Conveyor Idlers: Troughing Idlers & Flat Idlers

Common Conveyor Idler Types

Troughing Idlers

• Purpose: Support the belt and material during transport.
• Configuration: Typically have three rollers: one horizontal (center roll) and two angled (wing rolls).
• Common troughing angles: 20°, 30°, and 45°.
• Applications: Used in bulk material handling to center and support the belt.

Impact Idlers

• Purpose: Absorb impact forces in loading zones to protect the belt.
• Features: Rubber-coated or cushioned rollers. Heavier-duty frames to handle material impact.
• Applications: Placed at transfer or loading points.

Picking Idlers

• Purpose: Used in manual sorting operations or for material centering.
• Configuration: Shallow troughing angles (e.g., 20° or less).
• Applications: Commonly used in industries like agriculture and mining.

Return Idlers

• Purpose: Support the belt on its return run (no material load).
• Features: Single flat roller or V-return roller configuration.
• Applications: Reduce sag in the belt during its return phase.

Self-Aligning Idlers

• Purpose: Correct belt misalignment automatically.
• Features: Pivoting mechanism that adjusts the belt's tracking.
• Types: Troughing self-aligning idlers and Return self-aligning idlers.

Transition Idlers

• Purpose: Provide gradual support for the belt as it transitions from the tail or head pulley to the troughing idlers.
• Troughing Angle: 10° or 15°.

Conveyor Idlers Configuration

Conveyor Idler Standard

CEMA(CEMA B, C, D, E, F), DIN, ISO, GB, AS, GOST, SANS, etc.

Common Roll Diameter

76 mm, 89 mm, 108 mm, 127 mm, and 152 mm.

Conveyor Idler Roller Materials

• HDPE
• Steel
• Stainless Steel
• Galvanized steel

Conveyor Idler Set Bracket Material

• Steel
• Stainless Steel
• Galvanized steel

Conveyor Idler Roller Numbers

It can include 1 roll, 2 rolls, 3 rolls, 5 rolls, and 6 rolls.

1. What are conveyor idlers in a belt conveyor system?

Conveyor idlers are assemblies consisting of rollers and support frames that support, guide, and maintain the shape of a conveyor belt carrying bulk materials.

2. What types of conveyor idler sets are used for bulk material handling?

Common types include troughing idler sets, return idler sets, impact idler sets, self-aligning idler sets, transition idler sets, and garland idler sets.

3. What is a troughing idler set?

A troughing idler set typically consists of three rollers arranged to form a trough. It supports the loaded belt and helps contain bulk materials during conveying.

4. What is the difference between carrying idlers and return idlers?

Carrying idlers support the loaded upper belt, while return idlers support the empty belt on its return run.

5. What are impact idler sets used for?

Impact idler sets are installed at loading and transfer points to absorb impact from falling materials and help protect the conveyor belt.

6. What is a self-aligning idler set?

A self-aligning idler set is designed to help correct conveyor belt mistracking. It should be selected and installed according to the cause of misalignment and the conveyor manufacturer's recommendations.

7. What is a transition idler set?

A transition idler set gradually changes the belt profile between a flat pulley and a fully troughed carrying section, helping reduce excessive belt stress.

8. What is a garland idler set?

A garland idler set consists of multiple rollers connected in a suspended assembly. It can accommodate belt movement and is used in selected heavy-duty bulk conveying applications.

9. How do I choose the right conveyor idler set?

Consider belt width, belt speed, material density, throughput, lump size, loading impact, trough angle, conveyor inclination, and operating conditions.

10. What troughing angles are available for conveyor idler sets?

Common troughing angles include 20°, 30°, 35°, and 45°. The appropriate angle depends on belt design, material characteristics, conveyor capacity, and operating requirements.

11. Which conveyor idler standards are available?

Conveyor idler sets can be specified according to standards such as CEMA, DIN, ISO, AS, and SANS. Dimensions and performance requirements should be confirmed against the selected standard.

12. Can conveyor idler sets be customized?

Yes. Idler sets can be customized according to belt width, roller diameter, troughing angle, frame dimensions, roller arrangement, material, and installation requirements.

13. How do conveyor idler sets affect belt conveyor performance?

Properly selected idler sets help support the belt, maintain belt profile, reduce excessive sag, and promote stable tracking. Incorrect selection or poor alignment can increase wear, rolling resistance, and maintenance requirements.

14. What information is needed to order conveyor idler sets?

Provide the conveyor belt width, idler type, troughing angle, roller diameter and length, frame dimensions, applicable standard, material requirements, operating conditions, and quantity. Drawings or existing assembly dimensions are helpful.