TL;DR
Noise from an idler roller almost always means a seized or worn bearing. Walk the conveyor at low speed with the covers removed to identify the bad roller by sound and wobble.
What you might see
- grinding or squealing from rollers
- rhythmic thumping as belt passes a point
- noise changes with belt speed
- visible wobble on one or more rollers
Likely causes
Idler roller bearing seized from lack of lubrication or contamination ingress
Flat spot on a roller from extended stop while loaded
Damaged or cracked roller shell vibrating as the belt passes over it
Belt splice bump creating a repeating impact on idlers at the splice frequency
Required tools
- Roll pin punch and hammer
- Replacement idler rollers (Hytrol standard hex axle)
- LOTO kit
- Tape measure
Safety first
- Lock out the drive before reaching into the conveyor frame to change a roller.
- A seized roller with a running belt can catch a glove or sleeve. Never reach over a moving belt.
Procedure
- 1
Run the conveyor empty at slow speed and walk the length to isolate the noise source. Seized rollers often smoke or feel hot to a brief touch on the shaft end.
- 2
Lock out the drive motor.
- 3
Spin each suspect roller by hand. A seized roller does not turn or turns with grinding resistance.[1]
- 4
Replace any seized or wobbling roller. Hytrol EZLogic rollers use a standard hex axle; remove the roll pin or clip securing the axle and slide the roller out.[1]
- 5
Check the replacement roller's bearing for the correct sealing type. Use sealed bearings in wet or dusty environments.
- 6
Check the belt splice for a raised edge or a damaged fastener creating a repeating thump. Re-splice if the mechanical fastener is raised more than 3 mm.
Sources
Hytrol EZLogic Accumulation Conveyor Service Manual, Hytrol Conveyor Company
Hytrol EZLogic Conveyor IOM, roller and bearing replacement procedures (general)
View source
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