These cylindrical components are essential parts of conveyor systems, transferring power from the drive motor to the belt, facilitating material movement. They are typically positioned along the length of the conveyor frame, supporting the belt and ensuring its smooth, continuous operation. Different types exist, including grooved rollers for improved belt traction and tracking, as well as impact rollers designed to absorb shock from heavy or irregularly shaped items. The size and material composition vary depending on the specific application, with factors like load capacity, belt speed, and operating environment influencing the selection.
Efficient material handling is crucial across numerous industries, and these rotating elements play a vital role in achieving that. By enabling the controlled and consistent flow of goods, they contribute to increased productivity, reduced manual labor, and enhanced operational safety. Their historical development has mirrored advancements in industrial automation, evolving from simple wooden cylinders to precisely engineered components capable of withstanding demanding conditions in modern manufacturing, logistics, and mining operations. The ability to customize these components for specific applications has further solidified their importance in diverse sectors.
This discussion will further explore key aspects of these critical components, covering topics such as material selection, design considerations, maintenance procedures, and common troubleshooting techniques. Understanding these aspects is fundamental for optimizing conveyor system performance and ensuring long-term reliability.
1. Material Selection
Optimal material selection for conveyor belt drive rollers is crucial for ensuring system efficiency, longevity, and safety. The chosen material directly influences the roller’s ability to withstand operational stresses, environmental conditions, and the specific demands of the conveyed material. Careful consideration of these factors is essential for minimizing downtime and maximizing return on investment.
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Steel
Steel rollers offer high strength and durability, making them suitable for heavy-duty applications and environments where impact resistance is paramount. Different steel alloys can be selected based on specific needs, such as stainless steel for corrosive environments or hardened steel for high-impact applications. For example, steel rollers are commonly used in mining operations and heavy manufacturing.
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Aluminum
Aluminum rollers provide a lighter weight alternative to steel, reducing the overall system weight and energy consumption. This can be particularly advantageous in applications requiring higher belt speeds or where the conveyor structure has load limitations. Aluminum’s corrosion resistance also makes it suitable for certain environments. An example would be food processing conveyors.
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Plastic (e.g., HDPE, PVC)
Plastic rollers, such as those made from High-Density Polyethylene (HDPE) or Polyvinyl Chloride (PVC), offer excellent corrosion resistance and are often used in applications involving wet or corrosive materials. They are generally lighter and less expensive than steel or aluminum, but with lower load-bearing capacity. These are frequently employed in packaging and light-duty material handling.
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Rubber-Covered Rollers
Rubber lagging or coatings can be applied to steel or aluminum rollers to enhance grip, reduce slippage, and cushion conveyed items. Different rubber compounds offer varying degrees of abrasion resistance, hardness, and temperature tolerance. These are advantageous when handling fragile items or when increased belt traction is required, such as on inclined conveyors.
The selection of roller material significantly impacts the overall performance and lifespan of a conveyor system. Matching the material to the specific application requirements, considering factors like load, environment, and budget, is essential for maximizing system efficiency and minimizing long-term costs. While steel offers strength, aluminum provides lighter weight, and plastics offer corrosion resistance, the ultimate choice depends on a careful analysis of operational parameters and desired outcomes. This informed decision contributes directly to optimized performance and longevity.
2. Diameter
Roller diameter significantly influences conveyor belt system performance and efficiency. Larger diameter rollers generally reduce belt tension and flexing, leading to decreased wear and tear on both the belt and the rollers themselves. This is particularly important in long conveyor runs where cumulative stress can significantly shorten belt lifespan. Conversely, smaller diameter rollers increase belt tension and flexing, potentially causing premature wear, especially under heavy loads. The relationship between roller diameter, belt tension, and wear is a crucial factor in conveyor system design and optimization. For instance, in mining operations transporting heavy ore over long distances, larger diameter drive rollers are essential for minimizing belt fatigue and maximizing system longevity.
Furthermore, roller diameter affects the required drive motor power. Larger rollers require less torque to move the belt, potentially reducing energy consumption and operating costs. This is because a larger diameter translates to a greater lever arm, reducing the force needed to overcome friction. Smaller rollers, while requiring less initial investment, may lead to increased energy consumption over time due to higher friction losses. Therefore, the choice of roller diameter involves a trade-off between initial cost and long-term operational efficiency. In applications like package handling where loads are lighter and conveyor runs are shorter, smaller diameter rollers can be a cost-effective choice. However, in heavy-duty applications, the long-term benefits of larger diameter rollers often outweigh the higher initial investment.
In conclusion, the selection of appropriate roller diameter is a critical design consideration for conveyor systems. It directly impacts belt lifespan, energy efficiency, and overall system performance. Careful analysis of load requirements, conveyor length, and operational costs is necessary to determine the optimal roller diameter for a specific application. Balancing initial investment with long-term operational efficiency is key to achieving a cost-effective and reliable conveyor system. Neglecting the influence of roller diameter can result in increased maintenance costs, premature component failure, and reduced system lifespan.
3. Bearing Type
Bearing selection is critical for conveyor belt drive roller performance and longevity. Bearings directly influence rotational efficiency, load-bearing capacity, and maintenance requirements. Different bearing types offer varying performance characteristics, making careful selection essential for optimizing conveyor system reliability and total cost of ownership. Understanding the trade-offs between cost, performance, and maintenance requirements of various bearing types is crucial for informed decision-making.
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Ball Bearings
Ball bearings are commonly used in conveyor rollers due to their relatively low cost, high speed capabilities, and low friction. They are suitable for lighter loads and higher speeds but are less robust than roller bearings. Sealed ball bearings offer protection against contaminants, extending lifespan in dusty or harsh environments, such as those found in food processing or packaging facilities.
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Roller Bearings
Roller bearings offer higher load-carrying capacity compared to ball bearings, making them suitable for heavy-duty conveyor applications. Different roller bearing types, such as cylindrical, spherical, and tapered roller bearings, offer varying performance characteristics related to radial and axial load capacity. Tapered roller bearings, for example, are well-suited for applications with combined radial and axial loads, common in inclined conveyors or those handling bulk materials in mining or aggregate processing.
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Sleeve Bearings
Sleeve bearings, also known as plain bearings, offer a simpler and more economical alternative to rolling element bearings. They are typically used in low-speed, light-duty applications where precision and high efficiency are less critical. While generally less durable than ball or roller bearings, sleeve bearings can be suitable for specific applications with minimal radial loads and slow speeds, such as some light-duty assembly line conveyors.
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Specialty Bearings (e.g., Hanger Bearings)
Certain conveyor systems utilize specialized bearings like hanger bearings, designed for specific mounting configurations and load distributions. Hanger bearings are often employed in overhead conveyor systems where rollers are suspended from a support structure. Their design facilitates smooth rotation and load support within the specific constraints of the overhead configuration often seen in automotive assembly plants or paint lines.
The choice of bearing type significantly impacts conveyor system performance, maintenance needs, and overall cost. While ball bearings offer a cost-effective solution for lighter loads, roller bearings provide robustness for heavy-duty applications. Sleeve bearings offer simplicity and economy in low-speed scenarios, while specialty bearings address specific design constraints. Careful consideration of load requirements, speed, operating environment, and maintenance requirements is essential for selecting the optimal bearing type for a given conveyor application. Appropriate bearing selection contributes directly to optimized system performance, reduced downtime, and minimized lifecycle costs.
4. Shell Thickness
Shell thickness is a critical design parameter for conveyor belt drive rollers, directly influencing their load-bearing capacity and resistance to deflection. A thicker shell provides greater rigidity and strength, allowing the roller to withstand higher radial loads without deformation. Conversely, a thinner shell, while potentially offering cost savings in material usage, may deflect excessively under heavy loads, leading to uneven belt tracking, increased friction, and premature wear. This relationship between shell thickness, load-bearing capacity, and deflection is a crucial consideration in roller design and selection. For example, in heavy-duty applications like mining or steel mills, where conveyors transport extremely heavy materials, robust rollers with thick shells are essential to prevent deflection and ensure reliable operation.
Furthermore, shell thickness affects roller durability and resistance to impact damage. Thicker shells offer greater protection against dents and deformation caused by impacts from heavy or irregularly shaped materials. This is particularly important in applications where the conveyor handles abrasive or sharp-edged materials, such as in recycling plants or rock quarries. In such environments, a thicker shell contributes significantly to the roller’s lifespan and reduces the frequency of replacements. Conversely, in applications handling lighter, less abrasive materials, like packaged goods, a thinner shell may suffice, offering a balance between cost-effectiveness and adequate durability. Choosing the appropriate shell thickness depends on a careful analysis of the conveyed material’s characteristics and the operating environment.
In conclusion, shell thickness is a key factor influencing the performance, durability, and cost-effectiveness of conveyor belt drive rollers. A thorough understanding of the relationship between shell thickness, load-bearing capacity, deflection, and impact resistance is essential for optimizing roller design and selection. While thicker shells offer increased strength and durability, thinner shells can provide cost savings in appropriate applications. Careful consideration of the specific application requirements, including load characteristics, material properties, and operating environment, is paramount for selecting the optimal shell thickness and ensuring reliable, long-term conveyor system performance.
5. Lagging
Lagging plays a crucial role in optimizing the performance and lifespan of conveyor belt drive rollers. It refers to the application of a specialized covering material to the roller’s outer surface. This covering enhances grip, reduces slippage, and protects both the belt and the rollers from wear and tear. Understanding the various types of lagging, their applications, and their impact on conveyor system efficiency is essential for informed decision-making.
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Material Types
Lagging materials vary widely, each offering specific properties suited to different applications. Rubber lagging is common due to its high friction coefficient, providing excellent grip and reducing belt slippage, especially on inclined conveyors or those handling heavy loads. Polyurethane lagging offers superior abrasion resistance and is ideal for applications involving sharp or abrasive materials. Ceramic lagging provides extreme hardness and wear resistance, suitable for extremely demanding environments like those encountered in mining or quarrying. The choice of lagging material directly impacts the roller’s ability to maintain belt traction, resist wear, and withstand the specific challenges of the conveyed material and operating environment. For example, rubber lagging might be suitable for general-purpose conveying, while ceramic lagging would be preferred for handling abrasive materials like crushed rock.
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Thickness and Pattern
Lagging thickness and pattern also influence conveyor system performance. Thicker lagging generally provides greater grip and impact protection but can increase rolling resistance and energy consumption. Different lagging patterns, such as diamond, chevron, or plain, are designed to optimize grip and material flow in specific applications. Diamond and chevron patterns enhance traction, particularly on inclines, while plain lagging is suitable for general conveying where high grip is not paramount. The selection of lagging thickness and pattern depends on the specific needs of the conveyor system, balancing grip requirements with energy efficiency and material flow characteristics. For instance, a thicker, patterned lagging might be necessary for a steep incline conveyor handling heavy loads, while a thinner, plain lagging could suffice for a horizontal conveyor transporting lighter packages.
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Application Methods
Various methods exist for applying lagging to conveyor rollers. Vulcanized lagging involves bonding a pre-cured rubber layer to the roller shell, providing a durable and long-lasting bond. Cold bonding uses adhesives to attach the lagging, offering a simpler and often more cost-effective alternative, but with potentially reduced bond strength. Slip-on lagging involves pre-fabricated sleeves that fit over the roller, offering easy installation and replacement. Mechanical fastening, using bolts or clamps, secures the lagging to the roller, providing a robust attachment method, especially for high-impact applications. The choice of application method depends on factors like roller material, lagging type, and budget considerations. For example, vulcanized lagging might be preferred for heavy-duty applications requiring maximum bond strength, while slip-on lagging offers a convenient solution for quick replacements.
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Maintenance and Replacement
Regular inspection and maintenance of lagging are crucial for ensuring optimal conveyor system performance. Worn or damaged lagging can reduce grip, leading to belt slippage, increased energy consumption, and premature belt failure. Replacing worn lagging promptly minimizes downtime and prevents further damage to the conveyor system. Factors influencing lagging lifespan include material type, operating environment, and the conveyed material’s characteristics. Regular inspection schedules and established replacement procedures contribute significantly to maintaining conveyor system efficiency and reliability. For instance, in a mining operation handling abrasive materials, lagging might require more frequent inspection and replacement compared to a conveyor transporting packaged goods in a controlled environment.
Effective lagging selection, application, and maintenance are integral to optimizing conveyor belt drive roller performance and maximizing system lifespan. The interplay between lagging material, thickness, pattern, and application method directly impacts grip, wear resistance, and overall system efficiency. By carefully considering these factors and implementing appropriate maintenance procedures, conveyor operators can ensure reliable, cost-effective material handling and prolong the life of their equipment. Ignoring the importance of lagging can lead to decreased efficiency, increased downtime, and ultimately, higher operating costs.
6. Maintenance
Regular maintenance of conveyor belt drive rollers is crucial for ensuring optimal system performance, minimizing downtime, and extending the lifespan of critical components. Neglecting roller maintenance can lead to a cascade of problems, including belt misalignment, increased friction, premature wear, and ultimately, costly system failures. A proactive maintenance program focuses on preventing these issues through routine inspection, lubrication, cleaning, and timely replacement of worn or damaged parts. This proactive approach maximizes system reliability and minimizes the total cost of ownership.
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Roller Rotation and Alignment
Regularly checking roller rotation and alignment is fundamental. Rollers should rotate freely without binding or excessive noise. Misaligned rollers can cause belt tracking issues, increased friction, and premature wear on both the belt and the rollers. Proper alignment procedures, using specialized tools and techniques, ensure that rollers are parallel to each other and perpendicular to the belt’s direction of travel. In applications involving heavy loads or abrasive materials, frequent alignment checks are especially critical. For example, in a mining operation, regular roller alignment ensures efficient material transport and minimizes belt damage caused by misalignment-induced friction.
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Lubrication
Proper lubrication is essential for minimizing friction and wear within the roller bearings. Different bearing types require specific lubrication schedules and greases. Over-lubrication can be as detrimental as under-lubrication, potentially attracting contaminants and causing premature bearing failure. Following manufacturer recommendations for lubrication type, frequency, and application method is crucial for maximizing bearing lifespan and ensuring smooth roller rotation. In high-speed or high-temperature applications, specialized lubricants may be required to maintain bearing performance and prevent premature failure. For instance, in a food processing facility, using food-grade lubricants ensures compliance with hygiene standards while maintaining roller functionality.
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Cleaning and Debris Removal
Maintaining clean rollers is vital for preventing the buildup of material, dust, and debris that can interfere with roller rotation and belt tracking. Regular cleaning schedules, using appropriate cleaning methods and tools, minimize the risk of material accumulation and its associated problems. In environments with significant dust or debris, such as cement plants or woodworking shops, more frequent cleaning may be necessary. Specialized cleaning tools, like scrapers or brushes, can effectively remove accumulated material without damaging the roller surface or lagging. For example, in a sawmill, regular cleaning prevents sawdust buildup that could impede roller rotation and damage the conveyor belt.
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Inspection and Replacement
Regular visual inspections of rollers are crucial for identifying signs of wear, damage, or misalignment. Inspecting for cracks, dents, excessive wear on the shell or lagging, and bearing noise or stiffness allows for proactive replacement of worn components before they cause major system failures. Establishing a preventative maintenance schedule based on operating conditions and manufacturer recommendations ensures timely replacement of worn parts, minimizing downtime and maximizing system reliability. In critical applications where downtime is costly, such as in baggage handling systems at airports, regular inspections and prompt replacement of worn rollers are essential for maintaining continuous operation. For example, replacing a worn roller bearing before it seizes prevents further damage to the roller shell and potential belt damage.
Effective maintenance of conveyor belt drive rollers is essential for achieving optimal system performance, minimizing downtime, and extending the lifespan of critical components. By focusing on roller rotation and alignment, proper lubrication, cleaning and debris removal, and regular inspection and replacement of worn parts, operators can ensure the reliable and efficient operation of their conveyor systems. A proactive maintenance program, tailored to the specific application and operating environment, minimizes the risk of costly breakdowns and maximizes the return on investment in conveyor equipment.
7. Placement
Strategic placement of conveyor belt drive rollers is essential for optimized system performance, belt lifespan, and overall efficiency. Roller placement directly influences belt tracking, tension distribution, and load support. Incorrect placement can lead to belt misalignment, increased friction, premature wear, and even catastrophic belt failure. Understanding the principles governing optimal roller placement is crucial for designing and maintaining effective conveyor systems. For instance, in a long conveyor system transporting heavy materials, strategically placed rollers ensure even load distribution, preventing belt sag and minimizing stress on the belt and supporting structure. Uneven spacing can lead to localized stress points, accelerating belt wear and increasing the risk of failure.
Several factors dictate optimal roller placement, including belt width, load characteristics, conveyor length, and incline angle. For wider belts or heavier loads, more closely spaced rollers provide better support and minimize deflection. On inclined conveyors, rollers are typically spaced closer together on the incline to prevent slippage and ensure controlled material flow. In curved sections, rollers are positioned strategically to guide the belt smoothly through the curve, minimizing friction and side loading. Furthermore, the type of roller, such as drive, troughing, or return rollers, influences placement strategies. Drive rollers, responsible for powering the belt, are placed near the loading and discharge points, while troughing rollers support the load-carrying side of the belt, and return rollers support the underside of the belt. Precise placement of each roller type ensures efficient power transmission, load support, and belt tracking throughout the conveyor system. In a coal mine, for instance, strategically placed troughing rollers ensure the efficient transport of large volumes of material, while precisely positioned drive rollers maintain consistent belt speed and minimize energy consumption.
In conclusion, precise roller placement is a critical aspect of conveyor system design and maintenance. It directly impacts belt tracking, tension distribution, load support, and overall system efficiency. Careful consideration of belt width, load characteristics, conveyor length, incline angle, and roller type is essential for determining optimal placement strategies. Correct roller placement maximizes belt lifespan, minimizes maintenance requirements, and ensures reliable, cost-effective material handling. Neglecting the importance of strategic roller placement can lead to increased wear and tear, premature belt failure, and costly downtime.
Frequently Asked Questions
This section addresses common inquiries regarding conveyor belt drive rollers, providing concise and informative responses to facilitate a deeper understanding of their function and importance within conveyor systems.
Question 1: How does roller diameter influence belt tension?
Larger diameter rollers decrease belt tension, reducing wear and tear. Conversely, smaller diameters increase tension, potentially leading to premature belt fatigue. Choosing the correct diameter balances initial cost with long-term belt lifespan and energy efficiency.
Question 2: What are the key factors in selecting the appropriate lagging material?
Lagging selection depends on the conveyed material and operating environment. Rubber lagging provides good general-purpose grip, polyurethane offers abrasion resistance, and ceramic lagging excels in harsh, abrasive conditions. The choice impacts belt traction, wear resistance, and overall system efficiency.
Question 3: How does bearing type affect roller performance and maintenance?
Bearing type influences load capacity, speed capabilities, and maintenance requirements. Ball bearings suit lighter loads and higher speeds, roller bearings handle heavier loads, and sleeve bearings are suitable for low-speed, light-duty applications. Selecting the correct bearing type optimizes performance and minimizes maintenance.
Question 4: Why is regular roller alignment crucial for conveyor system efficiency?
Proper roller alignment ensures even belt tracking and minimizes friction. Misaligned rollers can cause belt wander, increased wear, and energy loss. Regular alignment checks and adjustments are essential for maintaining efficient and reliable conveyor operation.
Question 5: What is the significance of shell thickness in roller selection?
Shell thickness determines the roller’s load-bearing capacity and resistance to deflection. Thicker shells handle heavier loads and resist impact damage better, while thinner shells are more cost-effective for lighter applications. Choosing the appropriate thickness balances strength and cost-effectiveness.
Question 6: How does proper lubrication contribute to roller longevity?
Proper lubrication minimizes friction and wear within roller bearings, extending their operational life. Using the correct lubricant type and adhering to recommended lubrication schedules are crucial for preventing premature bearing failure and ensuring smooth roller rotation.
Understanding these key aspects of conveyor belt drive rollers contributes significantly to optimized system design, operation, and maintenance. Careful consideration of these factors ensures efficient, reliable, and cost-effective material handling.
The next section will delve into advanced topics related to conveyor belt drive rollers, including detailed analysis of specific applications and troubleshooting common issues.
Optimizing Conveyor Systems
Maximizing conveyor system efficiency and longevity requires careful attention to drive roller selection, placement, and maintenance. These tips provide practical guidance for optimizing performance and minimizing downtime.
Tip 1: Prioritize Roller Alignment: Precise roller alignment is paramount. Misalignment induces belt wander, accelerates wear, and increases energy consumption. Regular alignment checks and adjustments are essential for optimal performance.
Tip 2: Select Appropriate Lagging: Lagging choice directly impacts belt traction, wear resistance, and overall efficiency. Consider the conveyed material and operating environment. Rubber suits general applications, polyurethane offers abrasion resistance, and ceramic excels in harsh conditions.
Tip 3: Optimize Roller Diameter: Roller diameter influences belt tension and lifespan. Larger diameters reduce tension and wear, while smaller diameters increase tension. Balance initial cost with long-term belt life and energy efficiency considerations.
Tip 4: Choose the Right Bearing: Bearing selection impacts load capacity, speed, and maintenance. Ball bearings suit lighter loads and higher speeds; roller bearings handle heavier loads; sleeve bearings are for low-speed, light-duty applications. Select based on specific operational demands.
Tip 5: Consider Shell Thickness: Shell thickness affects load-bearing capacity and resistance to deflection and impact. Thicker shells provide greater strength but increase cost. Balance strength requirements with cost-effectiveness for the specific application.
Tip 6: Implement a Robust Lubrication Schedule: Proper lubrication minimizes friction and extends bearing life. Adhere to manufacturer recommendations for lubricant type, frequency, and application method. Over-lubrication can be as detrimental as under-lubrication.
Tip 7: Maintain a Clean Environment: Regularly remove debris and buildup from rollers and surrounding areas. Accumulated material can interfere with roller rotation and belt tracking, leading to increased wear and reduced efficiency. Implement cleaning schedules appropriate for the operating environment.
Tip 8: Conduct Routine Inspections: Regular inspections are crucial for identifying wear, damage, or misalignment. Proactive replacement of worn components prevents major system failures and minimizes downtime. Establish an inspection schedule based on operating conditions and manufacturer recommendations.
Implementing these strategies contributes significantly to enhanced conveyor system performance, reduced maintenance costs, and extended operational life. Attention to these details maximizes return on investment and ensures reliable material handling.
This discussion concludes by summarizing key takeaways and offering final recommendations for achieving and maintaining optimal conveyor system performance.
Conclusion
This exploration has highlighted the critical role conveyor belt drive rollers play in efficient and reliable material handling across diverse industries. From mining operations to food processing, these components are fundamental for conveying goods smoothly and consistently. The analysis encompassed material selection, diameter considerations, bearing types, shell thickness, lagging options, maintenance procedures, and strategic placement, emphasizing the interplay of these factors in optimizing conveyor system performance. Careful consideration of each aspect is essential for minimizing wear and tear, reducing downtime, and maximizing the lifespan of conveyor systems.
As industries continue to demand increased efficiency and throughput, the importance of properly designed and maintained conveyor belt drive rollers remains paramount. Investing in high-quality components and implementing robust maintenance programs are crucial for achieving long-term cost savings and ensuring uninterrupted material flow. Further research and development in roller technology promise continued advancements in durability, efficiency, and specialized applications, contributing to the ongoing evolution of material handling solutions.
