Increased Performance at a Copper Mine

Schaeffler offered the customer the optimum solution for its requirements. Thanks to the new X-life bearings and the special housing, it was possible to increase the output of the system by 50 percent without the need for high levels of investment in modifying the existing system. The problems affecting the take-up pulleys – which led to frequent failures – were resolved and higher plant availability was achieved as a result.

At the copper mine, a complex conveying system transports enormous quantities of crushed ore. Day after day, the overland conveyor system transports 150 000 tons of ore per hour over a distance of eight kilometres. The customer was planning to increase the throughput (speed) of the system by 50 percent, without making any changes to overall structure, framework, foundation or footprint. The key challenge was to fi nd bearings that would not only fi t the existing housings but also withstand the new, extreme loads and still have acceptable bearing life. Furthermore, the system was experiencing frequent failures of the tension/take-up pulleys even at the existing performance rate, so improved bearings and housings were necessary also for those locations.

The relevant sales engineer contacted the Schaeffler Technology Center in Danbury, USA. Following thorough analysis, the engineer here determined that upgrading the existing bearings to the new E1 X-life version was the best solution for the new requirements. The problem that this version was not yet in production was discussed with the relevant product line in Germany. It was possible to bring forward the start of production by more than one year in order to fulfi ll the delivery requirements of the customer. At the same time, an expert from Schaeffl er Canada was able to resolve the problem with the take-up pulleys. He designed a special housing that would accomodate a larger shaft size and bearing but maintain all critical dimension. So no changes were needed to existing mounts.