Wear-resistant ceramic rubber composite liner丨two-in-one丨rollers wrapped rubber

With the continuous development of industrial technology, the performance requirements of conveyor systems are increasing.Two-in-one linersCeramics with pockmarks andRoller CoveringAs three important industrial materials and technologies, they play a key role in enhancing the wear resistance, anti-skid performance and extended service life of equipment. This paper will discuss in depth the characteristics and advantages of these three technologies and their applications in various industrial fields.

I. Two-in-one liner technology

1.1 Basic concepts and structure

The 2-in-1 liner is a compositeabrasion resistant material, usually made from a combination of two materials with different properties. Common combinations include the combination of a metal substrate with a polymer wear layer, or a composite structure of different hardness metals. The design aims to combine the advantages of both materials, maintaining the strength of the substrate and the wear-resistant properties of the surface layer.

1.2 Technical characteristics and advantages

The main advantages of 2-in-1 liners are reflected in the following aspects:

• Excellent wear resistance: The wear-resistant layer on the surface is made of high-hardness material, which significantly improves the resistance to abrasion.
• Excellent impact resistance: Underlayment provides good toughness and absorbs impact energy
• Light weight: Reduced weight compared to pure metal wear plates 20%-30%
• Convenient installation: Modular design for easy replacement and maintenance
• cost-effective: Long service life and reduced downtime for replacement

1.3 Areas of application

2-in-1 liners are widely used in:

• Hoppers and chutes for mining machinery
• Coal conveyor systems in thermal power plants
• Raw material conveying equipment for cement plants
• PortMechanical loading and unloading systems
• metallurgicalHigh-wear areas of the industry

II. Ceramic with pockmarking technology

2.1 Technical principles

Ceramic with pockmarks is a surface treatment technique that alters the surface properties by creating regular miniature depressions (pockmarks) on the ceramic surface. These pockmarks are usually between 0.5-3mm in diameter and 0.2-1mm in depth, arranged in a specific pattern.

2.2 Performance advantages

The ceramic band twister technology delivers multiple performance enhancements:

• Enhanced surface friction coefficient: The hemp point structure increases the microscopic roughness of the contact surface, and the anti-slip performance is improved by more than 30%.
• Improved material flow: Reduce material adhesion, especially suitable for wet, sticky material conveying
• Increased wear life: Spike structure disperses the impact force and the ceramic surface wears uniformly
• Reduced operating noiseNoise level reduction of 15-20% compared to smooth ceramic surfaces.
• Self-cleaning effect: Spot structure reduces material buildup and keeps surfaces cleaner

2.3 Typical application scenarios

• Ceramic rollers for belt conveyors
• Material Sorting EquipmentWear-resistant liner
• Anti-stick conveyor belts for the food processing industry
• metallurgyCorrosion-resistant conveying systems for the industry
• Mechanical seals for high wear environments

Third, the drum coating technology

3.1 Technical overview

Roller covering refers to the process of wrapping a layer of elastic wear-resistant material on the surface of metal rollers. According to the use of different environments and requirements, rubber material can be divided into natural rubber, synthetic rubber (such as nitrile rubber, neoprene rubber), polyurethane, etc., the surface pattern also has a variety of designs.

3.2 Technical characteristics

Modern drum covering technology has the following characteristics:

• Excellent anti-slip properties: Coefficient of friction 3-5 times higher than metal surfaces
• Good cushioning: Reducing material impact on conveyor belts
• Significant noise reductionNoise reduction of 10-15 dB compared to metal drums
• Protecting conveyor belts: Reduces belt wear and extends service life
• Adaptation to multiple environments: Different formulas can resist oil, acid and alkali, high temperature, etc.

3.3 Areas of application

Roller wrapping technology is widely used:

• Belt Conveyor Systems for Mining
• Large-scale loading and unloading equipment at port terminals
• Raw material conveying lines in steel mills
• Conveying equipment for the grain processing industry
• Automated sorting systems for logistics warehousing

IV. Synergistic application of the three technologies

4.1 System integration advantages

In practical industrial applications, 2-in-1 liners, ceramic belt pockets and drum wrapping technology are often used in concert to form complete wear-resistant conveying systems:

1. Two-in-one linersFor highly abrasive fixed parts
2. Ceramic with pockmarksTechnology for parts requiring anti-adhesion and abrasion resistance
3. Roller CoveringFor rotating parts and contact surfaces requiring cushioning

This combination extends the life of the entire conveyor system by 2-3 times and significantly reduces maintenance costs.

4.2 Typical case studies

Take the coal conveyor system renovation of a large coal mine as an example:

• Before conversion: pure metallinerThe belt needs to be replaced every 3 months on average, and the life of the belt is about 6 months.
• Remodeled:
• Chutes with 2-in-1 liners have an extended service life of up to 18 months
• Ceramic rollers with pockmarks reduce coal adhesion and increase cleaning efficiency 40%
• Specially formulated roller cover rubber adapts to humid environments and extends belt life up to 15 months.
• Combined benefits: 651 TP3T reduction in annual maintenance costs and 701 TP3T reduction in downtime

V. Selection and maintenance recommendations

5.1 Technology selection considerations

The selection of suitable technical solutions should be considered:

• Material characteristics (particle size, humidity, acidity, alkalinity, etc.)
• Capacity and operating frequency
• Environmental conditions (temperature, humidity, corrosivity, etc.)
• Budget and payback cycle requirements
• Maintaining Convenience Needs

5.2 Installation and maintenance points

• Installation in strict accordance with manufacturer's specifications
• Regularly check for wear and tear and establish maintenance files
• Choose a professional team for repairs and replacements
• Keep the system clean to avoid foreign objects that can increase wear and tear
• Establish a preventive maintenance program rather than remedying the situation after the fact

reach a verdict

As key components of modern industrial conveyor systems, 2-in-1 liner, ceramic belt twister and drum covering technologies provide efficient, wear-resistant and cost-effective solutions for a wide range of industries through their unique technical characteristics and synergistic effects. With advances in materials science and manufacturing technology, these technologies will continue to innovate and make outstanding contributions to improved performance and lower maintenance costs for industrial equipment. Enterprises should consider their own needs and product characteristics when selecting and implementing these technologies.