Belt Conveyor Roller Wear Liner with Embedded Inserts
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Solution Overview
Problem
Belt conveyor rollers experience rapid wear due to friction with the inner face of the conveying belt, leading to premature degradation and potential belt damage.
Innovation Solution
A belt conveyor roller wear liner featuring a shock-absorbing matrix with embedded inserts, providing a continuous belt-contacting surface and a retention groove, is designed to be superposed on the roller cylindrical body, reducing wear and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional steel wear liners are used on belt conveyor rollers, then wear resistance is improved, but the risk of belt damage increases due to high friction and shock
Solution Approach 1:
The wear liner uses a composite structure combining a polyurethane matrix with embedded ceramic or metal inserts. The polyurethane matrix provides shock absorption and reduces belt damage, while the embedded inserts provide wear resistance. This composite approach resolves the contradiction by integrating materials with complementary properties.
Solution Approach 2:
The wear liner features localized hard inserts embedded in a softer polyurethane matrix. The hard inserts are positioned at specific locations where wear occurs, providing localized wear resistance, while the surrounding polyurethane material provides shock absorption and protects the belt from damage. This local differentiation of material properties resolves the contradiction between wear resistance and belt protection.
2Duration of action of stationary object
If hard wear-resistant materials are used on rollers, then roller durability is improved, but friction with the belt increases causing more wear
Solution Approach 1:
The composite structure of soft polyurethane matrix with hard embedded inserts creates a balanced surface that provides wear resistance through the inserts while the polyurethane matrix maintains lower friction characteristics, reducing belt wear compared to traditional hard steel liners.
Solution Approach 2:
The invention changes the surface hardness parameter by using a softer polyurethane matrix compared to traditional steel liners, while compensating for wear resistance through the embedded hard inserts. This parameter modification reduces friction and belt wear while maintaining roller durability.
3Reliability
If the wear liner covers the entire roller surface, then protection is maximized, but material usage and cost increase
Solution Approach 1:
The wear liner is segmented into discrete embedded inserts distributed across the polyurethane matrix rather than a continuous hard material layer. This segmentation allows protection to be concentrated at specific wear zones, reducing overall material usage while maintaining effective protection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The wear liner significantly reduces the risk of roller and belt deterioration, improves durability, and minimizes the risk of belt damage, outperforming traditional steel wear liners in terms of longevity and performance.
Implementation Method 1
a shock-absorbing matrix
Implementation Method 2
Due to their permanent contact with an inner face of the conveying belt and the friction inbetween
Data Source
AI summary
The present disclosure concerns a belt conveyor roller wear liner superposable against an outer peripheral surface of a roller cylindrical body, the roller wear liner comprising: a shock-absorbing matrix; and a plurality of inserts, spaced-apart from one another and embedded in the shock-absorbing matrix with external surfaces of the inserts and the shock-absorbing matrix, extending between the inserts, being exposed outwardly, the roller wear liner being substantially ring-shaped. It also concerns a corresponding belt conveyor roller assembly, a corresponding belt conveyor and a corresponding method.