DASH Engineering are a Perth based engineering consultancy specialising in rolling bearing applications and failure analysis. Through years of work with Pilbara-based mining clients, it became apparent that the current ‘standard’ for contamination mitigation (sealing) in conveyor pulley bearings is ineffective, un-reliable and un-predictable, resulting in failures occurring unexpectedly and costing millions in downtime and lost production.

‘A solution is required’

The statement from a major Pilbara-based iron ore producer, after a series of failures and subsequent investigations, revealed ingress of contamination to be the root cause of failure.

Data shows that standard ‘Taconite Seal’ designs are fundamentally ineffective against contamination ingress and do not allow for misalignment of the shaft or axial float of the bearing, both of which are required in a conveyor pulley.

The challenge set for DASH Engineering was to develop a seal that was:

1.  Effective against ingress of ‘dirt and water’;
2.  Able to function effectively whilst installed in inherently misaligned applications (up to the limits of the bearing);
3.  Able to accommodate axial float;