types of idler in belt conveyor

Types of Idlers in Belt Conveyors

Belt conveyors are a vital component in many industries, facilitating the efficient transport of materials across varying distances. One of the key components of a belt conveyor system is the idler. Idlers are the rollers that support the conveyor belt and help maintain its alignment and tension. There are several types of idlers, each designed for specific applications and environments. This article will explore the main types of idlers used in belt conveyors, their functions, and their importance in ensuring smooth and effective conveyor operation.

1. Flat Idlers

Flat idlers are the most commonly used type in belt conveyor systems. They are designed to provide a smooth surface for the conveyor belt to ride on. Flat idlers consist of cylindrical rollers and are particularly effective in reducing friction between the belt and the idler. This type helps in supporting the belt load and maintaining its alignment, which is essential for efficient material transport.

2. Trough Idlers

Trough idlers have a distinct design featuring a series of rollers arranged at an angle, forming a trough shape. This design helps in containing bulk materials on the conveyor belt, preventing spillage and improving stability. Trough idlers are typically used in applications where bulk materials, such as coal, minerals, or grains, are being transported. They come in various configurations, including the standard trough (20°, 35°, or 45°), depending on the material's size and flow characteristics.

3. Return Idlers

Return idlers are located on the return side of the conveyor belt. Their primary function is to support the belt during its return journey to the loading point. Return idlers reduce wear on the belt and help maintain tension, preventing sagging. They can be flat or rubber coated to minimize friction and extend the conveyor system's service life.

4. Impact Idlers

Impact idlers are designed to absorb the energy produced when bulk materials fall onto the conveyor belt. These idlers typically feature a rubber or cushioned surface to reduce the impact's force on the belt and idler system. Utilizing impact idlers is essential in applications where heavy loads are dropped onto the conveyor, as they help protect against damage and extend the lifespan of both the belt and the idler.

5. Self-Aligning Idlers

To maintain proper belt alignment and prevent excessive lateral movement, self-aligning idlers are deployed. These idlers have a unique design that allows them to adjust automatically according to the belt's position. By ensuring that the belt remains centered on the idlers, self-aligning idlers help minimize wear and reduce maintenance requirements.

6. Training Idlers

Similar to self-aligning idlers, training idlers are installed to assist in keeping the belt aligned. However, they are specifically designed to correct any misalignment that may occur during operation. Training idlers help maintain optimal belt performance and prevent potential operational issues, such as increased friction or wear.

Conclusion

The choice of idlers in a belt conveyor system is crucial for optimizing performance and ensuring the longevity of the system. Each type of idler serves a unique purpose, ranging from minimizing friction and impact to ensuring proper alignment. Understanding the types of idlers available and their respective applications can significantly enhance the efficiency of material handling operations, ultimately leading to reduced costs and improved productivity in various industries. Proper maintenance and selection of idlers can lead to significant improvements in conveyor system reliability and performance.