Idlers are the cylindrical rollers underneath the conveyor belt that supports the weight and impact of transported materials. Because this conveyor component takes the impact of material, it&#;s crucial to have the right idlers in place for specific applications. In this article, we detail the different types of idlers and their role in specific applications.
Our CEMA B, CEMA C, and CEMA D idler are ideal for industries that transport material with the risk of spills or in an environment that sees excessive moisture and high-humidity.
As a leading name in conveyor idler suppliers, we use our patented impact-resistant polymer endcaps to extend the life of each roller. When compared to regular steel end caps, our polymer end caps are more lightweight, corrosion-resistant, and cost-effective. Idlers are at risk of seizing due to excess debris or spillage for industries that operate in an area with potential for particle contamination. To prevent this issue, our rollers are equipped with:
Heavy-duty industries such as mining, ship-loading, steel and iron manufacturing, and construction, among others, require CEMA E and CEMA F rollers. These idlers are designed for heavy applications and come standard with our High Safety Anti-Lock Shield and High Moisture Seal.
When it comes to tough conveyor applications, conveyor idler suppliers focus on providing durability and strength that minimizes damage to conveyor components. These idlers are manufactured with a steel end cap and an oversized shaft resulting in a longer life and less maintenance, which leads to reduced downtime and an improved bottom line.
Rollers are one of the key parts that affect the use of belt conveyor, accounting for about 30%-40% of the weight of the whole machine and 5%-30% of the price of the whole machine. In the belt conveyor, the rollers are used to support the conveyor belt and the cargo, and they are the main support device of the conveyor belt.
According to the classification of use, the rollers can be divided into supporting idler, self-aligning idler and impact idler, and today let&#;s talk about a detailed introduction of these 3 roller sets, and 4 kinds of failure forms of roller wear.
Part I
Introduction of 3 types of roller sets
A. Support roller set
Composition: It consists of immovable frame and rotating rollers.
Function: It is used to support the conveyor belt and the material on it. The part used to carry the branch is called the troughing roller set, and the one used to support the unloaded branch with a cut is called the return roller set.
1.Troughing roller set
The troughing roller set can be divided into two roller sets, three roller sets and five roller sets according to the number of rollers installed. The more the number of rollers, the larger the slot shape, the smoother the belt bending and the longer the service life. The three roller set is the most widely used, and the slot angle of the roller is 30°, 35° and 45°. The larger the slot angle is, the stronger the conveying capacity is, and the runout and material scattering can be reduced.
2.Return roller set
Function: To support and restrain the unloaded conveyor belt.
Structure: flat roller set is generally used. When the conveyor belt is long, in order to prevent the conveyor belt from running off, V-return roller sets are also used.
B. Self-aligning roller set
Function: To correct the runout of the conveyor belt and ensure the normal operation of the conveyor.
Causes of runout: material eccentric accumulation, uneven distribution of tension along the conveyor belt width, frame deformation, damage to the roller bearings, wind load, etc.
1.Friction roller set
The principle of centering: when the conveyor belt is deviated, the tape gives the roller a force in the same direction as the running direction, and its part of the force makes it rotate axially, and the other part of the force makes the roller move axially, thus prompting the conveyor belt to move to the center line of the conveyor.
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2.Side rollers forward tilting type centering roller set
The principle of centering: the two side rollers of the three roller set are tilted forward at a certain angle (3~5°) towards the running direction of the conveyor belt, so that there is axial friction between the conveyor belt and the side rollers. When the conveyor belt is deflected, the friction force on one side is greater than the other side, which prompts the conveyor belt to return to the center of the conveyor.
Features.
Simple structure and reliable working. However, there is sliding friction between the conveyor belt and the side rollers, and the belt wears more.
3.tapered roller set
Aligning principle: both sides of the rollers are conical, when the conveyor belt is running, there is sliding between the side rollers and the conveyor belt, and the sliding friction between the side rollers and the conveyor is the same as the running direction of the conveyor belt. When the conveyor belt runs in the middle, the sliding friction on both sides is the same; when the conveyor belt deviates, the sliding friction on the deviating side becomes bigger and pushes the conveyor belt back to the middle position.
C. Impact roller set
Function: Installed at the loading of conveyor belt to reduce the impact of material and reduce the damage to the bearings of the rollers.
Types: rubber ring type, spring plate type and heavy duty buffer rollers.
Advantages: light weight and low rotational inertia of buffer rollers. The weight of the polymer material used for the rollers is light, one seventh of steel, and the weight of the rollers made of this material is about one half of the normal rollers, and the rotational inertia is small, and the friction between the rollers and the belt is small.
Part II
4 kinds of fault forms of roller wear
The operating condition of the rollers not only affects the stability of belt conveyor operation and operating cost, but the damaged rollers may scratch the conveyor belt and cause more losses.
1. Wear of the roller barrel skin
Mainly the middle of the rollers are worn to fracture, some rollers and the edge of the conveyor belt contact wear will also cause fracture. The main reasons: 1) The rotation resistance of the rollers is large, and the friction resistance between the rollers and the conveyor belt is large, causing friction. 2) The rotation direction of the rollers and the running direction of the conveyor belt have a deflection angle, forming a deflection friction resistance causing wear of the rollers. 3) The operating environment of the rollers themselves is poor, causing direct contact between the rollers and materials or other items, such as friction.
2.The roller bearing is damaged
It is mainly because the bearing of the roller is not flexible and the bearing point is worn out, and there is also serious rust causing the roller not to rotate. Main reasons: 1) unreasonable selection of belt conveyor rollers, resulting in bearing life expiration damage. 2) poor sealing effect of roller bearings, resulting in grease pollution, resulting in poor bearing lubrication and damage. 3) belt conveyor roller assembly filling grease quantity is low or grease quality is not good, resulting in roller lubrication failure and damage. 4) belt conveyor machine design is unreasonable, resonance of the roller, accelerating the cause of bearing damage.
3. Bending and deformation damage of the rollers
The bending damage of the roller is complicated, mainly because the bending deformation of the roller shaft is large, the deflection angle is too large, thus causing the shaft and bearing seat friction, also easy to cause damage to the roller seal. 1) The belt machine roller selection is unreasonable, can not meet the strength and stiffness requirements. 2) The belt machine machine design is unreasonable, but the local roller force is large, resulting in overload and deformation damage.
4. Other damaged forms of the rollers
Such as cylinder skin and bearing seat desoldering, cracking, bearing out, etc.
The main reason is that the manufacturing quality of the rollers is poor, the bearing positioning is unreasonable; the roller barrel skin is thin, the welding is not firm, there is false welding; the bearing installation is not in place, etc.
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