces that trap and remove dirt and water. The centrifugal force creates a flinging effect between the rotating and stationary surfaces that helps remove particles. In vertical labyrinths the path extends radi-

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ally and effectively utilizes centrifugal forces to exclude contaminants by making it difficult for the particles to move axially Figure 18. In horizontal labyrinths the path extends axially and utilizes centrifugal forces to exclude contaminants by making it difficult for the particles to move radially Figure 19. Horizontal labyrinths can be easily assembled and usually require fewer components than a vertical labyrinth. An effective vertical labyrinth can be created in less distance thereby minimizing the moment arm. Double, triple, or multiple labyrinths simply describe the number of paths present in the labyrinth (Figure 19). A labyrinth seal is a non-contact seal. Consequently it does not limit the speed of the bearing. A lip seal is a contact seal that is often incorporated into the seal configuration of an idler Figure 20. Lip seals are made out of a variety of materials and help to minimize the dirt or other air-borne abrasives that can contaminate the bearing lubricant. The seal can be arranged to exert a force radially or axially against a moving surface usually depending on the labyrinth style. A lip seal is very effective at excluding contaminants but has some drawbacks that must be considered. First of all, lip seals typically have a short service life. Over time the lips will wear and lose contact and allow contaminates, humid air, and moisture into the bearing cavity. Next, the lip exerts a spring force radially or axially on the adjacent seal component. This results in added power require-

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ment just to turn the idler roll. This can be substantial on long conveyors. Lastly, there is a limit to the lip sliding speed. The lip seal is generally very close to the bearing cavity so the heat caused by the friction of the lip seal can increase the running bearing temperature. High bearing temperatures break down lubricant and ultimately reduce bearing life. These drawbacks should not minimize the value of excluding contaminants. There are applications in which the use of lip seals is imperative. Also, modern lip seals have been developed that work longer and more effectively with narrow contact bands and minimal radial loads that are uniform over time. Ball bearings are often manufactured with seals, called closures, integrated directly into the bearing. Closures can be simple trash shields or rubber lipped contact seals. Elaborate closures incorporate multiple lip seals and a grease filled cavity that protects the inner lip seal Figure 21. The idler manufacturer's labyrinth seal configuration in combination with the closures creates a formidable barrier against contaminants.

LUBRICATION
All bearings require lubricants. The use of grease lubrication is prevalent in the idler industry. Grease is easily retained in its cavity and is effective in sealing against moisture and particles. Lubricants have four roles: to prevent the direct metallic contact between the rolling elements, race ways and cages to prevent bearings from corrosion and wear to prevent ingress of contamination to cool the bearing Up to thirty percent of all bearing failures are a result of improper lubrication. Over-greasing forces the rolling elements to push through excess grease leading to temperature rises. Under-greasing will allow the direct contact of metallic surfaces. Chemical attacks or thermal conditions can decompose or break down the lubricant. Low temperature greases or the mixing of incompatible greases may not provide adequate viscosity. If a bearing cannot operate without grease, then grease retention becomes an important consideration. The pumping action caused by the wide surface and line contact of the roller on a tapered roller bearing forces the grease away from the rolling elements Figure 22. The only way to replace it is to regrease the idler. The grease is retained by the idler manufacturer's seal. This seal is usually too far away to hold the grease close to the tapered rollers. Ball bearings travel a narrow path with only point contact, so very little grease is displaced Figure 23. The bearing manufacturer's seal is effective in holding the grease in close contact with the rolling elements. For many years, the industry demanded a CEMA C, D, and E series idler that could be relubricated. However, the use of factory sealed non-relubricated ball bearings in idlers has grown in popularity. Even when tapered roller bearing idlers are required there remains the desire for a sealed-for-life idler. This demand has prompted the use of factory sealed tapered roller bearing idlers where effective grease retention is critical, yet difficult to attain. Idlers that can be relubricated have non-purgeable and purgeable seal con-

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figurations. A purgeable sealing system allows the user to purge contaminants out of the bearing cavity. However, the grease mixed with the air pockets causes the labyrinths to "breathe" allowing contaminants to be drawn into the bearing cavity. Proper maintenance becomes critical with this design. Non-purgeable sealing systems are designed to lubricate the bearing, not to act as a seal against contaminants. They also restrict the exit of grease from the cavity. Single point lubrication is effective for non-purgeable designs, but it is impossible to purge all six bearing cavities and labyrinth seals from one point on a purgeable design. Purgeable seals require lubrication approximately every 2000 hours while non-purgeable seals can often operate at 10,000 hour greasing intervals. Grease selection is important. A wide temperature range, mineral oil-based grease is required for a standard idler application. Some applications require special grease. High or low ambient temperatures, the presence of chemicals, and the required reliability may necessitate special grease.

ROLL CONSTRUCTION
The only rotating element affecting idler life yet to consider is the roll itself. A roll with a hole worn through its shell or the separation of the enddisc from the shell constitutes an idler failure to the same extent as a seized bearing. There are no CEMA standards for roll construction other than roll diameter.

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The diameter of a roll and its shell thickness can drastically affect idler life. Selecting a larger diameter roll reduces the rpm of the bearing as well as increases the wearable surface area of the roll. For abrasive materials a thicker shell will provide longer life at only slightly higher costs. Roll concentricity is important in providing smooth running and an even wear pattern for rolls and belt. A roll that does not rotate concentric with the shaft will introduce vibration within the bearing that will decrease bearing life. Extreme cases can aggravate belt training which in turn can subject more load and higher belt tensions to one roll. A very controversial issue in the industry is the method of attachment of the enddisc to the shell. Some idler manufacturers butt the enddisc up against the roll end and weld a fillet weld around the roll Figure 24. Some manufacturers counterbore the end of the roll, inset the enddisc inside the roll, and weld a fillet weld around the inside of the roll Figure 25. Companies that manufacture the inset enddisc (Figure 25) purport that the belt will abrade the exposed fillet weld (Figure 24) and cause the enddisc to separate from the shell prematurely. They also claim that the exposed fillet weld will wear the bottom cover of the conveyor belt. These allegations have initiated much marketing hype that has needlessly confused idler consumers. Very seldom will the belt travel to the edge of an outer roll. It is common to find paint still adhering to the roll on the edge of the outer roll where the exposed weld is located Figure 26. The radius of the belt at the junction of the center roll and the outer roll is usually sufficient to bridge the two exposed welds if the idler roll gap is minimal Figure 27. The drawback to the inset weld (Figure 17) is that some wear thickness is removed in the counterbore process. If the shell did wear in this area it would reach the enddisc more swiftly than the exposed fillet weld roll. Ultimately, either design is effective since the wear at the enddisc attachment is minimal. The roll material can also affect idler life. Steel rolls are regularly constructed using electric resistance welded tubing. It provides excellent wear for most applications. For tough applications of corrosion, abrasion, and severe material build-up there are several roll materials available: urethane, ceramic, polyethylene, and rubber discs.

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IDLER FRAME
The idler frame has less effect on idler life than the rotating components. The frame must adequately support the rolls without excessive deflection. The rolls must be retained in the frame at all times. The frame must be built within CEMA dimensional tolerances such that an adjacent idler is not overloaded due to idler misalignment. The roll shafts must be affixed in the frame in such a way that shaft rotation is resisted. The idler must be adequately secured to the conveyor preferably with the ability to double bolt mount the idler on larger sizes. Smaller idlers only require single bolt mounting which offers savings through fewer holes in the idler, fewer bolts, and fewer holes in the conveyor.

MAINTENANCE AND ENVIRONMENT

Poor conveyor maintenance can lead to idler failures. If idlers are not lubricated at correct intervals it can accelerate bearing failure. If a failed roll is not replaced the adjacent idler may be overloaded. If material spillage has not been cleared away from the idler it may suffer additional wear. Idlers that are out-of-square are subjected to more friction and additional wear. Idler installation resulting in idler misalignment can cause premature bearing failure. Some environments are detrimental to idler life. Dusty applications present more frequent contamination problems. Wet applications can severely reduce bearing life since most seals cannot exclude water. Acidic material can corrode and rust the frame, roll, and bearings. High ambient temperatures can significantly increase bearing operating temperature and reduce bearing life and lubrication viscosity. It is important to know the environment of the application in order to select the proper idler options that maximize idler life.

CONCLUSION
In conclusion, the length of time an idler will support and protect a belt can only be estimated after careful consideration of the factors affecting idler life and how they apply to the application. The perfect idler would operate for the full L10 life of the bearing and then all the components would fail at the same time. Realistically, our estimating tools only allow us to select the idler components that will maximize idler life for a given application. According to the application, consider idler class, bearing style, seal type, lubrication, roll construction, maintenance and environmental conditions. Knowledge of how these criteria relate to idler life is crucial if the perfect idler is ever going to be obtained.

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NOTES:

TM

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