Idler types used in conveyor systems

Understanding the various types and designs of idlers is essential for optimizing the performance of conveyor systems. Idlers play a crucial role in the conveying process, impacting efficiency and reliability. According to recent sources, idlers vary in design and functionality, with each type suited for specific applications within the conveyor setup.

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Carry vs. Return Idlers

The development of idlers has led to numerous roller variations, each with unique functional attributes like reducing belt pressure and ensuring effective cleaning.

The primary distinction among idler designs is between carry and return idlers:

• Carry idlers facilitate the movement of material from point A to point B.
• Return idlers are responsible for bringing the conveyor belt back to point A.

Nevertheless, the classification of rollers becomes more detailed as elaborated below.

Troughing Idlers

Troughing idlers fall under the category of carry idlers. They consist of a central roller with wing rollers angled to form a trough (commonly at 45 degrees). This configuration ensures that materials remain centralized on the belt, preventing spillage during transport.

The arrangement of troughing idlers typically appears in sets of 3 or 5. Using more rollers helps distribute the load more effectively, thus enhancing transportation capacity.

Impact Idlers

Impact idlers are positioned at loading points on the belt where materials are introduced. They are designed with rubber disks that absorb the high-pressure impacts created by newly added materials.

These idlers are closely spaced and are generally manufactured with a diameter of 89mm.

Transition Idlers

Transition idlers are essential for managing the increased pulling tension near the head and tail pulleys. They continuously adjust the troughing angle from 0 to 45 degrees right after the head pulley, maintaining the correct belt shape for effective material transportation. Conversely, they flatten the belt from 45 degrees to 0 degrees before reaching the tail pulley to ensure proper tension distribution.

The alignment of the belt to the pulley is critical in preventing long-term damage, and typically, conveyor systems incorporate two or three sets of transition idlers.

Return Idlers

When the belt returns to the feeder, it still requires support, albeit less robust than that needed during material transport. As such, return idlers can be spaced two or three times the distance apart compared to carry rollers, and may use just one or two rollers per idler.

A single roller is often termed a flat return idler, spanning the entire width of the belt and attached to the conveyor frame. Using two rollers creates a V return idler.

These return idlers may also feature rubber disks to remove sticky materials from the belt surface.

Training Idlers

To ensure the belt aligns properly when transitioning onto the pulley, training idlers are employed. These idlers correct for any misalignment caused by improper belt splicing or uneven material loading, thus preventing damage when the belt is under tension.

Garland Idlers

In scenarios demanding higher mobility or in unsuitable environments for static idlers, garland idlers are utilized. These are attached to the conveyor framework, allowing for enhanced movement albeit at a reduced loading capacity.

Take-Up Tension Controller

A tension controller is integral to the effective operation of a conveyor system. It ensures the belt maintains high tension, which facilitates faster movement and mitigates vertical resonations that can hinder performance.

Idlers Offered at KSK Belt

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