Failure analysis of idler roller bearings in belt conveyors

Abstract In this paper, we examined a hundred roller bearings of belt conveyor idlers where a fault occurred. Such examinations of damages of bearings indicate possible causes that lead to damages, as well as the necessary measures to eliminate them completely or at least reduce them. The bearings examined had been collected for 6 months, during the idler repair. After examining the bearings, each identified damage was illustrated by an appropriate photograph, classified according to ISO 15243:2004 (E) standard and appropriately described in the form of manifestation and cause. Research has shown that the most dominant damages are plastic deformation in the form of increased gaps and oxidation corrosion. In addition, a description and photographs of the consequences of certain types of damage to roller bearings were given. The paper also examines the impacts of the installation sites of idlers, lateral (oblique) and horizontal position. Possible main causes of damage to roller bearings are diagrammatically shown by the fault tree analysis (FTA). The established fault tree can be a useful tool for engineers in maintaining and defining the requirements while requesting new idlers.