Dunlop Catalog Simulation
Dunlop Catalog Simulation
CLASSIC HD
CLASSIC PLUS
CLASSIC
Optimising the
component design
Fenner Dunlop utilise custom developed idler
design software to maximise the accuracy and
speed of product design and manufacturing.
3D CAD software and Finite-Element Analysis (FEA)
packages allow us to optimise the component design
and selection process whilst maintaining flexibility.
ROLLER SHELL
TIR Avg Trough Roller = 0.50mm Avg Trough Roller = 0.50mm Avg Trough Roller = 0.15mm
ROLLER SHAFT
Material GB/T 905 – Q235 GB/T 905 – Q235 GB/T 905 – Q345
BEARING
Deep Groove Ball Bearing, Deep Groove Ball Bearing, Deep Groove Ball Bearing,
Type
C3 Clearance C3 Clearance C3/C4 Clearance
Lubrication Sealed for Life, ENS equivalent Sealed for Life, ENS Sealed for Life, ENS
SEALING
Material Fire Resistant Nylon Fire Resistant Nylon Fire Resistant Nylon
SURFACE PROTECTION
Type 2 Coat Paint System 2 Coat Paint System 2 Coat Paint System
PERFORMANCE CHARACTERISTICS
*Based on 152 Dia Roller, 6306 NSK Bearing with Self Cleaning Labyrinth Seal running at 750rpm. Running Friction
measured at the face as per SANS1313-1. ** Subject to LECS Warranty Terms and Conditions
1
8 7
Classic
All-purpose economy roller
GB/T 13793 - Q235B The Classic Roller shell consists of a 4mm shell compared to the 3.5mm industry
Material standard shell thickness. Unlike the A.S steel specifications we’re able to specify
(Grade PD.C, PT.B, PS.C)
a tolerance for each parameter so the roller quality is matched to the client’s
Shell Thickness 4mm requirements. This shell uses:
TIR Avg Trough Roller = 0.50mm • High Accuracy (PD.C) Diameter tolerance for consistent TIR
• Medium/high accuracy (PT.B) shell thickness tolerance
• High accuracy (PS.C) shell straightness tolerance.
All these tolerances meet or exceed AS1450 requirements. We believe by
specifying each individual tolerance we can supply a more consistent roller and
have better control over our quality. (refer material specifications comparison sheet)
ROLLER SHAFT
Material GB/T 905 – Q235 The Shaft material is of Grade 8 Q235 precision ground cold drawn bar to GB/T905
Type Plain
Material SPCC The bearing housing is SPCC pressed steel, 3.5mm in thickness. The housing
has an interference fit into the shell to provide accurate concentricity, It’s then
Type Pressed
robotically fillet welded to completely seal and lock the housing in place. Welds are
Fit Interference + Weld not in contact with the belt at any time, maximising belt life and roller fatigue life.
BEARING
Manufacturer LYC, NSK Have your choice of NSK or more economical LYC brand bearing in your roller. Both
options consist of a double steel shield deep groove ball bearing with C3 clearance.
Sealing 2Z
Fenner Dunlop prefer ENS grease in our NSK bearings for the best performance
Type Deep Groove Ball Bearing, C3 Clearance under varying local temperatures especially in the hot Australian climate.
SEALING
Material Fire Resistant Nylon Our Rollers use fire resistant self-cleaning labyrinth seals. Our seals consist of a 4
part design comprising of:
Type Self Cleaning Labyrinth
• A primary steel outer seal that utilizes centrifugal force to expel containments at
Grease HP-R Blue the face of the roller, this is extremely effective once the roller is at speed and
can self-drain water at a 0-45 degree angle.
• A secondary steel containment chamber
• A tertiary grease filled multi labyrinth seal chosen to minimise running friction
whilst still preventing the ingress of contaminants.
• Finally there is a back seal on the opposite side of the bearing to stop reverse
contamination of the bearing.
Both the front and rear sealing are filled with HP-R type grease which provides a
high drop point of 250 degrees whilst providing optimal viscosity for best ingress
protection, low running friction and low energy consumption.
SURFACE PROTECTION
Type 2 Coat Paint System The standard roller comes with a 2 coat paint system which is applied to the
face, bearing housing and shaft ends providing storage protection and anti-rust
Coating Thickness 40μm properties whilst in service.
PERFORMANCE CHARACTERISTICS
Running Friction 2N*
Warranty** 12 months
* Based on 152 Dia Roller, 6306 NSK Bearing with Self Cleaning Labyrinth Seal running at 750rpm. Running Friction measured at the face as per SANS1313-1
** Subject to Warranty Terms and Conditions
1
9 8 7
Classic Plus
High quality roller - built to last
GB/T 13793 - Q345B The Classic Plus Roller shell consists of a 4mm shell compared to the 3.5mm
Material industry standard shell thickness. Unlike the A.S steel specifications we’re able
(Grade PD.C, PT.B, PS.C)
to specify a tolerance for each parameter so the roller quality is matched to the
Shell Thickness 4mm+ client’s requirements. This shell uses:
TIR Avg Trough Roller = 0.50mm • High Accuracy (PD.C) Diameter tolerance for consistent TIR
• Medium/high accuracy (PT.B) shell thickness tolerance
• High accuracy (PS.C) shell straightness tolerance.
All these tolerances meet or exceed AS1450 requirements. We believe by
specifying each individual tolerance we can supply a more consistent roller and
have better control over our quality. (refer material specifications comparison sheet)
ROLLER SHAFT
Material GB/T 905 – Q235 The Shaft material is of Grade 8 Q235 precision ground cold drawn bar to GB/
T905. The shaft is precision machined to house the bearing with a stepped
Type Plain
shoulder for increased bearing support.
Bearing Seat Tol. h8
Material SPHE The bearing housing is SPHE pressed steel, 3.5mm in thickness. The housing
has an interference fit into the shell to provide accurate concentricity, It’s then
Type Pressed
robotically fillet welded to completely seal and lock the housing in place.
Fit Interference + Weld Welds are not in contact with the belt at any time, maximising belt life and roller
fatigue life.
BEARING
Manufacturer NSK NSK deep groove ball bearing with C3 clearance are used in all Classic Plus
Rollers and utilize 2zz or 2rs sealing depending on the application. Fenner Dunlop
Sealing 2Z
exclusively use ENS grease in our NSK bearings for the best performance under
Type Deep Groove Ball Bearing, C3 Clearance varying local temperatures especially in the hot Australian climate.
SEALING
Material Fire Resistant Nylon Our Rollers use fire resistant self-cleaning labyrinth seals. Our seals consist of a 4
part design comprising of:
Type Self Cleaning Labyrinth
• A primary steel outer seal that utilizes centrifugal force to expel containments at
Grease HP-R Blue the face of the roller, this is extremely effective once the roller is at speed and
can self-drain water at a 0-45 degree angle.
• A secondary steel containment chamber
• A tertiary grease filled multi labyrinth seal chosen to minimise running friction
whilst still preventing the ingress of contaminants.
• Finally there is a back seal on the opposite side of the bearing to stop reverse
contamination of the bearing caused by condensation.
Both the front and rear sealing are filled with HP-R type grease which provides a
high drop point of 250 degrees whilst providing optimal viscosity for best ingress
protection, low running friction and low energy consumption.
SURFACE PROTECTION
Type 2 Coat Paint System The standard roller comes with a 2 coat paint system which is applied to the
face, bearing housing and shaft ends providing storage protection and anti-rust
Coating Thickness 40μm
properties whilst in service.
PERFORMANCE CHARACTERISTICS
Running Friction 2N*
Warranty** 18 months
* Based on 152 Dia Roller, 6306 NSK Bearing with Self Cleaning Labyrinth Seal running at 750rpm. Running Friction measured at the face as per SANS1313-1
** Subject to Warranty Terms and Conditions
1
9 8 7
Classic HD
High quality roller - built to last
GB/T 13793 – Q345B The Heavy Duty Roller shell consists of a 6mm shell compared to the 3.5mm
Material industry standard shell thickness. Unlike the A.S steel specifications we’re able
(Grade PD.C, PT.B, PS.C)
to specify a tolerance for each parameter so the roller quality is matched to the
Shell Thickness 6mm + client’s requirements. This shell uses:
• High Accuracy (PD.C) Diameter tolerance for consistent TIR
TIR Avg Trough Roller = 0.15mm
• Medium/high accuracy (PT.B) shell thickness tolerance
• High accuracy (PS.C) shell straightness tolerance.
All these tolerances meet or exceed AS1450 requirements. We believe by
specifying each individual tolerance we can supply a more consistent roller and
have better control over our quality. (refer material specifications comparison sheet)
ROLLER SHAFT
Material GB/T 905 – Q345 The Shaft material is of Grade 8 Q345 precision ground cold drawn bar to GB/
T905. The shaft is precision machined to house the bearing with a stepped
Type Stepped
shoulder for increased bearing support.
Bearing Seat Tol. h6
Material Q345 Bearing housings are made from cast Q345 and precision machined for best fit.
Housings are specifically designed for each application to maximise roller life and
Type Cast/Machined
durability whilst minimizing bearing deflection and fatigue. The housing has an
Fit Interference + Weld interference fit into the shell to provide accurate concentricity, It’s then robotically
fillet welded to completely seal and lock the housing in place. Welds are not in
contact with the belt at any time, maximising belt life and roller fatigue life.
BEARING
Manufacturer NSK, FAG, SKF NSK deep groove ball bearing with C3 or C4 clearance are used in all Classic
HD rollers and utilize 2zz or 2rs sealing depending on the application. FAG &
Sealing 2Z, 2RS
SKF bearings are also available upon request. Fenner Dunlop exclusively use
Deep Groove Ball Bearing, ENS grease in our NSK bearings for the best performance under varying local
Type temperatures especially in the hot Australian climate.
C3/C4 Clearance
Lubrication Sealed for Life ENS
SEALING
Material Fire Resistant Nylon Our Rollers use fire resistant self-cleaning labyrinth seals. Our seals consist of a 4
part design comprising of:
Type Self Cleaning Labyrinth
• A primary steel outer seal that utilizes centrifugal force to expel containments at
Grease HP-R Blue the face of the roller, this is extremely effective once the roller is at speed and
can self-drain water at a 0-45 degree angle.
• A secondary steel containment chamber
• A tertiary grease filled multi labyrinth seal chosen to minimise running friction
whilst still preventing the ingress of contaminants.
• Finally there is a back seal on the opposite side of the bearing to stop reverse
contamination of the bearing caused by condensation.
Both the front and rear sealing are filled with HP-R type grease which provides a
high drop point of 250 degree’s whilst providing optimal viscosity for best ingress
protection, low running friction and low energy consumption.
SURFACE PROTECTION
Type 2 coat paint system The standard roller comes with a 2 coat paint system which is applied to the
face, bearing housing and shaft ends providing storage protection and anti-rust
Coating Thickness 70μm
properties whilst in service.
PERFORMANCE CHARACTERISTICS
Running Friction 2N* All premium HD Rollers come dynamically balanced to reduce noise and vibration
and are 100% quality checked at final assembly to ensure reliable and optimal
Balance Quality G16
performance.
Warranty** 24 months
*Based on 152 Dia Roller, 6306 NSK Bearing with Self Cleaning Labyrinth Seal running at 750rpm. Running Friction measured at the face as per SANS1313-1
** Subject to Warranty Terms and Conditions.
ROLLER TUBE MATERIAL COMPARISON:
AS1450 vs GB/T 13793
GEOMETRIC PROPERTIES
Mechanical Properties
GEOMETRIC PROPERTIES
Diameter Variation h8 h8
Mechanical Properties
Q235B : 20 %
Elongation before Fracture M1020 : 13 %
Q345B : 18 %
Rollers life cycle
Whilst the initial capital cost of a roller is often the
only commercial consideration in a new product
purchase, the total life-cycle cost is generally
much more important.
Recycling
Cost of disposal,
recycling options
Replacement
Operation life (L10, Roller
Life-Cycle
grease life, etc.), supply
chain & leadtimes
Maintenance Purchase
Time between maintenance, Capital Cost
wash down etc.
Operation Installation
Friction, rim drag - Ease of installation,
Power Consumption OH&S - manual feeding
Each phase in a roller’s life Fenner Dunlop can work with site operations to
synergise these processes and help reduce the total
has an associated cost, from roller cost. We design specifically for site conditions
so our Rollers are not over or under engineered,
the initial capital expenditure maximizing running efficiency ie power consumption.
disposal and replacement. the bearing life of the Classic and Classic Plus Rollers.
This very basic example considers only the capital cost
and life expectancy, ignoring other factors including
revenue lost from system downtime (ie. the benefits
could be greater).
The below is an illustrative example of the benefits of
considering the life-cycle cost rather than simply just
the upfront costs.
Cost per year of operation $27.65 per year $25.52 per year 8% reduced cost
Note: 6306ZZ NSK bearings, 2200N @ 500RPM. ISO Life represents standard bearing life calculation methods. ABLE L10 represents overall design
life calculation, incorporating fatigue, load, lubrication and contamination failure methods. Fenner Dunlop Whole-of-life design optimizes ABLE life,
representing a far lower life cycle cost impact to the client’s maintenance costs.
Thinking Globally. Acting Locally.
Idlers
Cleaners
Idlers
Cleaners
Idlers
Drives
Idlers
Cleaners
Idlers
Cleaners
Thinking Globally. Acting Locally.
Thinking Globally. Acting Locally.
Darwin
Cairns
Townsville
Mackay
Mt Isa
Port Hedland
Karratha
Emerald
Gladstone
Brisbane
Somersby
Perth Whyalla Sydney
Wollongong
Adelaide
Melbourne
MAP KEY
Manufacturing
Burnie
Service Centre
It doesn’t matter what challenge you are facing with your conveyor or how small
or large the problem, we have Fenner Dunlop service centres nationwide with
fully trained technicians ready to take your call and provide the required support.