Quality of the rollers

Quality of the rollers

In large belt conveyors, thousands of conveyor rollers are in continuous use - often under extreme conditions. This fact alone results in the demand for maximum availability of each individual roller. Downtime, especially unplanned downtime, can significantly reduce the economic efficiency of conveyor systems. Conveyor roller failures can cause such downtimes - even if only a single roller out of thousands fails! It is therefore important to keep the number of roller failures as low as possible, which in turn means the demand for the longest possible service life and high quality of the rollers.

Our conveyor rollers, pulleys, idlers and conveyor roller garlands for bulk material handling systems meet this requirement - for many years to come.

Whether lignite mining in Germany or Thailand, various underground mines, sand and gravel pits in Eastern Europe, copper mines in Chile or iron ore mines in Brazil and Australia - hundreds of belt conveyors with our rollers are in use worldwide - even under extremely unfavorable operating conditions. We are one of the market leaders for conveyor rollers in the German lignite mining areas.

Our standard range includes all types of conveyor rollers as well as complete idlers and conveyor roller garlands for belt conveyors with belt widths of up to 3,200 mm. Thanks to our 90 years of expertise in the field of conveyor rollers and roller bearings technology, we can supply solutions for a wide range of applications.

Quality means a lot to us. "Made in Germany" is and remains a guiding principle and a central message of Artur Küpper GmbH & Co. KG.

Technology as the basis for the success of our conveyor rollers

In essence, the following technological components form the basis for the success of our conveyor rollers:

1. Reliable seals

A patented labyrinth seal developed by us creates the conditions for problem-free operation even under extreme environmental conditions (see QLR hybrid seal). It offers very good protection against both water and dust (see laboratory and field tests).

If the operating conditions are particularly demanding, we use additional sealing or protective elements:

• Roller protector - additional elastic seal to increase the protection against dust particles and splash water. It extends the service life of the QLR seal.
• "Weather shield" - to protect ther rollers against blocking due to jamming of small stones between the idler frame and the rotating face of the idler roller. By installing the fixed weather shield, the risk of jamming is almost completely eliminated.
• Dust cover and rain protection cap - they form an additional sealing assembly for protection in extreme conditions.
• Customized special solutions - in exceptional cases, further additional elements are useful (e.g. for cleaning with a high-pressure cleaner). We can develop these for you on an application-oriented basis.

2. Optimized bearings

For the production of conveyor rollers, we use AKT bearings as standard, which have been specially designed for use in the conveyor rollers:

• Adjustments to the bearing geometry;
• Properties and quantity (about 60% of the free bearing volume) of the grease;
• Design and material of the bearing cages for increased service life and improved emergency running properties;
• Seals on both sides (Z-shields).

3. Suitable materials and high quality of the conveyor roller components and laggings

All half-finished components and parts are purchased in accordance with the relevant standards and are subjected to strict quality controls on delivery. For many purchased materials, e.g. for the tubes, our own factory standards apply, which add further restrictions to the specifications of the generally applicable standards (see material purchasing and cutting).

4. Application-related calculations and structural design

Both the manufacture and design of the conveyor rollers and the corresponding calculations are always carried out by us on an order-related and therefore application-related basis. We make sure that our conveyor rollers fit your conveyors.

5. Precise and reliable production

Every step of our production and quality assurance is carefully considered and weighed up - always with the aim of achieving the highest quality and customer satisfaction.