By replicating real operating conditions, the Loaded Run Up Machine detected faults that standard unloaded testing could not. The result was verified bearing performance, increased pulley longevity and zero pulley failures over a 12-month period. 

The Challenge

With the need to have improved and unwavering reliability in conveyors in todays changing global climate, the risk of failure needs to be managed and eliminated effectively. For many years, conveyor pulleys have had bearings fitted by experienced fitters with failures still occurring. Each failure potentially costs the company hundreds of thousands of dollars in down-time, on top of the costs associated with repairs and change-outs.

Many blue-chip clients have started looking for a way to verify that equipment is in suitable condition to run successfully, right from when it first arrives on-site. Subsequently, BMA Broadmeadows updated site supply standards to request that vibration analysis be completed on all OEM and aftermarket supply/repair works.

This provided a challenge for Fenner Conveyors’ engineering business, ACE, to find a way to test various pulleys across applications - a single machine that was capable of testing 25 tonne iron ore pulleys, alongside 300kg wash-plant pulleys. The customer required ACE to test four dual-drive 10 tonne pulleys - the largest pulleys ACE had been required to test.

The Solution

ACE designed a Loaded Run Up Machine, increasing pulley testing capabilities by all dimensions, including weight, load, diameter, face-width, and housing centres.

• Designed to test against site VA standards.
• PLC Variable loading conditions mimic site operations.
• PLC Variable wrap angle to mimic site operation.
• Infinitely variable belt speed to handle the different speed requirements.
• Risks were managed to ensure that all personnel were safe when operating/around the gear.

The Results

Known bearing faults and frequencies were verified by both ite data and failure analysis.

With the ability to discover lower amplitude of frequencies, ACE were able to reduce the risk of bearing failure.

Mimicking operating set up ensured results were representative of VA on-site, giving the customer confidence that pulleys are built to standards and would not fail.

Loaded Run Up testing proved that it can handle all pulleys available in the Australian market.