China Standard Cema Certification Conveyor Roller Idler Carrier Roller Idler Trough Idler

Product Description

The idler is an important part of the belt conveyor, with many types and large quantities. The function is to support the belt, reduce the running resistance of the belt, and ensure the smooth operation of the belt. The operation of the idler must be flexible and reliable. Reducing the friction between the conveyor belt and the idler plays a key role in the life of the conveyor belt.It is not easy to manufacture a high-quality idler. The criteria for judging the quality of idlers are as follows: radial runout of idlers; flexibility of idlers; axial movement.You can use them in industries of Mining, Steel mill, Cement plant, Power plant, Chemical Plant, Sea Port, Storage, etc.

The Advantage of the Trough Roller&Idler:

1. The trough roller has the characteristics of corrosion resistance: acid and alkali salts are difficult to corrode it.  
2. Trough roller have strong hardness: strong wear resistance. 
3. Good sealing: the trough roller is fully sealed, and the 2 ends are equipped with plastic labyrinth sealing rings, and the oil grease will not leak, which can make the rolling shaft long-term; The slotted idler is operated in a fully sealed state.  
4. Long service life of the trough roller: the slotted roller is 2-5 times longer than the steel roller, and can reduce the wear of the belt, the belt does not run, prolonging the service life of the belt.
5. Low operating costs: The trough roller can reduce the comprehensive cost of the belt conveyor and reduce the maintenance man-hours.
6.Trough rollers are widely used in open-air dust and highly corrosive environments, such as mines, power plants, steel mills, stone mills, cement plants, coal washing plants, salt plants, alkali plants, fertilizer plants, docks and other transportation places often use trough rollers.

The specification Range of the Trough Roller&Idler:

The Form of the Trough roller:

1.Roller idlers Dia 50mm-219mm, length 190-3400mm, which are used in the steel industry, harbor, coal industry, power industry, cement industry, etc
2.Tube: Q235
3.Shaft: 45# STEEL
4.Bearing: Single & Double Row Deep Groove Ball Bearing 2RZ&2Z with C3 clearanc
5.Seals: Grease retaining inner seal with Multi-stage Labyrinth and Retention Cap with Outboard Rubbing Flinger Seal.
6. Lubrication: Grease is Lithium soap type grease with Rust Inhibitors.
7. Welding: Mixed gas shielded arc welding end

8. Painting: ordinary painting, hot galvanized painting, electric static spraying painting, baked painting.Besides we can manufacture the rollers and idlers according to the buyers' requirements.

The Various Kinds of the Idler:

 

Troughing idlers are the most common idler used on the carry side of the conveyor. Extending their life expectancy can be a challenge. Our proven seal design and low maintenance rollers lead to less downtime and increased profits. 
Impact idler is used to absorb the shock of loaded material from chute at loading and transfer point, so as to protect belt from damage or deterioration. In order to ensure good bonding strength, the impact rubber rings are made of wear and impact resistant rubber are vulcanized.
Friction self-aligning idler roller is used to adjust the belt deviation, it has a strong ability to prevent belt from being damaged and sideslip. It is based on the principle of idler curvature and frcition to prevent and correct belt sideslip. Friction f self-adjusting conveyor roller has great ability to protect conveyor belt from damage and running offline. When conveyor belt runs offline, which side the conveyor belt runs to, the frictional force of this side will be increased.
Self-aligning Idler (Training Idler) offered comprise quality assured range of self-aligning conveyor idlers that are suitable for use in tracking of both return and load-carrying side and find use in reversible conveyor belts, high-load conveyor belts slow moving conveyor belts.
Steel Screw Idler are used on the return side of the belt as belt cleaner. Spiral steel welded on the spiral roller act as a screw and pushes the build-up material on the center to the edge of the belt, return roller. Our products are widely used in thermal power generation, harbours, cement plants, metallurgy and as well as the light duty conveying devices for industries.
Rubber Disc Idler used in acid and alkali resistant industry of conveyor, comb idlers can replace the metal roller , nylon roller, long life , easy installation, custom center smooth transportation, reduce conveyor belt deviation and protection conveyor belts and other characteristics .
Flat Return Idler  is mainly used for supporting materials and belts. Upper flat idler and lower flat idler are applicable to be fixed on conveyors used in port ,terminal, mine, cement plant, thermal power plant, grain silo/warehouse, sand plant, etc.

The Application of the Various Idler:
The Production Process of The Roller:
1. The roller parts, roller skin and bearing seat should be cleaned before welding, and the inside of the roller skin should be brushed with anti-rust paint, and there is no undercut during welding.
2. When installing, fill up grease in the oil chambers before and after the bearing, and add 1/2 space of lithium-based grease in the sealing groove and the bearing.
3. After the idler roller is installed, under the action of 500N axial pressure, the axial displacement of the roller is not more than 0.7mm, and when the belt speed is less than 3.15m/s, the beating between the outer diameters of the roller is less than 0.7m.
4. The idler is at 1 After the horizontal and vertical drop test at a height of meters, the roller parts should meet the following requirements: (1) The spoke parts and welds should not be damaged or cracked, and the corresponding joints should not be loosened; (2) The axial displacement of the roller should not exceed 1.5 mm
5. After the installation is completed, it should be ensured that the rotation is dexterous, and the size of the installation is within the scope of the drawings.
6. Derusting and painting : Remove the rolling oxide rust and foreign matter The processing mating surface should be painted to prevent theoil from being exposed. The non mating surface should be painted with topcoat or primer, and the dry film thickness should be at least 350m.
The Laboratorial Research of The Roller:
  There are some criteria of the rollers,after the order is made,we will have the test to confirm the quality of the rollers.Only when the above items meet the standard, can be shipped and installed.

1. Radial runout of the roller  directly affects the stability of material transportation 
2. Flexibility affects the service life of the roller and the belt, as well as the driving power of the whole machine
3. Axial string momentum affects the service life of the roller
4. Waterproof performance
5. Dustproof performance
6. Axial bearing capacity
7. Impact resistance
8.Rotational resistanc affects the service life of the belt

The Package and Delivery of The Roller:

 Our Workshop:

MACHINE:We have advanced laser cutting machines, a complete set of intelligent sheet metal forming equipment, robot welding and other processing and testing equipment.
PAINTING:  We use electrostatic spraying to ensure variety, model and quality of coatings, thinners and curing agents should meet the design requirements and the current relevant national standards. The steel surface should be free of welding slag, welding scars, dust, oil, water and burrs before painting. No mispainting or omission, and the coating should be free of peeling and rust. Inspection method: observation and inspection. Uniform brushing, consistent color,  no wrinkles,sagging and bubbles, good adhesion, and the color separation line should be clear and neat.
DELIVERY:The goods and product factory certificate, installation and use instructions and drawings, a full set of connectors. After the equipment arrives at the site, the company immediately arranges professional and technical personnel to guide the installation on site to provide customers with satisfactory services.
PACKAGE:Packed with steel frame or wooden box, according to the standardfor trade export or according to the special requirements of customers.

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Material: Steel
Application: Chemical Industry, Grain Transportation, Mining Transport, Power Plant
Structure: Spring Plate Type Roller
Bearing Type: Single Sealed Bearing
Type: Grooved Conveyor Idler
Color: Mulit-Color for Choice
Samples:
US$ 5/Piece
1 Piece(Min.Order)

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Customization:
Available

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ratchet wheel

Can you provide examples of machinery or equipment that commonly use ratchet wheels?

Ratchet wheels are commonly used in various machinery and equipment across different industries due to their ability to provide controlled motion and security. Here are examples of machinery and equipment that commonly incorporate ratchet wheels:

  • 1. Ratchet Wrenches: Ratchet wrenches, also known as socket wrenches, utilize ratchet wheels to enable continuous tightening or loosening of nuts and bolts without the need to remove and reposition the wrench. The unidirectional motion of the ratchet wheel allows for efficient and convenient use.
  • 2. Winches and Hoists: Winches and hoists, whether manual or powered, frequently employ ratchet wheels in their mechanisms. Ratchet wheels ensure controlled lifting, lowering, or pulling of loads while preventing unintended backdriving.
  • 3. Handbrakes in Vehicles: Many vehicles, especially older models, feature handbrake systems that rely on ratchet wheels. These ratchet mechanisms secure the vehicle's position when the handbrake lever is engaged, preventing the vehicle from rolling.
  • 4. Tie-Down Straps: Ratchet mechanisms are integral components of tie-down straps used for securing cargo during transportation. They maintain tension in the strap and prevent slack, ensuring that the load remains securely fastened.
  • 5. Conveyor Systems: Conveyor systems in manufacturing and logistics often incorporate ratchet wheels to control the movement of items along the conveyor belts. Ratchet wheels enable precise indexing and positioning of products.
  • 6. Scaffold Systems: Scaffold systems used in construction frequently feature ratchet wheels in their height adjustment mechanisms. Workers can raise or lower scaffolding platforms incrementally, ensuring safety and stability.
  • 7. Fishing Reels: Fishing reels, such as baitcasting and trolling reels, use ratchet wheels in their drag systems. This allows anglers to smoothly reel in fish while preventing the fish from pulling out line unintentionally.
  • 8. Safety Mechanisms: Various safety mechanisms and emergency stop systems employ ratchet wheels to ensure that once activated, the system remains in a safe state until intentionally reset. This is crucial in industrial and machinery safety applications.

These examples demonstrate the versatility of ratchet wheels in different industries and applications where controlled motion, security, and prevention of reverse movement are essential requirements.

ratchet wheel

What are the signs that indicate a need for ratchet wheel replacement or maintenance, and how can they be diagnosed?

Recognizing the signs that indicate the need for ratchet wheel replacement or maintenance is crucial for ensuring the reliability and safety of mechanical systems. Here are common signs and how to diagnose them:

  • 1. Excessive Wear: Check the ratchet wheel's teeth for signs of excessive wear or rounding. If the teeth are visibly worn down, it's an indication that the ratchet wheel may not engage properly and should be replaced.
  • 2. Irregular Tooth Engagement: During operation, if you notice irregular engagement of the ratchet wheel with the pawl or catch, it may indicate misalignment, damage, or wear. Investigate and address the issue to prevent further damage.
  • 3. Slippage: If the ratchet wheel slips when subjected to a load within its specified capacity, it's a clear sign of wear or damage. This can compromise the safety and reliability of the system and warrants immediate attention.
  • 4. Unintended Movement: In applications where a ratchet wheel is used to prevent unintended movement or reverse motion, any unexpected movement suggests a problem. This may be due to wear, damage, or a malfunctioning pawl mechanism.
  • 5. Noise and Vibration: Unusual noises, such as grinding or rattling, or excessive vibration during ratchet wheel operation can indicate issues with teeth engagement, misalignment, or worn components.
  • 6. Difficulty in Turning: If the ratchet wheel becomes difficult to turn, it may be due to increased friction caused by wear or contamination. This can lead to inefficient operation and should be addressed.
  • 7. Visual Inspection: Regularly inspect the ratchet wheel for visible damage, cracks, or deformities. Any visible defects should be taken as a sign that maintenance or replacement is needed.
  • 8. Pawl or Catch Condition: Examine the condition of the pawl or catch that interacts with the ratchet wheel. Signs of wear or damage on the pawl can affect the engagement and should be addressed.
  • 9. Reduced Efficiency: If the ratchet wheel system is no longer operating with the same level of precision and efficiency as before, it may be an indication of wear or misalignment.
  • 10. Routine Maintenance Schedule: Implement a routine maintenance schedule for ratchet wheel systems. Regular maintenance can help identify early signs of wear or issues before they become critical.
  • 11. Load Testing: Conduct load testing to ensure that the ratchet wheel can handle its specified load capacity without slipping or exhibiting signs of stress. Any failures during load testing should prompt maintenance or replacement.

Diagnosing the need for ratchet wheel replacement or maintenance often involves a combination of visual inspection, functional testing, and a good understanding of the system's expected performance. Addressing issues promptly can prevent failures and improve the safety and reliability of mechanical systems.

ratchet wheel

How does the design of a ratchet wheel contribute to its efficiency and reliability?

The design of a ratchet wheel is critical to its efficiency and reliability in various applications. The following design elements contribute to the effectiveness of ratchet wheels:

  • 1. Tooth Profile: The shape and profile of the teeth on a ratchet wheel are crucial. Teeth are typically angled to allow easy engagement with the pawl or catch mechanism when force is applied in the desired direction. The angle of the teeth ensures efficient and secure movement in one direction while preventing backward motion.
  • 2. Material Selection: The choice of materials for the ratchet wheel affects its durability and reliability. Ratchet wheels are commonly made of strong and wear-resistant materials such as hardened steel or alloy metals. High-quality materials ensure the wheel can withstand the forces and wear associated with its intended application.
  • 3. Tooth Size and Spacing: The size and spacing of the teeth on a ratchet wheel are designed to optimize performance. Smaller teeth allow for finer control and incremental movement, while larger teeth provide stronger engagement for heavier loads. Proper tooth spacing ensures smooth and reliable operation.
  • 4. Pawl Design: The design of the pawl or catch mechanism that engages with the ratchet wheel is equally important. The pawl should have a pointed end that effectively grips the teeth when engaged. It should also release easily when force is applied in the opposite direction to allow smooth and reliable operation.
  • 5. Lubrication and Maintenance: Adequate lubrication of the ratchet wheel and pawl is essential for reducing friction and wear. Regular maintenance, including cleaning and re-lubrication, ensures the efficient functioning of the ratchet mechanism over time.
  • 6. Load Capacity: The design of the ratchet wheel must align with the intended load capacity of the application. Heavier loads may require larger and more robust ratchet wheel designs with deeper teeth to withstand greater forces without slipping.
  • 7. Durability and Corrosion Resistance: In applications where exposure to harsh environments or moisture is a concern, ratchet wheels may incorporate coatings or materials that enhance corrosion resistance. This contributes to their long-term reliability.

The combination of these design considerations ensures that a ratchet wheel can efficiently transmit motion in one direction while effectively locking to prevent reverse movement. Proper design contributes to the overall efficiency, reliability, and safety of mechanical systems and tools that rely on ratchet mechanisms.

China Standard Cema Certification Conveyor Roller Idler Carrier Roller Idler Trough Idler  China Standard Cema Certification Conveyor Roller Idler Carrier Roller Idler Trough Idler
editor by CX 2024-04-08