What is an idler roller?

Idlers are an integral part of any conveyor system. These components support the belt once it is loaded, allowing it to move material smoothly from one location to another. Troughing idlers are designed such that the loaded belt itself forms a trough, which both reduces the risk of material spillage and increases the ultimate load-bearing ability of the conveyor for improved safety and productivity. Next, follow Next, follow Global Conveyor Supplies Company Limited (GCS) idler manufacturers to understand

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Idlers are cylindrical rods that extend under and along the conveyor belt. It is the most important component/assembly of the trough belt conveyor. The idler is usually located in the trough-shaped metal support frame under the support side to support the conveyor belt and materials.

Different types of idler rollers

Different types of idler rollers

There are two types of idler rollers: carrying idlers and return idlers. They are located on the support side and return side of the conveyor. These idlers have many types and functions due to specific applications.

Carrying idlers

Troughing idlers

Troughs are common carrying idler types on the load side of conveyors. They are usually installed in a trough-shaped frame on the load side along the length of the conveyor belt to guide the rubber conveyor belt and support the conveyed material. The troughing idler includes a central idler with a certain width and side wing idlers on both sides of the central roller.

Trough idlers usually have 20°, 35°, and 45° angles.

Impact idlers

 

In quarry and mining applications, when large, heavy and sharp materials fall onto the conveyor belt, they can cause impact and damage to the conveyor belt, which ultimately leads to downtime and higher replacement costs. Therefore, an impact idler is required in the material impact area.

It uses a rubber ring design to provide a buffer and absorb impact in the material impact area, and it minimizes the damage to the conveyor belt.

The interval between impact idler sets is usually 350 mm to 450 mm to provide overall support.

Picking table idlers

 

A picking table idler is usually used at the material loading point under the hopper. Compared with the troughing idler, the center roller of the picking table idler is longer, and the short roller with a 20° trough angle can disperse materials to the greatest extent and make inspection and classification easier.

Flat carrying idlers/Impact flat idlers

 

It is often used for conveying materials on high-speed flat belts. Transporting large, hard materials requires the use of impact flat belt idlers, which can buffer and protect the belt.

Self-training idler

 

The misalignment of the conveyor belt may cause material overflow. Therefore, when installing the idler rollers, a self-training idler group must be installed, which can control the alignment of the conveyor belt on the support side. A self-training roller is usually placed at intervals of 100-150 feet. When the total length of the belt is less than 100 feet, at least one training idler should be installed.

The self-training roller has a troughing angle of 20°, 35°, and 45°.

Return idlers

Flat return idlers

 

The flat return idler is the most common idler on the return side of the conveyor to support the return run of the conveyor belt. It consists of a steel rod installed on two lifting brackets, which can effectively prevent the belt from stretching, slack, and damage.

Rubber disc return idlers

 

Commonly used in the application of conveying viscous and abrasive materials, the rubber disc can remove the materials stuck on the conveyor belt on the return side.

Self-training return idlers

 

It is used to control the alignment of the conveyor belt on the return side to prevent damage to the conveyor belt and structure. The installation distance is the same as the self-training idler on the support side.

V-return idlers 

 

  The return idler group composed of two rollers is called V return idler group. Usually used for long-distance land conveyors, suitable for applications requiring heavy, high-tension fabrics and steel cord conveyor belts. Two rollers have a higher rated load than a single roller, which can provide better belt support and belt training.

The included angle of the "V "return idler is usually 10° or 15°.

Contact us for information on idler roller dimensions, conveyor idler specifications, conveyor idler catalog, and price.

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• More savings from the decreased power consumption
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Troughers are the most common idlers used on the carry side of the conveyor.

Extending their life expectancy can be a challenge. Our proven seal design and low maintenance rollers lead to less downtime and increased profits.

Metso’s troughing idlers come in 20°, 35°, and 45° and meet all CEMA dimensional requirements.

Damaged conveyor belts can result in downtime and high replacement costs.

Our impact idlers are designed to be used in impact areas where belt damage is common.

Impact rolls are designed with rubber tires which absorb impact forces minimizing belt damage.

When conducting visual or magnetic inspections, conveyed materials that are not properly flattened can cause issues.

Metso’s picking table idlers spread the material out by using a longer center roll and short concentrator rolls angled at 20° making inspection or tramp iron detection easier and more reliable.

In feeder applications, wide coverage is needed.

Metso provides a flat belt idler with a single roll placed horizontally supported on each end.

It has a rise bracket to provide the widest coverage while metering material flow.

Material spillage can occur when conveyor belts become misaligned. Strategically placing self-training idlers along the conveyor keep the belt running true.

Metso’s self-trainers are like troughing idlers, but with the ability to pivot at the center and are guided by edge rollers which in turn aligns the belt.

High belt tensions can cause idlers to fail. Live shaft idlers are designed to handle higher allowable loads than flat belt idlers.

Live shafts are comprised of a single roll with a pillow block bearing at each end.

The flat return is the most common idler on the return side of a conveyor.

Metso’s flat returns support the belt to prevent stretching, sagging, and failure.

These idlers consist of a single steel roll mounted on two drop brackets.

A big concern in applications with sticky material is removing material that has become affixed to the belt.

Metso’s rubber disc returns assist by removing carryback.

The rubber disc returns are similar to the flat returns, but have rubber discs strategically placed along the roll, as opposed to a steel shell found on the flat returns.

Aligning high tension fabric or cable belts can be problematic.

Metso’s v-return idlers provide a truer tracking belt and a longer life than standard flat returns. They consist of two rolls in a v-shaped profile of either 10° or 15°.

Belt, structure, and component damage can all occur when conveyor belts become misaligned.

Self-training return idlers eliminate this concern by ensuring the belt is tracking true.

Metso’s self-trainers are like flat return idlers, but with the ability to pivot at the center guided by edge rollers which in turn aligns the belt.