Idler pulley friction in belt conveyors

The application of a number of procedures on the design of rubber belt conveyors for bulk materials in which specific cases are considered and the actual operation powers and tensions compared is reviewed. Determination of actual friction losses for each idler as a function of position, the moving load and its properties, belt tension, weight of the pulley, temperature, geometry and physical properties of the belt and velocity is the main aim. A device is described that measures the vertical load, and the horizontal friction forces at each end of three idler pulley sets mounted in a standard frame, and separates vertical contact load, rolling friction torque and bearing friction, using eight outputs from the two side idlers and five outputs from the centre idler to be recorded on a data logger and down-loaded to a PC at the rate of 1 second per set of thirteen readings. Analysis of test data will provide accurate information on idler friction for conveyor designers, and if required, on the material and rubber belt friction loss components.