Conveyor idlers selection and design procedure

We will see here the conveyor idlers basics and various points that we need to consider while selecting and designing conveyor idlers with the help of this post. 

Figure : Conveyor Idler set

Idlers are an important component of a conveyor system, as they provide support to the conveyor belt and reduce friction between the belt and the supporting structure. Here are some of the details that should be considered for idlers in a conveyor:

1. Type of Idlers: There are various types of idlers available for conveyor systems, such as flat, troughed, impact, training, and transition idlers. The selection of idlers depends on the type and application of the conveyor.

2. Idler spacing: The spacing between idlers depends on the weight of the material being transported, the width of the conveyor belt, and the material's characteristics. The spacing should be such that the belt does not sag or mistrack, leading to damage to the belt and other components.

3. Roller Diameter: The diameter of the roller should be chosen depending on the load-carrying capacity and the size of the material being transported. Typically, larger rollers are used for heavy loads and smaller rollers for lighter loads.

4. Bearing Type: The type of bearing used in idlers can significantly impact the performance and maintenance requirements of the conveyor system. Sealed bearings are often preferred over open bearings, as they require less maintenance and are less prone to contamination. 

5. Material: The material of the idler should be chosen depending on the environmental conditions and the characteristics of the material being transported. Common materials for idlers include steel, aluminum, and plastic.

6. Idler Frame: The frame of the idler should be designed to provide adequate support to the roller and resist deformation under load. The frame should also be designed to allow for easy installation and maintenance.

7. Idler Seal: Proper sealing of the idler is important to prevent contaminants from entering the bearing, which can lead to premature failure. Seals should be selected based on the environment in which the conveyor operates.

8. Idler Alignment: Proper alignment of idlers is crucial to ensure the conveyor belt runs smoothly and reduces wear and tear on the belt and other components. Misaligned idlers can lead to mistracking and damage to the conveyor system.

Overall, the selection and design of idlers in a conveyor system should be done with careful consideration of the application, load requirements, environmental conditions, and other factors to ensure reliable and efficient operation of the conveyor.