Conveyor idlers and rollers primarily support the conveyor belt and its load. They are typically divided into load-bearing rollers (trough or flat), return rollers, and impact rollers. A proper roller layout can reduce vibration and wear on the conveyor belt. Rollers, typically rubber-coated, provide power and directional control for the conveyor belt.
Product Features
Low-resistance operation for significant energy savings
Idlers utilize P6-grade (or higher) bearings and labyrinth seals, resulting in a rotational resistance of ≤3.0 N and a simulated full-load friction coefficient of ≤0.020, yielding substantial cumulative energy savings on long-distance conveyor lines.
01
Reliable sealing and durability in harsh environments
Idlers feature multi-stage labyrinth seals for dust and water protection, while pulley bearing housings utilize annular labyrinth seals; this ensures reliable operation without seizing in high-dust or high-humidity environments, with an idler service life of ≥30,000 hours.
02
Pulley design based on tension calculations; no deformation under heavy loads
Drive pulley shell thickness and shaft diameters are calculated individually based on maximum belt tension. Critical welds undergo ultrasonic testing. Units with diameters ≥630 mm feature a cast-welded structure, ensuring stable operation under heavy-load, long-distance conditions.
03
Lagging matched to operating conditions; slip-resistant and wear-resistant
Herringbone lagging facilitates unidirectional drainage; diamond lagging is suitable for bidirectional operation; ceramic lagging offers superior wear resistance compared to rubber, making it ideal for highly abrasive applications such as ore and coal handling.
04
Excellent interchangeability and easy installation
Idlers and pulleys of the same specification feature uniform dimensions and standardized bearing center distances and mounting interfaces, allowing for direct on-site replacement and reduced downtime.
05
Applications
Conveyor Idlers and Rollers are widely used in belt conveyor systems for mining, ports, power plants, cement production, steel processing, and chemical industries. In coal mines, idlers need to meet strict requirements for flame resistance, anti-static performance, and underground safety standards. For port conveyor systems, corrosion resistance is essential due to long-term exposure to moisture and salt spray. In power plants and heavy industrial applications, reliable operation with minimal maintenance is a key factor. For industries handling cement, sand, and bulk materials, high-quality sealing and wear-resistant designs help reduce failures and extend service life.
Quality Control
Incoming Materials: Steel pipes are checked for outer diameter, wall thickness, and roundness; bearings are verified for brand, precision grade, and internal clearance; pulley shafts are checked against material certificates; and lagging materials are tested for hardness and wear resistance.
In-Process: Idler welds are inspected for appearance and positional accuracy; critical pulley welds undergo 100% ultrasonic testing and spot X-ray inspection; and shafts undergo electromagnetic particle or penetrant testing after machining.
Final Inspection: Idlers are individually tested for rotational resistance and radial runout, with spot checks for axial load capacity and dust/water resistance; pulleys are individually checked for rotational flexibility and radial runout, with dynamic balance reports provided for drive pulleys. Batch numbers ensure traceability, and inspection reports are included.
Frequently Asked Questions (FAQ)
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