Carrrying idler and idler set

We are manufacturing carrying idler and idler sets as per the customer requirements and drawing technical specification. It consists of manufacturing of 3 nos. of carrying idler and supporting frame.

A carrying idler set’s technical specifications define its design, materials, and performance to support a loaded conveyor belt. These specifications ensure the idler can handle the required weight, speed, and environmental conditions while providing a long service life.

Key Technical Specifications

• CEMA Class Rating: This is a crucial standard set by the Conveyor Equipment Manufacturers Association (CEMA) that classifies idlers based on their load-carrying capacity. A higher CEMA class (e.g., CEMA D, E, or F) indicates a more robust design with larger components and higher-rated bearings, suitable for heavier loads and more demanding applications.
• Belt Width: The carrying idler set’s length and troughing angle are designed to match a specific conveyor belt width. This is a critical dimension that ensures the idler provides full support for the belt and the material being conveyed.
• Troughing Angle: For most bulk material conveyors, the idler set consists of three rolls arranged in a trough shape. The troughing angle of the two outer rolls (typically 20°, 35°, or 45°) is specified to help contain the material and increase the conveyor’s carrying capacity.
• Roll Diameter: The diameter of the idler rolls is a function of the belt speed and CEMA class. A larger diameter is used for higher belt speeds to ensure the bearings achieve their rated life. Common diameters range from 4 to 8 inches (102mm to 203mm).
• Seals and Bearings: The idler’s performance and lifespan are heavily dependent on its bearings and sealing system. Specifications include the bearing type (e.g., sealed ball bearings) and the type of seal (e.g., triple labyrinth seal) designed to protect the bearings from dust, water, and other contaminants.
• Materials: The idler rolls are typically made from steel tubing, while the frame is made from steel channel or angle iron. The material grade and thickness are specified based on the CEMA class to provide adequate strength and rigidity.

Types of Carrying Idler Sets

• Troughing Idlers: The most common type. They consist of a central horizontal roll and two inclined “wing” rolls. This design creates a trough that helps center the bulk material and prevent spillage.
• Flat Idlers: Used for conveyors with a flat belt. They consist of a single, flat roller and are typically used for lighter loads, packages, or picking and sorting applications.
• Impact Idlers: A specialized carrying idler used at loading points. They feature rubber rings instead of a smooth steel shell to absorb the impact of falling material, protecting the belt from damage.