Wuhan Junwei's replaceable drum rubber coating insert is specially developed to solve the pain points of traditional drum rubber coating processing cycles, troublesome maintenance and replacement, and long downtime. It is widely used in various bucket elevator head wheels, coal mines/Steel mills/cement factories/ports and other scenarios. It is a new generation of efficient wear-resistant protection products that replace traditional vulcanization rubber coating.
The product adopts the "rubber + steel plate" high-pressure vulcanization integrated molding process and is matched with a welded metal stopper fixing structure. It can be quickly installed and replaced on site without removing the roller, greatly shortening downtime and reducing maintenance costs; the unique pattern design can significantly improve the friction and traction of the roller, avoid belt slippage, and effectively extend the service life of the roller and the conveyor belt.
The product supports full-specification customized production and can meet the needs of various working conditions such as cold resistance, high temperature resistance, antistatic, flame retardant, and non-toxic. It is the preferred solution for wear protection of rollers in heavy-duty conveying systems.
Quick replacement without disassembly
High wear resistance and strong traction
Vulcanization integrated molding
Customized adaptation for all working conditions
Product core structureWear resistant rubber tread surface: It adopts high-elasticity and high-wear-resistant rubber material, and has a unique prismatic groove + Z-groove composite pattern design to greatly increase the friction of the roller, provide stronger traction for the belt, and assist the belt to run stably; at the same time, it has excellent self-cleaning and heat dissipation performance.
high-pressure vulcanization adhesive coat: The steel plate and the rubber plate are bonded together through a high-pressure vulcanization process to ensure the stability of the bonding between the two materials, eliminate the problems of glue opening and delamination that are easy to occur in traditional rubber packaging from the root cause, and adapt to heavy and harsh working conditions.
Precision formed steel lining: According to the diameter size of the drum, precise arc forming is completed before leaving the factory to ensure the perfect fit of the steel liner and the outer wall of the drum to ensure the stability of long-term operation without looseness or deviation.
Rust-proof metal fixing stop bar: Special rust-proof metal stops are welded to the surface of the roller, which can firmly fix the rubber-coated insert on the surface of the roller, which is resistant to impact and does not fall off, and at the same time, can realize rapid insertion and replacement of the insert.
Structure and installation schematic diagram
core technology advantagesCompletely solve the industry pain points of traditional rubber packaging that require dismantling of the drum, external processing, and long-term shutdown. Installation and replacement do not require dismantling of the drum. It only requires a short on-site shutdown and loosening of the belt to complete the operation; the corresponding inserts can be replaced separately for local wear., no need to repack the entire drum, greatly shortening downtime, improving production efficiency, and reducing full-cycle use costs.
High pressure hot vulcanization process is adopted to realize high strength bonding between rubber and steel plate. The bonding strength is far superior to traditional cold bonding process, and common faults such as rubber coating layer opening, separation and falling off are eliminated from the root. Steel lining plates are precisely preformed according to the diameter of the drum before leaving the factory, perfectly fitting with the outer wall of the drum, ensuring operation stability and adapting to severe conditions such as heavy load and high horsepower drive.
Original prismatic groove and Z-groove compound grain design, greatly improve the friction coefficient between the pulley and belt, enhance traction, effectively avoid belt slip, improve transmission efficiency; pattern groove and insert installation clearance has excellent self-cleaning performance, can smoothly discharge the impurities between the belt and the pulley, ensure the smooth operation of the belt without deviation; at the same time, the groove forms a ventilation and heat dissipation channel, reduce the surface temperature of the belt and the pulley, and prolong the service life of the belt.
It provides three core categories: wear-resistant type, strong wear-resistant type, and flame retardant and antistatic type. Special performance products such as cold resistance, high temperature resistance, oil resistance, and non-toxic can be customized according to working conditions; it supports parallel, single slope, double slope, etc. A variety of insert structures can be adapted to drum-shaped rollers, transmission rollers of different diameters/lengths and bucket lift head wheels. A one-to-one customized solution can meet the working conditions of all industries such as mining, ports, metallurgy, and building materials.
Quick replacement on site without removing the drum
Highly elastic rubber long service life
Composite texture strong traction and high friction
Partial replacement reduces maintenance costs
Product Specifications and Selection Guide| Product type | steel plate thickness | Glue surface thickness | total thickness | standard width | Maximum length of single root |
|---|---|---|---|---|---|
| Standard wear-resistant type | 2mm | 13mm | 15mm | 138mm | 1830mm |
| Strong wear-resistant type | 2mm | 16mm | 18mm | 138mm | 1830mm |
| Matching fixed stop bar | 2.5mm | - | - | 20mm | 1830mm |
wear-resistant: Suitable for working conditions with normal conveying volume/lifting volume and normal operating speed, universal wear protection, suitable for scenarios such as grain transportation and conventional building materials transportation.
Strong wear-resistant type: Suitable for heavy-duty working conditions with large conveying volume/lifting volume and fast running speed. High-performance wear-resistant materials are suitable for heavy-duty scenarios such as mines, ports, and sand and gravel aggregates.
Flame retardant and antistatic type: Specially developed for underground coal mine conveyors, meets the requirements of coal mine safety regulations, and has core properties such as flame retardant, antistatic, wear resistance, and oil resistance.
Number of rows of rubber coated inserts = drum diameter (mm) × 3.14 ÷ 160
Number of inserts in single row = drum width (mm) ÷ 1830 (rounded up)
Total number of inserts = number of rows of inserts × number of inserts in a single row
example: Drum diameter 800mm, width 1000mm
Number of rows of inserts: 800 × 3.14 ÷ 160 ≈ 16 rows
Number of single row inserts: 1000 ÷ 1830 ≈ 1
Total number of inserts: 16 × 1 = 16 pieces
purchasing instructions: When ordering, you need to provide the working environment, performance requirements, drum diameter and drum length. Our company can provide one-on-one exclusive supporting solutions.
Installation and replacement instructions
Clean the surface of the roller and smooth uneven parts to ensure that the surface is free of oil and rust.
Draw a line equally on the surface of the roller according to the calculated number of rows, and the average line is parallel to the axis of the roller to determine the installation position of the stop bar.
Place the stop bar horizontally in the line drawing position, adjust the parallelism, clamp both ends with strong pliers, and weld and fix the weld plug hole.
Insert the rubber-coated insert flush under the wing of the stop strip, and clamp the insert with strong pliers to ensure a tight fit.
Place adjacent retaining strips, reserve 1mm of adjustment space, clamp and fix them, and then weld them. Repeat the operation until all inserts are installed.
If the remaining space is not enough for the entire insert, cut the insert according to the measured size and fix it with a stop.
Weld limit points at both ends of the insert to limit axial movement, clean the welding parts and apply anti-rust paint to complete the installation.
Stop the car briefly, loosen the belt, ensure that the roller can rotate freely, and clean up debris on the surface of the roller.
Remove the welding limit points at both ends of the insert to be replaced, and properly open the gap between the retaining strips.
Directly pull out the worn rubber-coated inserts without having to disassemble the roller and other intact inserts.
Insert a new coated insert and adjust the position to ensure a tight fit with the roller.
Re-weld the limit points at both ends, clean the welding parts, and apply anti-rust paint to complete the replacement.
When cutting and inserting, cut from the surface of the steel plate, and then use a tool knife to divide the rubber part to avoid overheating of the cutting plate and damaging the rubber. After cutting, the steel plate must be 5-8mm longer than the rubber.
Jumping hole spot welding is used when welding the stop strips, and the welding time for a single hole shall not exceed 3 seconds to avoid damage to the rubber layer at high temperatures.
After installation, you need to check that all inserts are firmly fixed and are not loose or convex before starting the machine.
Typical application scenario
Wuhan Junwei's replaceable drum rubber coating insert is specially developed to solve the pain points of traditional drum rubber coating processing cycles, troublesome maintenance and replacement, and long downtime. It is widely used in various bucket elevator head wheels, coal mines/Steel mills/cement factories/ports and other scenarios. It is a new generation of efficient wear-resistant protection products that replace traditional vulcanization rubber coating.
The product adopts the "rubber + steel plate" high-pressure vulcanization integrated molding process and is matched with a welded metal stopper fixing structure. It can be quickly installed and replaced on site without removing the roller, greatly shortening downtime and reducing maintenance costs; the unique pattern design can significantly improve the friction and traction of the roller, avoid belt slippage, and effectively extend the service life of the roller and the conveyor belt.
The product supports full-specification customized production and can meet the needs of various working conditions such as cold resistance, high temperature resistance, antistatic, flame retardant, and non-toxic. It is the preferred solution for wear protection of rollers in heavy-duty conveying systems.
Quick replacement without disassemblyHigh wear resistance and strong tractionVulcanization integrated moldingCustomized adaptation for all working conditionsProduct core structureWear resistant rubber tread surface: It adopts high-elasticity and high-wear-resistant rubber material, and has a unique prismatic groove + Z-groove composite pattern design to greatly increase the friction of the roller, provide stronger traction for the belt, and assist the belt to run stably; at the same time, it has excellent self-cleaning and heat dissipation performance.
high-pressure vulcanization adhesive coat: The steel plate and the rubber plate are bonded together through a high-pressure vulcanization process to ensure the stability of the bonding between the two materials, eliminate the problems of glue opening and delamination that are easy to occur in traditional rubber packaging from the root cause, and adapt to heavy and harsh working conditions.
Precision formed steel lining: According to the diameter size of the drum, precise arc forming is completed before leaving the factory to ensure the perfect fit of the steel liner and the outer wall of the drum to ensure the stability of long-term operation without looseness or deviation.
Rust-proof metal fixing stop bar: Special rust-proof metal stops are welded to the surface of the roller, which can firmly fix the rubber-coated insert on the surface of the roller, which is resistant to impact and does not fall off, and at the same time, can realize rapid insertion and replacement of the insert.
Structure and installation schematic diagramcore technology advantagesCompletely solve the industry pain points of traditional rubber packaging that require dismantling of the drum, external processing, and long-term shutdown. Installation and replacement do not require dismantling of the drum. It only requires a short on-site shutdown and loosening of the belt to complete the operation; the corresponding inserts can be replaced separately for local wear., no need to repack the entire drum, greatly shortening downtime, improving production efficiency, and reducing full-cycle use costs.
High pressure hot vulcanization process is adopted to realize high strength bonding between rubber and steel plate. The bonding strength is far superior to traditional cold bonding process, and common faults such as rubber coating layer opening, separation and falling off are eliminated from the root. Steel lining plates are precisely preformed according to the diameter of the drum before leaving the factory, perfectly fitting with the outer wall of the drum, ensuring operation stability and adapting to severe conditions such as heavy load and high horsepower drive.
Original prismatic groove and Z-groove compound grain design, greatly improve the friction coefficient between the pulley and belt, enhance traction, effectively avoid belt slip, improve transmission efficiency; pattern groove and insert installation clearance has excellent self-cleaning performance, can smoothly discharge the impurities between the belt and the pulley, ensure the smooth operation of the belt without deviation; at the same time, the groove forms a ventilation and heat dissipation channel, reduce the surface temperature of the belt and the pulley, and prolong the service life of the belt.
It provides three core categories: wear-resistant type, strong wear-resistant type, and flame retardant and antistatic type. Special performance products such as cold resistance, high temperature resistance, oil resistance, and non-toxic can be customized according to working conditions; it supports parallel, single slope, double slope, etc. A variety of insert structures can be adapted to drum-shaped rollers, transmission rollers of different diameters/lengths and bucket lift head wheels. A one-to-one customized solution can meet the working conditions of all industries such as mining, ports, metallurgy, and building materials.
Quick replacement on site without removing the drum
Highly elastic rubber long service life
Composite texture strong traction and high friction
Partial replacement reduces maintenance costs
Product Specifications and Selection Guide| Product type | steel plate thickness | Glue surface thickness | total thickness | standard width | Maximum length of single root |
|---|---|---|---|---|---|
| Standard wear-resistant type | 2mm | 13mm | 15mm | 138mm | 1830mm |
| Strong wear-resistant type | 2mm | 16mm | 18mm | 138mm | 1830mm |
| Matching fixed stop bar | 2.5mm | - | - | 20mm | 1830mm |
wear-resistant: Suitable for working conditions with normal conveying volume/lifting volume and normal operating speed, universal wear protection, suitable for scenarios such as grain transportation and conventional building materials transportation.
Strong wear-resistant type: Suitable for heavy-duty working conditions with large conveying volume/lifting volume and fast running speed. High-performance wear-resistant materials are suitable for heavy-duty scenarios such as mines, ports, and sand and gravel aggregates.
Flame retardant and antistatic type: Specially developed for underground coal mine conveyors, meets the requirements of coal mine safety regulations, and has core properties such as flame retardant, antistatic, wear resistance, and oil resistance.
Number of rows of rubber coated inserts = drum diameter (mm) × 3.14 ÷ 160
Number of inserts in single row = drum width (mm) ÷ 1830 (rounded up)
Total number of inserts = number of rows of inserts × number of inserts in a single row
example: Drum diameter 800mm, width 1000mm
Number of rows of inserts: 800 × 3.14 ÷ 160 ≈ 16 rows
Number of single row inserts: 1000 ÷ 1830 ≈ 1
Total number of inserts: 16 × 1 = 16 pieces
purchasing instructions: When ordering, you need to provide the working environment, performance requirements, drum diameter and drum length. Our company can provide one-on-one exclusive supporting solutions.
Installation and replacement instructionsClean the surface of the roller and smooth uneven parts to ensure that the surface is free of oil and rust.
Draw a line equally on the surface of the roller according to the calculated number of rows, and the average line is parallel to the axis of the roller to determine the installation position of the stop bar.
Place the stop bar horizontally in the line drawing position, adjust the parallelism, clamp both ends with strong pliers, and weld and fix the weld plug hole.
Insert the rubber-coated insert flush under the wing of the stop strip, and clamp the insert with strong pliers to ensure a tight fit.
Place adjacent retaining strips, reserve 1mm of adjustment space, clamp and fix them, and then weld them. Repeat the operation until all inserts are installed.
If the remaining space is not enough for the entire insert, cut the insert according to the measured size and fix it with a stop.
Weld limit points at both ends of the insert to limit axial movement, clean the welding parts and apply anti-rust paint to complete the installation.
Stop the car briefly, loosen the belt, ensure that the roller can rotate freely, and clean up debris on the surface of the roller.
Remove the welding limit points at both ends of the insert to be replaced, and properly open the gap between the retaining strips.
Directly pull out the worn rubber-coated inserts without having to disassemble the roller and other intact inserts.
Insert a new coated insert and adjust the position to ensure a tight fit with the roller.
Re-weld the limit points at both ends, clean the welding parts, and apply anti-rust paint to complete the replacement.
When cutting and inserting, cut from the surface of the steel plate, and then use a tool knife to divide the rubber part to avoid overheating of the cutting plate and damaging the rubber. After cutting, the steel plate must be 5-8mm longer than the rubber.
Jumping hole spot welding is used when welding the stop strips, and the welding time for a single hole shall not exceed 3 seconds to avoid damage to the rubber layer at high temperatures.
After installation, you need to check that all inserts are firmly fixed and are not loose or convex before starting the machine.
Typical application scenario在线客服
