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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.
How Troughing Idlers Work
Troughing idlers consist of three or more idlers that guide the conveyor belt. They are found on the carrying-side of the belt and are installed along the entire length of the conveyor. The troughing idlers work to keep the belt in the same configuration all along its length, which thus maintains the same cross-sectional area as the belt carries mined materials from their source to the drop off point. A troughing idler is comprised of a central idler roll, which has a fixed width, and two or more wing idlers located on each side of the central idler roll. The wing idlers can be adjusted up or down to change the toughing angle, which affects the depth of the trough created by the conveyor belt as it moves.
Benefits of Troughing Idlers
Troughing idlers offer two important benefits. First, the troughing idlers keep the belt&#;s shape consistent throughout its journey, which improves both stability and carrying capacity. Second, troughing idlers reduce the amount of material that may accidentally spill over the edge of the conveyor system, which improves productivity and also increases the safety of workers, who may be at risk from falling material while working near conveying equipment.
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Back to BlogBelts are designed with a troughed shape to enhance their capacity for carrying materials. Increasing the trough angle allows the conveyor to accommodate a larger volume of material. Idlers play a crucial role in shaping flat rubber or PVC belts into troughs. The maximum trough angle is determined by factors such as the belt carcass type, belt thickness, width, and tension rating. Manufacturers typically specify troughability on technical data sheets, indicating the minimum belt width required for different trough angles.
Exceeding the maximum trough angle for a specific belt can cause permanent deformation, leading the belt to adopt a cupped shape. Cupping makes the belt challenging to seal, clean, and track properly. It reduces surface contact between the belt and the conveyor's rolling components, impairing the components' ability to steer the belt effectively.
When a belt's troughability limit is surpassed, it may fail to form the trough correctly, resulting in sealing and tracking issues. A belt that is too stiff to trough properly will also struggle to track correctly within the conveyor system. This misalignment can quickly escalate into material spillage from the conveyor's edges and damage to the belt's edges.
Additionally, exceeding the belt's troughing capability can damage the top and bottom covers as well as the carcass around the idler junctions. If the belt's troughability is not compatible with the troughing idlers, it may increase the power required to operate the conveyor beyond its original design specifications.
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