ORF Rollers

CONVEYOR ROLLERS

ORF conveyor rollers are built to last. CLIMAROLL rollers have been setting the industry standard in the Middle East for years. They are designed for medium to extreme heavy duty requirements for various industries. Applications include: cement, quarrying, steel and process, batching, asphalt & bock, construction, fertilizers, warehouse, packaging and recycling industries. All rollers are suitable for continuous operation in the most extreme weather conditions and hostile environments. ORF Conveyor Rollers are designed for endurance and components originate from quality sources. Balancing determines a roller’s life, which is ensured by using concentric pipes, precision end-caps and double-bored spindles. Rolling resistance determines the power requirements for a conveyor, which is why ORF rollers are lubricated for life and double sealed to resist dust permeation.

CLIMAROLL ROLLERS SALIENT FEATURES 

Material Grade & Specifications

Construction

CLIMAROLL steel and rubber treaded conveyor rollers are manufactured under a rigid quality control system for higher life and performance, conforming to international standards viz. CEMA, ISO 1537 / DIN 22112. All roller shells are manufactured from ERW concentric steel tubes. Each shell end is machined to ensure concentricity to accept the bearing housing.  The two end caps are of die-formed construction secured by hydraulically pressing the ends of the tube, thus giving a smooth radius. Bearing housing is deep drawn from 3mm thick quality sheet steel.

CLIMAROLL conforms to bearing fit tolerance ISO M7; full TIG welded to shell. The roller spindle – shaft is made from MS drawn round bar and the ends machined to ensure perfect spin of the bearing. Particular attention is given to the bearing seat machining and seal location, which is finally centreless ground to fit tolerance of ISO h6.

Labyrinth sealing system at either end simultaneously acts as lubrication chamber and dust protection guard. Comprised of several sealing elements which prevent contaminants from entering the bearing. Individual elements of the system are circular in shape with interlaid lips which form a labyrinth. The shape of the lips is designed to prevent the intrusion of contaminants into the bearing chamber without increasing rotational frictional resistance. The system has two parts: male labyrinth and female labyrinth with 2 grooves each. The space between the lips of the labyrinth is filled with grease (lithium grease NLGI grade 2 or 3) for catching fine dust particles. Elements of the labyrinth sealing system are manufactured from polyamide-based material and polypropylene-based material.

This bearing seal assembly is secured in position by means of hardened spring steel Circlip in compliance with DIN 471 to prevent axial movement of the shaft, directly positioned on groove-machined spindle. A die-formed metal end cap coupled with polyamide seal is press-fit for additional protection to the bearing assembly. The final assembly is painted with 2 coats of red oxide and synthetic enamel Paint, 650 post red color, 75um.

Roller Manufacturing

Types of Roller

Monotrough Carrier Roller 

The monotrough idler set consists of three equal-sized type-D carrier rollers and one return roller of the same type. In this arrangement the side rollers can be set at any pre-determined angles of 25º, 30º, 35º or 45º.

Variatrough Carrier Roller 

A Variatrough Idler set consists of two types: A-side rollers and one type – B centre rollers. Side rollers of this arrangement can be set at angles of 20º, 30°, 40º, 50º or 60º in order to achieve the desired belt trough.

V-Type Carrier Rollers 

These idlers are used in place of normal 3-roll troughing idlers to support belt on carrying side. The pinching effect on belt between two rolls is high for these situations:

Garland– Suspended Type Rollers

This type of idler has 3 or 5 rolls of equal or unequal lengths which are linked in series and suspended at the ends by special lugs to the conveyor-stringers, to form a continuous chain of idlers. Garland Idlers have a link assembly between the connected rollers.

Characteristics 

1)  Garland Idlers are lighter when compared to fixed-frame idlers due to the absence of a steel frame.

2) Garland idler design is more forgiving than fixed, due to its chain-like design which allow the belt’s center line and idler centers to move relative

to the supporting frame.

3) Finds application more on yard, dump and shiftable conveyors, where alignment of conveyor structure may not be correct due to the mobility of

the conveyor on ground conditions.

Self Aligning Carrier Idlers Transom Sets

Sometimes difficult working conditions result in lateral movement of belts. Usage of self-align carrying idler transoms set help to correct belt tracking and maintain its centering. The Idlers are mounted on swiveling transform which is centrally pivoted on a stationary frame to swelling ring/bearing which permits rotation (5º to 10º) . Vertical guide roller is provided at each end of swiveling frame which tries to push the misaligned belt towards conveyor centre line. These rollers can be aptly positioned at 15 to 20mtrs from end pulleys at pitch of 30 to 40 mtrs on long conveyors.

Self Aligning Return Idlers Set 

Self-aligning return idlers under the return belt run at an interval of 21 to 30m in place of usual return idler. General practice is to use such idlers at every 7^th to 10^th pitch of standard Idler. The idler applies aligning force on return belt run whenever it deviates from conveyor centre line.

Flat & Rubber ring Return Rollers

The flat return idler has a single roll to support the return run of the belt conveyor. The idler consists of single roll and a pair of brackets to install below conveyor stringers.

Support Rollers 

Support rings make it easier to keep conveyors clean, prevent material clogging on return idlers and promote tracking. Steel rollers made of concentric tubes are generally used in monotrough transoms as return rollers. However in applications where the return side cannot be turned over or when the material conveyed is sticky, specially-designed support rings are fitted on the return roller.

The use of support rings substantially reduce the cost of cleaning maintenance, prevent material caking on the return rollers, promote smooth straight tracking of the belt and reduce breakaway resistance on start-up. CLIMAROLL SUPPORT RINGS make it easier to keep a conveyor system clean. They have proven particularly successful on systems where the return side cannot be turned over. When support rings are drawn over the existing idlers in accordance with assembly instructions, the small contact area of each ring leaves merely a thin trace of fine parallel lines on the belt cover.

Support Rings

For applications involving normal stressing, the ring is made from one material only .Size of the rubber ring is governed by the outer diameter of the tube to be used (ERW, seamless or boiler tubes). Inner diameter of the rings to be kept smaller than that of the tube’s outer diameter, giving it a firm and lasting seat.

Arrangement Of CLIMAROLL Support Rings

Special Rollers

Belt Tracking & Self Cleaning Rollers

Spiral metal coil turns running from center left and rightwards provide belt cleaning during its return, reduce material depositing and tracking.

Guide Rollers

Guide rollers are mounted vertically or at a suitable degree on transoms to restrain a belt’s lateral drift or movement. Most apt location of mounting is on a self-aligning transom. Rollers with one side shaft and threaded ends are most common.

Industrial Rollers

We produce a wide range of industrial rollers including V-rollers, nip rollers, idler rollers, freed rollers, pulleys, drive wheels, ringer rollers & custom-shaped rollers.

ORF’s in-house machine provides the ability to fabricate new rollers or wheels, as well as refurbish and recover existing rollers. Our precision machining ensures required dimensional tolerances and surface finish.

ARMORED® Rollers

Armored® is a range of products developed by ORF to suit extreme conditions. Applications range from military, desalination, road & transport and bulk material handling.

The Armored® roller is a first of its kind, designed for five years of operational life. Its rugged design ensures sustainable uninterrupted operation. It is also lighter than the average idler, ensuring low power consumption of the conveyor and easy maintenance. Special bearings ensure low roll resistance, further reducing power requirements during start/stop operations.

The Armored® layer ensures low abrasion, belt friendly operation, high resistance to chemical agents, corrosion resistance and low noise operation. The layer is also self cleaning, preventing material build-up limiting belt misalignment issues.

Roller Selection

Drum Pulleys

Salient features

Pulleys are dimensioned, designed & constructed according to characteristic of each belt conveyor system of ORF. Pulleys are manufactured using material of the highest quality, strict process control and employing advanced technology. Dependable, long performance, rigid sturdy design and reduced maintenance cost

Apt selection of pipe shell, side & stiffener plates, welding method, type of fitment and shaft design. Sizes: 200-1200mm dia x 500 – 2500mm length

Types: Head, Tail, Snub, Bend, Take-ups, Wing pulleys. Also motorized with a built-in drive and transmission.

Smooth steel surface without lagging for small belt width and power, dry and non-drive ends application

Bearings :

Salient features