FIELD OF INVENTION
The invention relates to idler roller for Conveyer system to transport bulk material specially used
in steel, cement, mines, coal and power industries. More particularly, the invention relates to idler
roller with wear resistance coating for conveyer system used in industries to transport material.
BACKGROUND OF THE INVENTION
The conveyer belt system consists of number of rotating points and fixed points such as drive
pulley, tail pulley, bend pulleys, sub pulleys, take-up pulleys and supported number of troughing
idler, return idler, short post stringers, tail frame, head frame, main structure and many other
parts. Depending on its capacity the idler rollers may be either straight or segmented and tilted.
Generally the conveyer belts are having two side (i) carrying side (ii) non-carrying side. During the
operation, the troughing idlers are always in contact with non-carrying side of belt and return
idlers are always in contact with carrying side of the conveyer belt. Fig.l shows the carrying side
and non-carrying side and general arrangement of conveyer belt.
When the material such as coke, iron ore, sinters lime stone, slag, coal, clinker, gypsum,
baramaites etc. which are very abrasive in nature are loaded at tail end side of the conveyer belt,
the belt carries them till the discharge end side supported underneath by troughing idler rollers
which then come into contact with non-carrying side of conveyer belt. After the material is
discharged, the return rollers come in contact with carrying side of the conveyer belt. The fine
dust being abrasive in nature absorb moisture and stick on the surface of carrying side of the beit
and significantly reduces the life of return idler rollers. Being abrasive and sticky in nature, it also
reduces the life of other idler rollers significantly. This causes frequent conveyer belt breakdown
resulting production stoppages. This leads to frequent preventive maintenance work to avoid

breakdown and subsequent changing of worn out rollers in conveyer belt. The whole process is
very costly, hazardous and time consuming that finally results to huge loss of production.
The idler rollers of prior art are made of Chromium tungsten (CRW) steel and have a wear life of
approximately two weeks to three months depending on the environment in which they are used.
In the most abrasive environment such as slag and coke of steel industries and clinker of cement
industries, the life of the rollers is 2-3 weeks. Also it takes about four hours to replace the worn
out idler rollers with new one.
OBJECTS OF THE INVENTION
It is therefore, an object of the invention to propose idler rollers with wear resistance coating for
conveyer system to transport material which eliminates the disadvantages of prior art.
Another object of the invention is to propose idler rollers with wear resistance coating for
conveyer system to transport material which has a coating of high abrasion resistance properties
and very low co-efficient of friction.
A still another object of the invention is to propose idler rollers with wear resistance coating for
conveyer system to transport material which has longer life.
A further object of the invention is to propose idler rollers with wear resistance coating for
conveyer system to transport material which enables avoiding frequent preventive maintenance
and production loss.

BRIEF DESCRIPTION OF THE DRAWING
Fig-1 shows a conveyer belt with idler rollers and pulleys
Fig.2 shows the raw material handling system
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION
According to the present invention, idler rollers of a conveyer system are coated with a coating
which is a unique combination of polymer and ceramic. The product has high abrasion resistance
properties and very low co-efficient of friction. It is coated on the idler by casting material as
integral part of idler to achieve long life without changing the prior art. The coated idler rollers
has a very long life and it reduces the downtime and hence production loss. A combination of
polymer and ceramic gives the coating material the required unique properties of wear resistance
and low co-efficient of friction. Life of rollers is improved and down time is reduced such that
there is no downtime in between 1st planned shut down to 2nd planned shut down. This decreases
the production cost.
Before the coating of the idler, they are cleaned and subsequently subjected to chemical
treatment. A special type of bonding agent for bonding metal to polymer is used. Then follows the
coating which is heated at temperature 90-110°C in a heating chamber. These idlers are then
processed for 72 hours post curing at 70° temperature. After this the material are finished. After
coating the material on the mild steel idler, the polymer and ceramic combined is in full contact
and remains intact because a fine film of organo metallic compound react with metal and polymer
and thus the polymer becomes an integral part of the idler. It is a direct casting on mild steel idler
and no separate casting and fitting process is involved.
Fig.2 shows the raw material handling system (1) with conveyer belt (2,2a,2b,2c) carrying the
raw material (3). These conveyer belts move over the idler rollers (4,5 and 6).

WE CLAIM
1) Idler rollers with wear resistance coating for conveyer system to transport material
comprising;
idler roller (4,5,6) casted and coated with polymer and ceramic based coating for imparting
longer life to the roller
2) Idler roller with wear resistance coating for conveyer system to transport material as
claimed in claim 1, wherein the coating product has a very high abrasion resistance
properties and low co-efficient of friction.
3) Idler roller with wear resistance coating for conveyer system to transport material as
claimed in claim 1, wherein a special bonding is applied for bonding metal to polymer.
4) Idler roller with wear resistance coating for conveyer system to transport material as
claimed in claim 1, wherein the idler is coated by casting material as integral with the
idlers.
5) Idler roller with wear resistance coating for conveyer system to transport material as
claimed in claim 1, wherein the idler roller is subjected to post curing.
6) Idler roller with wear resistance coating for conveyer system to transport material as
claimed in claim 1, wherein the roller is made of mild steel.

Idler roller (4,5,6) for conveyer system being made of mild steel is casted and coated with a
polymer and ceramic combined coating for imparting longer life. The coating product has a
very high abrasion resistance properties and low co-efficient of friction. Idler is coated by
casting material as integral with idler. The idler is subjected to post curing.