DTII Belt Conveyor Comb Roller for Mining Machinery

DTII Belt Conveyor Comb Roller for Mining Machinery

The DTII Belt Conveyor Comb Roller is a specialized component of the DTII conveyor system, an advanced version of the TD75 standard, widely used in mining, coal, cement, and other heavy industries. Positioned on the return side or at specific points along the conveyor, comb rollers feature a unique comb-shaped design with spaced teeth or bars, typically made of steel or rubber, to prevent material buildup on the belt. This self-cleaning mechanism dislodges sticky materials like coal dust, mud, or aggregates, ensuring the belt remains clean and reducing the risk of misalignment or damage.

Built for durability in harsh mining environments, DTII comb rollers enhance conveyor efficiency, reduce maintenance costs, and extend belt life. This page explains what comb rollers do, where they’re used, how to install them, what users say, and answers common questions, all in plain language to help you decide if they’re right for your conveyor system.

DTII Belt Conveyor Comb Roller for Mining Machinery Dimensions:

Unit: mm

h	d	Bearing model	L	b	h	f	Weight of rotating parts (kg)	Drawing No	Number of sections
108	20	4G204	465	14	6	14	4.23	DTⅡGS2105	2
			950				7.7	DTⅡGS2111	1
133	25	4G205	600	18	8	17	6.76	DTⅡGS3207	2
			700				7.68	DTⅡGS3208	2
			800				8.52	DTⅡGS3210	2
			1150				11.73	DTⅡGS3212	1
159		4G205	700				9.72	DTⅡGS4208	1
			1400				15.30	DTⅡGS4213	2
		4G305	700				9.84	DTⅡGS4308	2
			800				11.04	DTⅡGS4310	2
			1400				15.3	DTⅡGS4313	1
			1600				20.4	DTⅡGS4314	1
	30	4G306	800	22			11.5	DTⅡGS4410	2
			1400				18.35	DTⅡGS4413	1
			1600				20.71	DTⅡGS4414	1

DTII Belt Conveyor Comb Roller for Mining Machinery Features:

The DTII Comb Roller is designed to support the conveyor belt while preventing material buildup through its self-cleaning comb-shaped design, ensuring smooth operation and minimal maintenance in rugged mining environments. Here’s what makes it stand out:

1. Self-Cleaning Comb Design

   • Features a comb-shaped structure with spaced teeth or bars (steel or rubber) that dislodge sticky materials like coal dust or mud from the belt.

   • Prevents material buildup, reducing belt misalignment and wear.

2. Durable Materials

   • Roller tubes made of Q235 steel (equivalent to SS400/JIS G3101/ASTM A36) for strength in heavy-duty applications.

   • Shafts crafted from 45# steel (equivalent to DIN C45/JIS S45C/ASTM A1045) for precision and durability.

   • Optional rubber or polyurethane teeth for enhanced wear resistance and corrosion protection in abrasive environments.

3. High-Quality Bearings

   • Equipped with deep groove ball bearings (6204, 6205, 6305, etc., with C3 clearance, 2RZ/2Z seals) for smooth rotation and long lifespan.

   • Triple labyrinth seals protect against dust, dirt, and moisture, ideal for mining conditions.

4. Low Noise and Vibration

   • Precision manufacturing and balance testing minimize noise and vibration during operation.

   • Reduces wear on the belt and conveyor frame, extending system longevity.

5. Corrosion Resistance

   • Options for zinc plating, baking paint, or epoxy coatings to resist rust in environments like coastal ports.

   • Rubber or polyurethane teeth provide additional durability in corrosive or abrasive conditions.

6. Customizable Design

   • Roller diameters from 89mm to 219mm, lengths from 150mm to 2500mm, fitting belts 500mm to 2400mm wide.

   • Customizable comb spacing, tooth material, and frame designs to match specific conveyor setups and material types.

7. Standards Compliance

   • Meets DTII, DTII(A), CEMA (B, C, D, E), JIS, and ISO 9001:2008 standards for quality and safety.

   • Tested for radial runout (≤0.5mm), axial displacement (≤1.2mm), and rotation resistance (≤3.5N) to ensure reliability.

DTII Belt Conveyor Comb Roller Applications:

The DTII Comb Roller is used on the return side or specific sections of conveyors to support the belt and prevent material buildup, making it ideal for handling sticky or wet materials in various industries. It’s perfect for these applications:

1. Mining

   • Prevents buildup of sticky coal dust, iron ore, or bauxite on return belts in underground or open-pit mines.

   • Suits long-distance systems, like a 4 km conveyor in Shanxi, ensuring clean belts and stable operation.

2. Cement Plants

   • Removes sticky cement or clinker residues from return belts, reducing maintenance.

   • Corrosion-resistant coatings withstand abrasive environments.

3. Ports and Terminals

   • Cleans sticky materials like coal or grain from return belts during loading/unloading.

   • Rust-resistant options are ideal for salty coastal conditions.

4. Construction

   • Prevents buildup of sticky aggregates or mud on return belts on job sites.

   • Works with mobile or fixed conveyors for versatile setups.

5. Power Plants

   • Cleans coal dust or ash from return belts in fuel or waste systems.

   • Designed for dusty, high-tension environments.

DTII Belt Conveyor:

Purpose and Scope of Use:

DTII、DTII(A) fixed belt conveyors. Their main parameters, transmission power, and tension calculation methods adopt ISO international standards, and are widely used in various industries.The material is transported by a single or multiple unit synthetic transportation system.This conveyor is suitable for working in temperatures ranging from -25°C to 40°C.

Product Features:

◆ Conveying materials is below 2.5t/m3◆ Can be divided into 500, 650, 800, 1000, 1200, 1400, 1600, 1800, 2000、2200, 2400◆ Can be divided into：0.8, 1.0, 1.25, 1.6, 2.0, 2.5, 3.15、4.0, (4.5), 5.0, (5.6), 6.5 

Belt  width  (mm)	0.8	1.0	1.25	1.6	2.0	2.5	3.15	4	(4.5)	5.0	(5.6)	6.5
500	69	87	108	139	174	217
650	127	159	198	254	318	397
800	198	248	310	397	496	620	781
1000	324	405	507	648	811	1014	1278	1622
1200		593	742	951	1188	1486	1872	2377	2674	2971
1400		825	1032	1321	1652	2065	2602	3304	3718	4130
1600					2186	2733	3444	4373	4920	5465	6122
1800					2795	3494	4403	5591	6291	6989	7829	9083
2000					3470	4338	5466	6941	7808	8676	9717	11277
2200							6843	8690	9776	10863	12166	14120
2400							8289	10526	11842	13158	14737	17104

Note:1. The conveying capacity in the table is calculated based on horizontal transportation, with a dynamic stacking angle of 20° and a roller groove angle of 35°.2. The belt speeds of 4.5m/s and 5.6m/s in the table are non-standard values and are generally not recommended for use.

Installation Guidelines:

Installing DTII Comb Rollers is straightforward with these steps:

1. Verify Specifications

   • Ensure the roller’s diameter, length, comb spacing, and frame design match your conveyor’s belt and return side requirements.

   • Confirm the frame can support the roller’s weight and belt tension.

2. Position the Rollers

   • Install comb rollers on the return side, typically spaced 3-4 meters apart based on belt width and material type.

   • Use sturdy frames to secure the rollers, ensuring alignment with the belt.

3. Align the Rollers

   • Set rollers perpendicular to the belt to ensure even support and effective cleaning.

   • Use a laser level or string line to align rollers with adjacent idlers for consistent tracking.

4. Inspect Bearings and Seals

   • Verify bearings are lubricated with lithium soap grease and triple labyrinth seals are intact.

   • Avoid disturbing seals to maintain dust and water resistance.

5. Adjust Belt Tension

   • Set tension to keep the return belt taut without overloading the rollers. Use:[ T = \frac{P_p \cdot 1000}{v} ] where (T) is tension (Newtons), (P_p) is power (kilowatts), and (v) is belt speed (meters/second).

6. Test the System

   • Run the conveyor at low speed with no load to check roller performance, cleaning effectiveness, and belt alignment.

   • Adjust roller positions if material buildup persists or the belt drifts.

Installation Tips

• Use trained technicians to meet safety and industry standards.

• Document installation details for maintenance records.

• Contact us for expert setup assistance.

Maintenance Tips

Regular care keeps DTII Comb Rollers performing well:

• Inspect Regularly: Check comb teeth, rollers, bearings, and frames every 3-6 months for wear or damage.

• Lubricate Bearings: Apply lithium soap grease every 6 months to ensure smooth rotation.

• Clean Comb Teeth: Remove material buildup from teeth to maintain cleaning effectiveness.

• Check Alignment: Ensure rollers remain perpendicular to prevent belt drift [].

• Use OEM Parts: Replace with DTII-compliant parts to maintain performance [].

• Avoid Damage: Do not strike rollers or comb teeth with heavy objects to prevent damage to bearings or seals.

Customer Feedback:

Here’s what users of DTII Comb Rollers say:

1. Australian Iron Ore Mine

   “These comb rollers prevent ore buildup on our return belts. They’re tough and have cut our cleaning time significantly.” – James Carter, Site Engineer

2. South African Port Terminal

   “The corrosion-resistant coatings are perfect for our coastal setup. These rollers need minimal upkeep and keep our belts clean.” – Thandiwe Zulu, Logistics Manager

3. Chilean Copper Mine

   “Our conveyor efficiency is up 20% with these comb rollers. They handle sticky ore residue like a charm.” – Sofia Martinez, Maintenance Supervisor

Related Questions (FAQs):

Got questions? Here are clear answers with keywords to help you find us:

1. What’s a DTII Comb Roller?

A return-side roller with a comb-shaped design that prevents material buildup by dislodging sticky materials from the conveyor belt.

2. How does it clean the belt?

The comb-shaped teeth or bars scrape off sticky materials like coal dust or mud, keeping the belt clean and aligned.

3. What’s it made of?

Q235 steel for roller tubes, 45# steel for shafts, with optional rubber or polyurethane teeth for durability.

4. How often should I maintain it?

Inspect every 3-6 months, lubricate bearings, clean comb teeth, and check alignment. Don’t tamper with seals.

5. Where’s it used?

Mining, cement plants, ports, construction, and power plants for handling sticky materials like coal or ore.