Optimization Conveyor Roller, LKAB

Abstract

This master thesis presents a study on the structural optimization of conveyor idlers, focusing on the idler shell and shaft. The research aims to enhance the performance and efficiency of conveyor systems by reducing weight and improving stability of idler roller, beginning with a thorough load analysis to determine the static and dynamic forces exerted on idler. The study employs a combination of numerical simulations and analytical methods to analyze the idler's structural integrity and performance, using SOLIDWORKS and ANSYS, and provide insights into stress distribution, deformation characteristics, and mode shapes inherent in idler roller system, forming the basis for further optimization. Alternative materials such as Resin Epoxy, PVC, and HDPE are evaluated against traditional structural steel for roller shell. Comparative analysis of mechanical properties, weight reduction potential, and cost-effectiveness identifies these materials as a viable alternative to steel, offering opportunities for improved performance and environmental stability. Moreover, the optimization of hollow shaft results in weight reduction while maintaining structural integrity, as evidenced by finite element analysis results. Modal analysis of the idler system reflects its dynamic behavior and vibration characteristics, enabling the development of damping strategies to ensure smooth operation under varying load conditions. In conclusion, this master thesis focuses on structural analysis for optimizing conveyor idler, addressing key challenges in materials handling systems and paving the way for further innovation in the field.