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Maximize Reliability: A Step-by-Step Guide to Selecting the Right Conveyor Idlers 2023

1.Why do we choose the right conveyor idler?

As the main component of the belt conveyor, the conveyor idler is distributed under the belt conveyor belt, mainly used to support the belt and bear the load, shock absorption, avoiding belt misalignment, cleaning the belt is also its main function, therefore, its quality and correct selection, plays an important role in the service life, safe and stable operation and energy consumption of the whole belt conveyor, the guide recommended idler is suitable for ordinary belt conveyor with bandwidth of 500~2400 and high strength belt conveyor with high speed, high capacity and long distance, it is widely used in metallurgy, coal, hydropower, building materials, chemical industry, seaport, wharf and other fields, and can transport all kinds of bulk, granular, bulk materials and articles with a accumulation capacity of 0.5~2.5t/m³

2.. Conveyor idler performance index

No.	project name	performance index
1.	Working life	Normal use, the life is not less than 50000 hours, and the damage rate during the effective use period is not exceed 5%
2.	Rotational resistance coefficient of the idler	Factory laboratory test: 0.010; Under the engineering service conditions: 0.020.
3.	Radial run-out	0.5mm (idler length <550mm) 0.6mm (idler length 550-950mm) 1.0mm (idler length> 950-1600mm) 1.2mm (idler length> 1600mm)
4.	Axial displacement of the idler	0.5mm
5.	idler dust and water volume	After the idler runs continuously in the container with dust for 200 hours, the dust does not enter the sealed grease chamber. After continuous operation for 72 hours under water condition, the water intake is 10g.
6.	idler axial bearing capacity	10 KN (idler diameter 108mm)
		15 KN (idler diameter 133-159mm)
		20 KN (idler diameter> 159 mm)
7.	idler drop test	All parts and welds shall not be damaged and detached; The axial displacement of the idler after falling shall not be greater than 1.2mm; The idler tube body and the bearing seat shall not be loosened; The rotation resistance coefficient of the falling idler shall not be greater than 1.5 times that before falling.

3. Selection diameter of conveyor idler

When choosing the idler, attention should be paid to its appearance is smooth and clean, without obvious defects, and the performance indicators meet the following requirements.

3.1 The relationship between the idler diameter and the belt width is shown in Table 1

Table 1

3.2 When selecting the idler, the speed shall not exceed 600 r/min. The relationship between the diameter of the idler and the belt speed is shown in Table 2

Table 2:

Idler diameter (mm)	Belt speed m/s
	0.8	1	1.25	1.6	2	2.5	3.15	4	5	6.5
	Idler rotation speed, r / min
89	172	215	268	344	429	537
108	142	177	221	283	354	442	557
133		144	180	230	287	359	453	575
159		120	150	192	240	300	379	481	601
194			123	158	197	246	310	394	492
219							275	349	436	567

3.3 idler load calculation
3.3.1 Static load calculation:

After the calculation, record the larger value of the static load and the dynamic load, and check the conveyor idler bearing capacity (table8) to select the conveyor idler so that the bearing capacity is greater than or equal to the calculated value.

Table 3 Idler spacing a₀mm

loose density Kg/m³	Belt width
	500 650	800 1000	1200 1400	1600 1800 2000 2200
	Idler spacing
≤1600	1200	1200	1200	1000
＞1600	1000	1000	1000	1000

Table 4 Idler load coefficient e

Idler Group	e
One idler	1
Two idler	0.63
Three idler	0.8

3.3.2 Dynamic load calculation

Table 5 Running coefficients f_s

Table 6 Working condition f_a

_{Table 7 Impact coefficient}_fd

3.4 The relationship between bearing specifications and bearing capacity is shown in Table 8

Table 8 Bearing capacity of the idler:

In conclusion, selecting the right conveyor idler is crucial for ensuring the smooth and efficient operation of your conveyor system. By following the guidelines outlined in this comprehensive guide, you can make informed decisions based on factors such as load capacity, belt width, roller material, and environmental conditions. Remember to consider the specific needs and requirements of your application to choose idlers that offer durability, reliability, and optimal performance. With a well-chosen conveyor idler, you can enhance productivity, reduce maintenance costs, and maximize the overall efficiency of your material handling processes.

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