Optimized Return Belt Conveyor Idlers: Ensuring Centralization, Reducing Wear, and Adapting to Harsh Conditions

Return belt conveyor idlers are primary troughing sets having the function of supporting the empty belt on its return section and therefore maintaining belt centralization.

Rulmeca engineered configuration consists of one or two rollers set in a “V” formation at 10° angles. Also, different arrangements can be selected according to specific application requirements: fixed sets with plain steel rollers or spacer rings; suspended garland sets with plain rollers and rings.

The decision involves considering several factors. In particular, accurately defining belt width in relation to material flow and determining appropriate speed are crucial steps in selecting the correct transom support and roller series. Also, special attention should be given to the most corrosive environments or abrasive transported materials. In the event, not only galvanization treatments should be applied to transoms. Even rollers should be designed to withstand harsh conditions and prevent buildup accumulation. Indeed, since return rollers come into contact with the dirty belt side, residual material can deposit unevenly on them, leading to belt misalignment and premature wear. In such conditions, using Rulmeca return rollers with rubber rings can help to limit material adhesion. Another recommended way to mitigate this issue, basically suitable for long conveyor systems, is belt inversion over 180 °after the drive drum and before the return drum. Thus, return rollers no longer come into contact with the carrying upper strand of the belt where material buildup accumulates.

With regard to long conveyors, another design specification is recommended. For conveyors exceeding 300 meters in length, a double return set helps to keep belt alignment. However, sometimes it can be necessary to correct belt tracking using self-centering troughing sets even on the return section.