Polymer Roller The conveyor belt's load-bearing components are primarily composed of high-molecular materials such as ultra-high-molecular-weight polyethylene (UHMWPE), nylon (PA), and polyurethane (PU), paired with metal shafts and precision bearings. A
Polymer Roller The conveyor belt's load-bearing components are primarily composed of high-molecular materials such as ultra-high-molecular-weight polyethylene (UHMWPE), nylon (PA), and polyurethane (PU), paired with metal shafts and precision bearings. At the core, these components are designed to replace traditional metal idlers, addressing challenging operating conditions characterized by high dust levels, strong corrosiveness, high humidity, and materials with strong adhesion. This innovative solution delivers exceptional performance in terms of "wear resistance, corrosion protection, low friction for energy efficiency, and anti-sticking capabilities," making it ideal for industries like mining, chemical processing, and building materials. Its key value lies in extending equipment lifespan, reducing maintenance costs, and enhancing the overall stability of conveyor systems.
1. Structural Design: Balancing Performance and Stability
The structural design of the polymer roller revolves around "matching conveying needs and enhancing core performance," with the following key components:
Polymer roller shells: the core contact component, manufactured via integral injection molding or compression molding, with a thickness ranging from 8 to 20 mm. The surface undergoes polishing treatment (roughness Ra ≤ 0.8 μm), ensuring low friction and excellent anti-adhesion properties. For certain heavy-duty models, a composite structure of "polymer outer layer + metal inner liner" is employed, significantly enhancing load-bearing strength.
Metal shafts: Made from 45# steel or 304 stainless steel, they undergo tempering and chrome plating. The shaft diameter ranges from 15 to 80 mm, ensuring both structural strength and corrosion resistance. Additionally, the shaft ends feature a stepped design to prevent axial movement.
Precision bearings: Paired with deep groove ball bearings or self-aligning roller bearings, and equipped with high-temperature/high-low-temperature-resistant grease (selected according to operating conditions), ensuring smooth rotation and minimizing operational resistance.
Sealing System: Employs a dual sealing mechanism—combining "labyrinth" and "contact" designs—with sealing elements made of fluororubber or polyurethane. The system achieves protection ratings of IP65 to IP68, effectively preventing dust and moisture ingress while significantly extending bearing life.
Connection components: The bearing housing is made of engineering plastic or cast iron and is securely fastened to the roller shell using either a snap-fit mechanism or bolts, ensuring high assembly precision and preventing loosening during operation.
II. Core Advantages: Upgraded Highlights Compared to Traditional Conveyor Rollers
Superior wear resistance and impact strength: The high-performance polymer material offers wear resistance 3 to 5 times greater than conventional carbon steel idlers and 1.5 to 2 times better than nylon idlers. Additionally, it boasts exceptional impact toughness (with a UHMWPE elongation at break ≥300%), making it highly resistant to cracking even under heavy-duty material impacts—such as at mining transfer points—thus extending its service life by 2 to 3 times.
Comprehensive corrosion and erosion resistance: High-polymer materials boast chemically stable properties, offering exceptional resistance to acids, alkalis, salt spray, and humidity. As a result, they remain free from rusting or corrosion when used with corrosive chemicals, in high-salt coastal environments, or under damp conditions found deep underground—effectively addressing the longstanding pain points of traditional metal rollers, such as "easy corrosion and short lifespan."
Low-Resistance, Energy-Saving, and Noise-Reducing: The polymer surface boasts a friction coefficient as low as 0.08–0.12 (compared to 0.3–0.4 for metal rollers), significantly cutting conveyor drive power consumption by 15%–30%. Additionally, the elastic material ensures gentle, flexible contact with the conveyor belt, keeping operational noise below 65 dB—far quieter than the approximately 75–85 dB produced by conventional metal rollers—thereby enhancing the overall work environment.
Anti-adhesion and Anti-jamming: The polymer surface is smooth and hydrophobic, making it resistant to adhesion of materials such as coal, mineral powder, and slurry. This prevents roller jamming caused by material buildup, reducing equipment downtime due to failures—and is especially well-suited for conveying sticky materials.
Lightweight Design: Polymer materials have a density of only 1.0–1.2 g/cm³ (compared to 7.85 g/cm³ for steel), making the roller bearings 30%–50% lighter than their metal counterparts. This reduces the load on conveyor belts and lowers installation labor intensity, while also minimizing bearing wear.
Wide temperature range adaptability: Capable of handling extreme temperature environments from -40°C to 120°C (special materials extend this range further, down to -60°C and up to 150°C). In harsh outdoor conditions or high-temperature material-handling applications, the product maintains stable performance without deformation.
III. Applicable Industries and Typical Application Scenarios
Polymer rollers, thanks to their superior overall performance, are widely used in the following industries:
Mining industry: Underground and surface conveyor systems for coal mines, iron ore mines, copper mines, and more—designed to handle raw coal, refined concentrate powder, tailings, and other materials, while enduring harsh, moisture-prone, and highly abrasive environments.
Chemical industry: Transporting corrosive materials such as fertilizers, soda ash, PVC powder, and acid-alkali solutions—preventing equipment corrosion and aging.
Construction Materials Industry: Cement, sand and gravel, ceramic raw materials, and gypsum powder conveyance—featuring anti-adhesion properties optimized for wet and sticky materials.
Port terminals: Bulk cargo (coal, ore, grain) handling and conveying belts, resistant to salt spray and anti-adhesive, designed for outdoor, humid environments.
Power Industry: Coal transportation in thermal power plants and biomass fuel delivery for power generation—low-resistance, energy-saving features help reduce energy consumption.
Food processing industry: Grain, flour, and feed conveyance—rust-free, non-contaminating to materials, and compliant with food-grade hygiene standards.
Waste Recycling Industry: Sorting and conveying lines for municipal waste and construction debris, featuring anti-adhesion and impact-resistant designs to minimize material buildup and operational failures.
IV. Selection Guide: Precisely Match Operating Conditions
Select based on material properties:
Dry, low-abrasion materials (such as grain, sand, and gravel): Nylon or standard UHMWPE materials are available, offering excellent cost performance.
High-wear, heavy-impact materials (such as ore and coal): Prioritize highly wear-resistant UHMWPE or polyurethane materials;
Corrosive materials (such as acid and alkali solutions, chemical powders): Choose UHMWPE or PU materials, paired with stainless steel shafts;
Viscous materials (such as slurry, wet coal): Choose UHMWPE material with a polished surface to enhance anti-adhesion properties.
Select equipment models based on device parameters:
Conveyor belt width (500–2400 mm): corresponds to roller length (100–2000 mm);
Conveying speed (≤3 m/s): Matches the roller's rated rotational speed (300–1500 r/min);
Load Capacity: For light loads (≤5 kN), select φ89–φ133 mm; for medium loads (5–15 kN), choose φ133–φ168 mm; and for heavy loads (＞15 kN), opt for φ168–φ219 mm (for composite-structure roller shells).
Select models based on environmental conditions:
Moisture/Outdoor Environment: Choose IP65-rated or higher sealed designs with stainless steel shafts;
High-temperature environments (80–120°C): Choose high-temperature-resistant PU or modified UHMWPE materials;
Low-temperature environment (-20°C to -40°C): Choose cold-resistant nylon or UHMWPE material.
V. Key Points for Installation and Maintenance
Installation Guidelines:
The roller shafts must be perpendicular to the centerline of the conveyor belt, with evenly spaced installations (carrier rollers at 1–1.5 m intervals, return rollers at 2–3 m intervals).
The roller shell surface fits tightly against the conveyor belt without any misalignment, preventing localized wear.
Use specialized tools for assembly to prevent violent hammering that could cause the roll shell to crack or damage the bearings.
Daily Maintenance:
Check the flexibility of roller rotation weekly (ensure no sticking or unusual noises), and clean off any materials adhering to the surface.
Inspect the seals for integrity monthly, replacing any that are damaged promptly; replenish bearing grease every 3 months (once a month under high-temperature operating conditions).
Regularly inspect the roller shell for wear; if the surface wear reaches or exceeds 3 mm, or if cracks appear, replace it promptly.
Storage requirements:
Store in a dry, well-ventilated environment, avoiding direct sunlight as well as contact with oils or corrosive liquids.
Stack no more than 3 layers high to prevent the roller shell from being compressed and deformed; apply rust-preventive oil to the metal shaft ends.
