Troughed Idlers Manufacturer Various Type Trough Idler for Belt Conveyor

Key FeaturesTrough rollers, also called load rollers or top rollers, are a critical component of any belt conveyor system. Their primary function is to support the conveyor belt along the load side (the upper part of the belt where material is being conveyed) and to form the belt into a trough. This......

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Product Description

Key Features Trough rollers, also called load rollers or top rollers, are a critical component of any belt conveyor system. Their primary function is to support the conveyor belt along the load side (the upper part of the belt where material is being conveyed) and to form the belt into a trough. This troughing action is critical to contain the bulk material being conveyed, prevent spillage, and optimize the belt's load-bearing capacity.

Roller Configuration: The most common trough roller consists of three rollers. A center-located horizontal roller forms the flat bottom of the trough, while two side rollers are angled upward. The angle of these side rollers can vary depending on the material being conveyed and the desired trough depth (common angles are 20°, 35°, or 45°). For very wide belts or high capacities, some designs may use five rollers to form a deeper trough. Sturdy Frame: The rollers are securely mounted to a sturdy steel frame that is directly attached to the main conveyor structure. The frame ensures stability and proper alignment of the rollers. Sealed Bearings: Each roller is equipped with sealed bearings (such as ball bearings or roller bearings) to ensure smooth, low-friction rotation. These bearings are designed to keep out dust, dirt, moisture and other contaminants common in industrial environments, maximizing roller life. Grease Fittings (Optional): While many modern rollers feature "greased for life" bearings, some heavy-duty or older designs may include grease fittings for periodic lubrication, which can further extend bearing life in demanding applications.

Specialty Types: Impact Rollers: A specialized trough roller used at the loading point. Trough rollers have elastic rubber rings or discs around their rollers to absorb the impact of falling material, protecting the belt and roller from damage. Self-Aligning Rollers (Self-Aligning Rollers): While not all trough rollers are self-aligning, some advanced roller models feature a pivoting mechanism that automatically corrects belt misalignment and guides the belt back to center.

Performance Benefits

Excellent material carrying capacity: By troughing the belt, these rollers effectively carry bulk materials, significantly reducing material spillage. This prevents waste, minimizes cleanup costs, and contributes to a safer work environment.

Maximized carrying capacity: Trough rollers allow the belt to carry a greater volume of material for a given belt width than a flat belt construction. This optimizes the throughput and efficiency of your conveying system.

Uniform belt support and stability: Trough rollers provide continuous and uniform support to the loaded belt along its entire length. This prevents belt sagging, reduces stress points, and maintains the structural integrity of the belt for more stable operation.

Reduced friction and power consumption: Well-designed rollers feature high-quality, low-friction bearings to ensure smooth belt gliding. This minimizes resistance to motion, which in turn helps reduce power consumption in the conveyor drive system.

Extended belt life: By providing proper support, preventing sagging, and ensuring smooth operation, trough rollers significantly reduce wear on the belt itself, extending its life and requiring less frequent replacement.

Durability and reliability: Made of strong materials and equipped with protected bearings, these rollers can withstand heavy loads, continuous operation and harsh environmental conditions, ensuring high reliability and long maintenance intervals.

Applications Mining and quarrying: Essential for transporting large quantities of coal, iron ore, copper, gravel, sand and other excavated materials. Aggregate plants and cement plants: Used in all stages of raw material handling, crushing and final product transport. Power plants: Primarily used for conveying coal, biomass and ash within the plant infrastructure. Ports and terminals: Essential for efficient loading and unloading of bulk cargoes on ships, trains and trucks. Steel mills: Used for transporting raw materials such as iron ore and coke as well as finished products. Grain handling and agriculture: Used in large grain silos, feed mills and other agricultural processing facilities to transport grain, seeds and fertilizers. Manufacturing and assembly: Used for conveying raw materials, parts and finished products, especially in industries that handle bulk or heavy items. Waste management and recycling centers: Used for transporting various types of waste and recyclable materials. Any bulk material transport system over long distances or with large volumes: Requires continuous and efficient transport of granular, lumpy or powdered materials.