Standard roller

Product Introduction

　　Rollers are crucial components of belt conveyors, coming in a wide variety and large quantities. They account for 35% of the total cost of a belt conveyor and bear more than 70% of the resistance; therefore, the quality of rollers is particularly important.

　　The function of idlers is to support the weight of the conveyor belt and the material being conveyed. Idlers must operate smoothly and reliably. Reducing the friction between the conveyor belt and the idlers plays a crucial role in extending the lifespan of the conveyor belt, which accounts for more than 30% of the total cost of the conveyor system. Although idlers are relatively small components in belt conveyors, manufacturing high-quality idlers is no easy task.

Product Features

　　● Small radial runout

　　Within the range of vibration levels specified by national standards, the conveyor can operate smoothly; otherwise, the conveyor belt may resonate and vibrate excessively, causing material spillage and environmental pollution. The smaller the radial vibration amplitude becomes as the belt speed increases, the more pronounced this advantage is. Standard idlers are made from high-precision steel tubes and undergo precision machining to ensure smooth rotation of the idlers.

　　● Standard rollers have low rotational resistance and are energy-efficient.

　　During the operation of belt conveyors, the flexibility of idlers becomes extremely important. If the idlers have poor flexibility and a high coefficient of rotational resistance, the entire belt conveyor system will have to expend more power and consume greater amounts of electricity. In some cases, this can even lead to belt tears or motor burnout; in more severe situations, it could even trigger a fire. Therefore, selecting idlers with a low coefficient of rotational resistance is a crucial aspect of belt conveyor design and equipment selection.

　　The rolling friction coefficient of the idler varies depending on the diameter of the idler and the bore size of the bearing, but in all cases it remains below 0.01. In contrast, when using conventional idlers, the simulated friction coefficient typically ranges from 0.022 to 0.030. This clearly demonstrates the superior energy-saving performance of this series of idler products.

　　● Permanent lubrication

　　Standard rollers use deep-groove radial ball bearings with double-sided seals. During manufacturing, these bearings are filled with grease and feature a permanent seal, eliminating the need for additional grease lubrication throughout their service life.

　　● Axis

　　The high-precision roller shafts are manufactured using specialized machining equipment.

　　● Pipe material

　　Select appropriate tubing with high precision and straightness to ensure uniform rotation during operation.

　　● Bearing

　　Appropriate tolerance fits have been selected between the bearing, the bearing housing, and the shaft. Taking into account the bearing’s own tolerance fits as well as its ability to adapt to operating conditions such as temperature rise during operation, a deep-groove ball bearing with a small clearance and SS double-sided sealing has been used.

　　● Bearing housing

　　The bearing housing, made from deep-drawn materials and precision metal molds, is welded automatically to both ends of the steel pipe. This creates a unified, high-strength structure that ensures a firm connection between the steel pipe and the bearing housing during operation. Even under the impact of a high-speed conveyor belt during operation, no damage will occur.

　　● Cavity-type sealing

　　Our company’s unique cavity-type seal features a non-contact design. Its rational structure results in low rotational resistance, a long service life, and excellent dust- and water-proof sealing performance. It is particularly well-suited for bulk material conveyors that handle large volumes over long distances. Testing conducted by a nationally recognized authority has confirmed that this seal’s dust- and water-proof performance significantly exceeds the national standards, and its operational performance has been highly satisfactory.