18th April 2016
Jimblebar Expansion Project: 15 876 Rollers, 5 440 Frames, 6.35km of Conveyor
With idler misalignment contributing up to 29% of conveyor power requirements, low noise rollers and high tolerance frames were a prerequisite for the Jimblebar Expansion.
The Low noise rollers for CV002 were machined accurately to 0.05 TIR (Total Indicator Run-out) and a 3.2 µm surface finish, with maximum imbalance of 0.014 Nm/Roll and balance quality G16 as per ISO 1940-1. Low noise rollers have the same extremely tight balance, surface finish, and TIR requirements of weigh rollers. This not only reduces noise, but also reduces reciprocating forces on the roller bearings and nearby structure, enhancing roller life reliability and reducing power requirements.
The High Tolerance frames for CV002 were fabricated to ensure that all rollers were parallel to within 0.5mm and all rolls were located within 1mm across their other dimensions. The frame mounting and positioning points were also fabricated to within 0.5mm across all their locating dimensions. On site the high accuracy frames were able to be as datum points in the BHPBilliton frame alignment jigs to assemble the conveyor. This allows for extremely low conveyor misalignment, again increasing roller life and reducing power requirements.
With the ability of our modern manufacturing and balancing machinery to repeatedly produce high precision conveyor products, strict tolerances are becoming a viable option for improving the performance, reliability, safety, and logistical control of modern conveyors and the other systems that interact with them.
The high tolerance Idler assemblies designed, engineered and manufactured by CPS, in conjunction with the BHPBilliton frame alignment jig, allowed the Sedgman Civmec Joint Venture to build and install a conveyor with lower misalignment and vibration parameters than industry standards. This allowed them to meet their lower power consumption KPI.
We will update on commissioning later in the year.