INSPECTION AND CUSTOMERS
Testing and inspection of idlers is carried out at each and every stage of the manufacturing process and is a continuous activity at our manufacturing facility. All our idlers are 100% checked for their dimensional accuracy as per specification and relevant standards during the manufacturing process as well as after assembly.
For the purpose of understanding, some of our standard inspection and testing procedures on the finished product are given below.
The rollers, once manufactured are subjected to following tests.
Free Rotation Test
This is required to check :
- Free rotation of idlers
- Proper setting of internal components.
- To know any rise in temperature in the bearing seating area.
Out of Run Test
The maximum allowable run-out for idlers is 0.8 mm, which is much lesser than the limit provided by IS: 8598. The run out test is carried out on a special fixture with a run out dial indicator.
Dust Ingress Test
This is one of the most important tests required to check any ingress of dust in the rollers bearings. Most of the idler rollers are used in an atmosphere with high contamination of dust particles. We ensure that all the rollers are perfectly sealed at bearing assembly to avoid any dust ingress while in use. This is achieved by performing dust ingress test, where a roller is rotated at a specific RPM in a closed chamber having a continuous cloud of dust which is maintained for a particular time period. At the end of the test, the bearing assembly is removed to check any ingress of dust inside the bearing assembly.
Water Ingress Test
This is similar to dust ingress test where the efficiency of sealing arrangement is tested against the ingress of water. The roller is rotated in a special fixture having water showers spraying water on to the roller housings at a particular pressure. At the end of the test, the bearing assembly is removed to check any ingress of water droplets inside the bearing assembly.
Friction Factor Test
The friction factor is an important parameter of a roller design and directly affects the efficiency and power requirement of a conveyor system. It also indirectly affects the life of the bearings.All our idlers are tested for friction factor less than 0.015 which conforms to IS-8598.The friction factor test is carried out dynamically under load on a special designed machine with a digital tachometer, which gives digital output of the dynamic friction factor.
Weld Quality Test
This is done to ensure a good quality of weld at the end discs and housing seats. This in either done visually or by Die Penetration Test as per agreed QAP with the customer.
Paint Thickness Test
To ensure a minimum thickness of red-oxide and paint enamel over the roller shell our idlers are tested with paint thickness gauge on client request.
