SWAY CONTROL RETURN IDLER
FIELD OF INVENTION
This invention relates to sway control return idler and deals more specifically with new and useful improvements in the three idler assembly which is rotatable mounted on the base frame by a pin and double bearing mechanism.

BACKGROUND ART
An idler is typically a cylindrical shaped component that rotates on a fixed central shaft, the central shaft being mounted on an angular frame structure. In order to minimize friction, an idler would rotate on the central shaft by way of bearings. In practice, an angular frame structure would support and mount a number of idlers. For example, a frame structure may include three carry idlers, which support the conveyor belt on its return path.
In conveyor systems stretching, sagging, misaligned, belt slippage and more serious problems happen that shorten the life of conveyor belt. This invention can prevent this problem by supporting the belt from the return side along with the self-aligning mechanism.
• Sagging:
The conveyor belt system in tensionless section of the belt that hangs down on the return side, this apparatus is used that sagging portion to support the belt and provided proper tension.
• Misaligned in Return Side:
Conveyor belt tracking, the process of aligning and managing a belt to maintain a specific path, is critical to creating the desired output of a belt conveyor system. When the belt drifts from one side to the other, also known as misaligned, then unexpectedly problems are coming there like belt damage, product damage, and maintenance troubleshooting issues. Uneven belt wear, and even an entire system malfunction, can

occur when a belt runs off its normal track.
• Belt Slippage:
Too little or too much tension of the belt can cause a direct impact to the performance of the belt conveyor system. If head pulley wears down, there is no longer an adequate amount of traction to grip the belt causing excessive stretching and conveyance slippage to occur.
• Belt Damage:
Belt damage can be caused in several ways such as excessive impact forces, Mistracking, and insufficient pulley traction among others.
• Fixed Frame Length:
For material handling belt conveyors are used in mines, thermal power plants, and other industries. But different size base structures are used for the same belt width conveyor system and due to fixed frame length in idler assembly it cannot be fitted easily in any structure.
In the prior art there is provided a Chinese specification CN103204351B discloses a kind of belt conveyer automatic deviation rectifying device and control method thereof, automatic deviation rectifying device comprises by the conjuncted aligning idler machining formed of multiple aligning roller rack, aligning roller rack is connected with hydraulic stem by bearing pin, ensure that aligning roller rack does aligning motion by hydraulic stem, the after body of hydraulic stem by hinge on upper conveyor belt fixed support; Automatic deviation rectifying device also comprise near head roll install, for catching the sideslip travel switch of belt deflection signal, manufacturing line run signal is sent to by cable and is positioned at the other control box arranged of load-transfer device, is provided with Hydraulic Pump, guidance panel and control system in control box. This kind of belt conveyer automatic deviation rectifying device and the control method thereof with above-mentioned special construction realize the automatic process from a series of continuous action of correction being detected by control

program and hydraulic efficiency pressure system, belt deflection phenomenon be can effectively correct in real time, steady, the reliability service of load-transfer device ensured.
SUMMARY OF INVENTION
According to the invention there is provided a sway control return idler with angular frame comprising of a roller holding strip assembly mounted on a rotatable pin shaft and double bearing mechanism configured for rotatably mounting a conveyor idler, during said operation position, said frame places a mounted idler in operational engagement with a conveyor belt; at least two conical rollers resting on four side roller holding strip one straight roller that rest on two middle holding strip; wherein that angular frame two edges extend straight at 90 degrees and this straight section act as a sway guard plate. Capable for controlling the swivelling angle during belt sway; wherein said double ball bearing is used to carry the axial load and thrust loads and allow to roller swivelling without damage; wherein said shaft with one side fixed with angular frame by bolts and threaded locking plate and other side mounted two bearings.
This invention has the power to solve the problem of the belt conveyor system, during material transport by using several mechanisms. This apparatus consists of three idlers that are held by an angular frame. That frame rotatably locked with a shaft and two bearings on the base frame. Now when belt slippage occurs, the total unit is automatically rotated to track the belt and keep the belt running true.
This apparatus can be used in different conveyor systems due to its adjustable frame length mechanism it can be easily fitted in any structure.
Other objects and advantages of the invention will be apparent during the course of the following description. In the accompanying drawings forming a part, of this specification and in which like numerals are employed to designate like parts throughout the same.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Fig 1 illustrates the front view and top view of conventional three idler assembly;
Fig 2 illustrates the exploded view of the improved three idler assembly in accordance with the present invention
Fig 3 illustrates the front view and side sectional view of the improved three idler assembly including rotatable pin shaft and double bearing in accordance with the present invention.
Fig 4(a) - (c) illustrates the different Structural analysis performed on the three idler assembly in accordance with the present invention.
DETAILED DSCRIPTION
Sway control return idler is a component of a belt-conveyor system that is used for auto controlling the belt sway as well as support the belt to prevent the belt sagging. Due to unequal loading and conveying wet material, conveyor belts has a tendency to misalign and due to misaligned material spillage can occur, for avoiding this problem and providing proper belt tension sway control return idler is used in the belt-conveyor system in return path. Which helps to support as well as auto align the belt and keep the belt running true.
FIG. 1 shows a preferred form of a conveyor idler support structure. This structure includes three idlers, supporting the conveyor belt on its return path. Each idler is rotatably mounted on its own support frame as shown in Fig 2. The structure also includes three idler cradles i.e one straight and two taper.
As shown in Fig 1, the angular frame (19) is basically a mild steel angle that carries total load like a beam. This angular frame rest on middle base frame (20) and carries the total load, which act on the pin shaft (7). The middle base frame also a mild steel channel, which two sides mounted outside the side base frame (2) by bolts and

threaded strip plate (30). The side base frame (2) other side weld with slotted leg plate (3). This two side base frames (2) can slide into the middle base frame (20). Thus the side frames are used for adjust horizontal length by sliding and set it as per required position. For supporting the said frames there is provided side support angle (4) used for mounting idler set to the belt conveyor structure. This angle top side has slotted and vertical side has threaded. Top side of this angle attached with conveyor structure table. Vertical side is mounted with side base frames. For further support and lock there is provided a slotted leg plate and threaded on side support angle. The slotted leg plate is an 8mm thick mild steel plate with two slots. This slotted leg plate is fixed with side base frame by way of welding and also bolting with side support angle (4). This slotted plate is used to adjust the height between the belt and idler by loosening the bolts and to move the total unit up or down.
The threaded strip plate is a strip plate which has three threads and is used for locking the side base frame with middle base frame.
The three idler assemblies comprises of a straight idler and two taper idlers. The straight idler (24) assembly is rotatably mounted on its own shaft by the way of bearing. It rest on angular frame and idler holding strip (13 and 19), which is mounted on the pin shaft. The angular frame also includes six idler holding strip (11,12 and 13) that hold two taper idler (25) and one straight idler (24). High quality diamond cut rubber jacket is used on an idler that can provide proper friction, tension and griping between belt and idler. This rubber coating idler increases the belt life in the conveyor system. Similarly, the taper Idlers (25) are rotatably mounted on its own shaft by the way of bearing. It rest on angular frame idler holding strip (11 & 12).
Angular frame includes six idler holding strips. This holding strip has slot arrangement for engaging a slot on a central shaft of an idler, as shown in FIG. 3. This arrangement allows for the mounting and demounting of an idler from the frame. In FIG.2 all of the idler support components are shown in an exploded position in fig 2, the said bearings are secured by bearing housing (10) and bearing housing cover (5) used for assembling double bearing and roller pin. It is mounted on middle base frame by bolts. There is

also provided roller pin (7) configured for rotatably connect three idler assembly cradle with the base frame.
Double ball bearing (8 and 9) is used to carry the axial load and thrust loads and allow to roller swivelling without damage. The idler holding angular frame two edges extend straight at 90 degrees and this straight section act as a sway guard plate for control the swivelling angle during belt sway.
• Auto Aligning System :
This invention has three idler assemblies that are rotatable mounted on the base frame by a pin and double bearing mechanism. This bearing mechanism can easily rotate the total assembly unit during belt slippage, then and then tracking the belt and keeping it running true. Now this way solved misaligned and belt slippage problems.
• Adjustable frame length for easily fitted in any structure:
In this apparatus bolting system is used in the base frame. Three channel type base frames have slotted and two side channels easily move through the middle channel. So to change base length two side channels are moved and fixed by bolting as per required length of main structure.
• Adjustable height control:
Similar bolting system is used in the side support plate to change the required height of this apparatus to maintain proper gapping between belt and idler.
• Proper Slope Angle:
This sway control return idler used in return path in belt conveyor system. The return side of the belt heavy material dust stuck on the belt, now when dust side of the belt passes directly over the idler, heavy dust falls on the idler set and it can be stuck this idler system. To avoid this problem an angle frame is mounted below the three idler and it slope angle is maintain.

Structural analysis
Structural analysis is done by Finite Element Method using ANSYS 18.1, where end is fixed support and distributed load is applied on roller. After increasing load it is seen that at load value 7000 N maximum stress generated is 289 MPa. Material is selected as structural steel. Density of material 7.85 kg/m.3 Young's modulus 200 GPa. Poisson's ratio is 0.3 Yield strength is 280 Mpa. Bulk modulus 166 GPa. Shear modulus 76.9 Gpa. Equivalent stress is shown in Fig:-4.a. Equivalent elastic strain is shown in Fig:-4.b. And total deformation is shown in Fig:-4.c
Load carrying capacity
According to distortion energy theory material is fail when shear strain energy per unit volume is equal to or greater than the shear strain energy at yielding. Equivalent Von misses stress is calculated from the Equation (1)
~ , , .
°VM — f— r
\ z
Where av ff2,0-3 are principal stresses along x, y and z axes.
From analysis it is seen that equivalent stress i.e. Von Misses stress developed at load 7000 N is almost equal to yield strength of structural steel i.e. 280 Mpa. So according to Von Misses criteria material is fail at this point. So failure load for this structure is 7000N. If it write in kg it will be 713 kg. Factor of safety is
So safe design load for this structure Failure Load
Factor of safety
=ZHkg
1.5
= 475 kg Finally design is safe for toad up to 475 kg

INVENTIVE STEP
• This apparatus design has four idler holding strip weld on angular frame which will be able to take more loads without failure and can operate without failure under highly loaded conditions. So this apparatus is used for conveying light to heavy weight materials.
• Double bearings and sway guard mechanism are used in this invention to auto adjust the belt sway, at a time absorbed the thrust load that applied on the belt. (At top Ball Bearing and at bottom Angular Contact Bearing is used). Now this way our invention protects the expensive belt in the conveyor system.
• High quality diamond cut rubber jacket is used on an idler that can provide proper friction, tension and griping between belt and idler. This rubber coating idler increases the belt life in the conveyor system.
• Two taper idlers are used in this invention that increases the support area during belt sway. So that taper roller can help with extra support and gripping the conveyor belt.
• Bearing housing is sealed properly to make it dust-free to avoid any contamination and jamming.
• Adjustable base frame length for easily fitted in any structure.
• Bolting system is use in side support plate to change the required height of this apparatus to maintain proper gapping between belt and idler.
Item No Item Name
2 Side Base Frame
3 slotted leg plate
4 Side Support Angle
5 Bearing Housing Cover
6 Bearing Seal
7 Roller Pin
8 & 9 Ball bearing
10 Bearing housing 11,12 and 13 Idler holding strip

19 Angular frame
20 Middle base frame
22 fixing plate
24 Straight Idler
25 Taper Idler
30 Threaded strip plate
While the present invention has been described with reference to a specific preferred embodiment, it will be apparent that various modifications and changes could be made to this embodiment without departing from the scope of the invention as hereinafter claimed. The above-mentioned description are provided to serve the purpose of clarifying the aspects of the invention, and it will be apparent to one skilled in the art that they do not serve to limit the scope of the invention. By way of example, the total arrangement of the different sections is customized. The above-mentioned three idler assembly as example is just one of the many configurations that the mentioned components can take on. All modifications and improvements have been incorporated • herein for the sake of conciseness and readability but are properly within the scope of the present invention.

We Claim:-
1. A sway control return idler comprising of:
a roller holding strip assembly mounted on a rotatable pin shaft and double bearing mechanism configured for rotatably mounting a conveyor idler, during said operation position, said frame places a mounted idler in operational engagement with a conveyor belt;
at least two conical rollers resting on two side roller holding strip one straight roller that rest on two middle holding strip;
at least one angle frame is used that act as a sway guard plate and capable for controlling the swivelling angle during belt sway;
wherein said double ball bearing is used to carry the axial load and thrust loads and allow to roller swivelling without damage;
wherein said shaft with one side fixed with angle frame and other side mounted two bearings.
2. The sway control return idler as claimed in claim 1, wherein said four idler holding strip are welded on angle frame configured for taking more loads
3. The sway control return idler as claimed in claim 1, wherein said double bearings and sway guard mechanism are configured for auto adjusting of the belt sway, at a time absorbed the thrust load due to convey the heavy material on the belt.
4. The sway control return idler as claimed in claim 1, wherein diamond cut rubber jacket is used on an idler providing friction, tension and griping between belt and idler.
5. The sway control return idler as claimed in claim 1, wherein said two taper idlers
used for track the belt sensitively at a time increase the support area during belt
sway and provide extra support and gripping to the conveyor belt.

6. The sway control return idler as claimed in claim 1, wherein said bearing housing is
sealed properly to make it dust-free to avoid any contamination and jamming.
7. The sway control return idler as claimed in claim 1, wherein said bolting system is employed in side support plate to change the required height of this apparatus to maintain proper gapping between belt and idler.
8. The sway control return idler as claimed in claim 1, wherein said base frame includes middle base frame and side base frame which are mild steel channel that carries total load like a beam;
wherein said middle frame rest on two side base frame and carries the total load which act on the pin shaft; and wherein said side base frame is mounted inside the middle base frame on one side by bolts and threaded strip plate and other side weld with slotted leg plate such that the two side base frames can slide into the middle base frame thereby configured for adjusting horizontal length by sliding and set it as per required position.

ABSTRACT
SWAY CONTROL RETURN IDLER
A sway control return idler comprising of a three idler assembly including an idler holding angler frame mounted on a rotatable pin shaft by a fixing plate and double bearing mechanism configured for rotatably mounting on the base channel, with sway guard mechanism, wherein two conical rollers and one straight roller are rest on an angle frame by idler holding strip. Two conical roller are help to track the belt sensitively and the extended flat edge portion of angular frame help to control the swivelling angle during belt sway; said a middle base channel and two side base channel are fixing by stainless steel bold and threaded strip that allow to adjust flexible base length, which help this return idler assembly fitted in variable length structure; wherein two side support angle are hold base channel by bolts and a slotted leg plate, which is weld with side base channel, that allow to adjust proper height between belt and idler assembly.