Product Overview
The "Return Idler" is an essential component of belt conveyor systems, specifically designed to support the conveyor belt on its return run (from the discharge point back to the loading point). Its primary function is to maintain proper belt tension, prevent sagging, and ensure smooth, efficient operation of the conveyor system. Typically installed on the underside of the conveyor belt, Return Idlers are widely used in various industrial applications, including mining, steel production, cement manufacturing, port logistics, and power generation.
Technical Specifications
The table below outlines the key technical specifications of the Return Idler:
Parameter | Specification |
Applicable Belt Width | 400 mm to 2800 mm (customizable) |
Roller Diameter | 89 mm, 114 mm, 133 mm, 159 mm (customizable) |
Tube Material | Q235 seamless steel pipe, optional corrosion-resistant alloys |
Bearings | Deep groove ball bearings (e.g., 6205, 6305), optional SKF, FAG, etc. |
Sealing System | Multi-labyrinth seal, IP65 or higher |
Surface Treatment | Electrostatic powder coating / Hot-dip galvanizing |
Bracket Material | Q235 steel with drop brackets |
Design Standards | DIN, CEMA, JIS, AS, SANS-SABS, GOST, etc. |
Load Capacity | CEMA B, C, D, E series (light to heavy duty) |
Product Types and Features
Return Idlers are available in various types based on function and application. The table below details each type’s features and use cases:
Type | Structural Features | Key Advantages | Applications |
Flat Return Idler | Single steel roller with two drop brackets | Simple structure, low maintenance cost | Light to medium loads, non-sticky materials |
V-Return Idler | Two rollers in a V-shape (10°/15°), with frame | Prevents belt misalignment, enhances tracking | Long - distance, heavy - duty systems |
Rubber Disc Return Idler | Steel roller with rubber discs | Self - cleaning, reduces material buildup | Mining, coal, wet/sticky environments |
Self - Aligning Return Idler | Pivoting frame with edge guide rollers | Auto - corrects belt misalignment, low maintenance | Systems prone to misalignment, complex conditions |
Functions and Benefits
Support and Tension Maintenance: Effectively supports the return belt, preventing excessive sagging and ensuring system stability.
Belt Tracking Optimization: V - shaped and self - aligning designs improve belt centering, reducing wear and downtime due to misalignment.
Durability: High - quality materials and sealing systems ensure reliable operation in harsh environments (e.g., high temperatures, humidity, dust).
Low Maintenance: Precision bearings and self - cleaning designs minimize lubrication and replacement needs, reducing operational costs.
Customization: Tailored to belt width, load, and environmental conditions, offering flexible solutions.
Application Scenarios
Mining: Handles bulk materials like ore and coal, ensuring efficient continuous production.
Steel Plants: Supports heavy material transport, resistant to high temperatures and wear.
Cement Plants: Suitable for dusty environments, providing stable return support.
Ports and Warehousing: Manages bulk goods (e.g., grains, ores), adaptable to high - humidity conditions.
Power Plants: Supports coal or biomass fuel transport, meeting high - load demands.
Installation and Maintenance
Installation Requirements
Ensure alignment with the conveyor belt centerline and secure brackets to the conveyor frame.
Select appropriate idler spacing (typically 1.5 m to 3 m) based on belt width and load.
Maintenance Recommendations
Regularly inspect bearing performance and apply grease as needed.
Clean rubber discs or roller surfaces to remove buildup and maintain self - cleaning functionality.
Check brackets and frames for integrity to prevent deformation from vibration or impact.
Quality Assurance
Return Idler products are manufactured in strict compliance with the ISO 9001 quality management system. All idlers undergo load testing, durability testing, and environmental adaptability testing to meet or exceed industry standards. Surface treatments (e.g., galvanizing or coating) are salt - spray tested to ensure corrosion resistance.
Ordering Information
Information Required for Ordering
Conveyor belt width (mm)
Idler type (Flat, V - Return, Rubber Disc, Self - Aligning, etc.)
Roller diameter and tube material requirements
Bracket material and angle (if specific requirements apply)
Bearing model and preferred brand
Quantity (units)
Special environmental conditions (e.g., high temperature, corrosive)
Lead Time
Standard products: 7 - 15 days; customized products: confirmed upon specification review.
Packaging
Wooden crates or pallets to ensure safe transportation.
Conclusion
The Return Idler is a critical support component in belt conveyor systems, directly impacting conveyor efficiency and equipment lifespan. With a diverse range of product types, excellent durability, and flexible customization options, our Return Idlers meet various industrial needs, delivering reliable and efficient material handling solutions.
For further technical support or detailed quotations, please contact our sales team.