The Essential Guide to Trough Idler Rollers

06 May.,2024

 

The Essential Guide to Trough Idler Rollers

Trough idler rollers are integral to the efficiency and functionality of conveyor systems, especially in industries that handle bulk materials. These rollers are designed to shape the conveyor belt into a trough, optimizing the belt’s ability to carry large volumes of material securely from one point to another. The primary purpose of trough idler rollers is to support the conveyor belt and the material it carries, preventing spillage by maintaining the belt in a troughed position. This design is crucial for the smooth and efficient transport of materials, as it ensures that the load is centered on the belt, reducing the risk of material loss or belt misalignment. By effectively supporting the belt and facilitating the transportation of materials, trough idler rollers play a vital role in the operational success of conveyor systems across various industries.

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What is Trough Idler Rollers

Delving deeper into the world of conveyor components, it becomes evident that trough idler rollers are more than just simple supporting elements. The term “troughing idler” refers to a specific configuration of rollers designed to shape the conveyor belt into a ‘trough,’ providing a concave surface that cradles the material being transported. This design is pivotal in conveyor technology as it significantly enhances the belt’s capacity to securely hold and transport bulk materials, minimizing spillage and optimizing efficiency.

When exploring idler roller types, it’s clear that the diversity in designs caters to various operational needs and applications. Beyond the trough idler rollers, there are several other types, each serving a unique purpose:

  • Flat Idler Rollers: These are used primarily on the return side of the conveyor belt to support the belt as it loops back to the beginning.
  • Impact Idler Rollers: Positioned at loading points where material is dropped onto the belt, these rollers are designed to absorb the shock and impact, protecting the belt from damage.
  • Return Idler Rollers: Similar to flat idlers but specifically designed to support the return side of the belt, often featuring rubber discs to help clean the belt.
  • Guide Idler Rollers: These are used to keep the conveyor belt aligned and prevent it from drifting off its intended path.
  • Spiral Idler Rollers: With their unique spiral design, these rollers help to clean the belt and are often used in applications where sticky materials are conveyed.
  • Self-Aligning Idler Rollers: These are designed to automatically adjust the belt alignment, preventing and correcting any misalignment issues.

Each of these idler roller types, including trough idler rollers, plays a crucial role in the functionality and efficiency of conveyor systems, tailored to meet the specific demands of various material handling applications.

See Also:

Types of Steel Idler Rollers and Their Applications Explained

Components and Sizes of Trough Idler Rollers

The design and functionality of trough idler rollers are pivotal in the efficient operation of conveyor systems. Understanding the components and sizes of these rollers is essential for optimizing performance and ensuring the longevity of the conveyor system.

Trough Idler Rollers Parts

A trough idler roller is composed of several key components, each contributing to its overall function and durability:

  • Central Roller: This is the main part of the idler and is designed to bear the bulk of the load. It is typically larger in diameter and positioned in the center of the idler frame.
  • Wing Rollers: Positioned on either side of the central roller, wing rollers are angled to create the trough shape, guiding the belt and supporting the edges of the material load.
  • Idler Frame: This component holds the rollers in place and is attached to the conveyor structure. It is designed to withstand the weight of the materials and the force exerted by the moving belt.
  • Bearings: Bearings are crucial for the smooth rotation of the rollers. They are typically sealed to prevent dust and debris from causing wear and tear.
  • Seals: Seals protect the bearings from contaminants, ensuring the longevity of the rollers by preventing dust, water, and other particles from entering the bearing area.
  • Shaft: The shaft connects the rollers to the frame and is a critical component in transferring the rotational motion to the rollers.

Trough Idler Rollers Sizes

The size of trough idler rollers is determined by several factors, including the width of the conveyor belt, the load it needs to support, and the material being transported. Common diameters for trough idler rollers range from 4 inches (102 mm) to 6 inches (152 mm), but they can vary based on specific requirements.

When selecting the right size for your conveyor system, consider the following:

  • Belt Width: The width of the conveyor belt dictates the length of the idler rollers. A wider belt requires longer rollers to support it effectively.
  • Material Load: The weight and volume of the material being transported influence the size and spacing of the idlers. Heavier loads may require larger and more robust rollers.
  • Conveyor Speed: Higher conveyor speeds may necessitate larger rollers to ensure stability and reduce vibration.
  • Operating Environment: Conditions such as temperature, humidity, and exposure to chemicals can affect the choice of roller size and materials.

Selecting the appropriate size and type of trough idler rollers is crucial for the efficiency, safety, and longevity of the conveyor system. It’s advisable to consult with manufacturers or specialists to ensure the optimal configuration for your specific application.

Types and Variations of Trough Idler Rollers

The world of conveyor systems is diverse, with various types of components tailored to meet different operational needs. Among these, trough idler rollers stand out for their specific design and application in creating an efficient material transport pathway. Understanding the types and variations of these rollers is crucial for optimizing conveyor performance.

Types of Idlers PDF/PPI Idlers Catalog

For those looking to delve deeper into the specifics, comprehensive guides such as Types of Idlers PDFs or the PPI Idlers Catalog offer a wealth of information. These resources detail the different idler types, including:

  • Standard Trough Idlers: The most common type, designed with a 20°, 30°, or 45° trough angle, suitable for most bulk material handling applications.
  • Impact Trough Idlers: Built with rubber discs or rings to absorb the impact at loading zones, protecting the belt and structure from damage.
  • Adjustable Transition Idlers: Used at the conveyor’s loading and discharge points to transition the belt from a flat to a troughed profile and vice versa.
  • Garland Trough Idlers: Consist of a string of idlers hung from a chain or wire, offering flexibility and adaptability to conveyor curves.
  • Suspended Trough Idlers: Mounted on a wire rope for long spans, reducing the number of support structures needed.
  • Self-Aligning Trough Idlers: Designed to automatically correct any misalignment of the conveyor belt, ensuring smooth operation.

Difference Between Idler and Roller

While the terms “idler” and “roller” are often used interchangeably in the context of conveyor systems, they have specific meanings:

  • Idler: Refers to the entire assembly that supports the conveyor belt and includes the rollers, frame, and bearings. Idlers are categorized based on their function (e.g., trough idlers, impact idlers, return idlers).
  • Roller: The cylindrical component that actually makes contact with the belt and rotates to facilitate belt movement. Rollers are part of the idler assembly.

Understanding these distinctions is crucial for accurately discussing and specifying conveyor components. Trough idler rollers, as a specific type of idler, are designed to support the belt in a troughed shape, enhancing the conveyor’s ability to carry bulk materials efficiently. Each variation of trough idler rollers is engineered to meet particular operational challenges, from impact absorption at loading zones to belt alignment correction.

Installation and Maintenance of Trough Idler Rollers

Proper installation and maintenance are crucial for the optimal performance and longevity of trough idler rollers in conveyor systems. Understanding the role of return idler rollers and the importance of selecting superior idler brands can significantly impact the efficiency and durability of your conveyor system.

Return Idler Roller

Return idler rollers play a complementary role to trough idler rollers in a conveyor system. While trough idler rollers support and shape the belt on the carrying side to transport material, return idlers are located on the underside or return side of the conveyor belt. Their primary function is to support the belt as it loops back to the beginning of the conveyor system. The relationship between trough and return idler rollers is symbiotic, ensuring the conveyor belt maintains its structure and tension throughout the entire circuit. Proper alignment and spacing of both trough and return idler rollers are essential to prevent belt misalignment, excessive wear, and potential system failures.

Superior Idlers

Choosing high-quality idler brands is paramount for the reliability and efficiency of conveyor operations. Superior idlers stand out due to their durability, precision engineering, and innovative features that address common conveyor challenges. Examples of features that distinguish superior idler brands include:

  1. Advanced Sealing Systems: High-quality idlers often feature labyrinth seals or multiple barrier seals to protect bearings from contaminants, extending the life of the idler.
  2. High-Grade Bearing Technology: Superior idlers utilize bearings designed for high load capacities and minimal maintenance requirements.
  3. Robust Frame Construction: The strength and rigidity of the idler frame are critical, with superior brands offering frames that resist bending and ensure alignment.
  4. Impact-Resistant Materials: Idlers from top brands may use materials that are specially treated or alloyed for high impact resistance, particularly important for impact trough idlers.
  5. Energy-Efficient Design: Some superior idler brands focus on reducing the rolling resistance of their idlers, which can lead to energy savings and reduced operational costs.
  6. Customization Options: Leading idler manufacturers offer customization options to fit specific operational needs, including variable trough angles, roller diameters, and bearing types.

Investing in superior trough idler rollers and ensuring their correct installation and regular maintenance can significantly enhance the performance and lifespan of your conveyor system. Regular inspections, timely replacements, and adherence to manufacturer guidelines are key to maintaining the integrity and efficiency of the conveyor system.

See Also:

Choosing the Right Return Idler Roller for Your Conveyor

Pricing and Selection of Trough Idler Rollers

When it comes to enhancing the efficiency and longevity of conveyor systems, the selection of the right trough idler rollers is paramount. Understanding the factors that influence the price and the criteria for selecting the ideal idler can significantly impact the overall performance and cost-effectiveness of your conveyor system.

Trough Idler Rollers Price

The price of trough idler rollers can vary widely based on several key factors. When considering your investment, it’s important to evaluate:

  • Material Quality: High-grade materials such as stainless steel or specialized alloys might increase the price but offer better durability and longevity.
  • Bearing Type: Advanced bearing technologies that offer higher load capacities and longer life expectancies can also contribute to a higher price point.
  • Sealing System: Idlers with superior sealing systems to protect against contaminants and extend maintenance intervals may come at a premium.
  • Customization: Customized dimensions, angles, or features tailored to specific operational needs can affect pricing.
  • Brand Reputation: Established brands known for quality and reliability might command higher prices but often provide better value in the long term.
  • Volume of Purchase: Bulk orders often come with discounts, affecting the overall pricing structure.

Conveyor Idlers

Selecting the right idler for your conveyor system requires careful consideration of several operational factors:

  • Load Capacity: Ensure the idler can support the weight and volume of the materials being transported without compromising performance.
  • Belt Speed: High-speed conveyors may require idlers designed to minimize vibration and noise while ensuring stability.
  • Material Type: The nature of the materials being conveyed (e.g., abrasive, corrosive, sticky) can dictate the need for specialized idler types and materials.
  • Operating Environment: Conditions such as temperature, humidity, and exposure to chemicals should influence the selection of idler materials and designs.
  • Maintenance Requirements: Consider idlers that offer ease of maintenance and longer service intervals to reduce downtime and operational costs.
  • Energy Efficiency: Some idlers are designed to reduce rolling resistance, which can lead to energy savings and lower operational expenses.

By carefully evaluating these factors and understanding the pricing dynamics of trough idler rollers, you can make informed decisions that optimize the performance and cost-effectiveness of your conveyor system. Remember, the lowest initial price may not always equate to the best value over the life of the system. Prioritizing quality, compatibility with your specific operational needs, and the reputation of the manufacturer can lead to more reliable and efficient conveyor operations.

Advanced Topics in Trough Idler Rollers

Exploring the advanced aspects of trough idler rollers reveals the depth of innovation and engineering that goes into optimizing these essential components of conveyor systems. The focus on design and durability, along with the development of innovative solutions, underscores the industry’s commitment to efficiency, reliability, and longevity.

Design and Durability

The design features of trough idler rollers are critical in ensuring their durability and the ability to offer maintenance-free service. Key design aspects include:

  1. Material Selection: High-quality materials resistant to wear, corrosion, and impact are chosen to enhance the durability of trough idler rollers.
  2. Bearing Protection: Advanced sealing mechanisms protect bearings from contaminants, extending their life and ensuring smooth operation.
  3. Structural Integrity: The frame and structure of the idler are designed to withstand heavy loads and harsh conditions without deformation.
  4. Precision Engineering: The rollers are engineered with precision to ensure they provide consistent support and alignment to the conveyor belt.
  5. Maintenance Accessibility: Design considerations include ease of maintenance, allowing for quick inspections and replacements without significant downtime.
  6. Innovative Coatings: Special coatings or treatments may be applied to the rollers to reduce friction, resist environmental challenges, and prolong the life of the idler.

Innovative Solutions

The continuous pursuit of innovation has led to the development of advanced products like PPI’s Equal Troughing Idlers, which boast unique features designed to enhance conveyor performance:

  1. Equal Roll Design: Ensures consistent belt support and material containment across the entire width of the belt, improving stability and reducing spillage.
  2. Adjustable Angle: Some innovative idlers offer the ability to adjust the troughing angle, accommodating different material types and conveyor configurations.
  3. Energy-Efficient Operation: Features such as low-rolling-resistance bearings reduce the energy required to operate the conveyor, leading to cost savings.
  4. Impact Absorption: Advanced idlers incorporate materials or designs that absorb impact at loading zones, protecting the belt and the idler from damage.
  5. Self-Cleaning Mechanism: Certain designs include features that help shed material buildup, maintaining the idler’s efficiency and reducing maintenance needs.
  6. Smart Technology Integration: Some of the latest innovations include the integration of sensors and monitoring systems to predict maintenance needs and optimize performance.

These advanced topics in trough idler rollers highlight the industry’s focus on creating products that not only meet the current demands of material handling but also anticipate future needs and challenges. By investing in durable designs and innovative solutions, companies can achieve more efficient, reliable, and cost-effective conveyor operations.

FAQs About trough idler rollers

What is a trough idler?

A trough idler is a specialized type of idler roller designed to support and shape the conveyor belt in a trough form. This configuration is essential for efficiently carrying bulk materials, as it helps to contain the materials on the belt and prevent spillage. Trough idlers typically consist of a central idler roll with a specific diameter and two wing idlers on either side, which can be adjusted to achieve the desired trough shape. The angle and configuration of these idlers are crucial for maintaining the belt’s integrity and ensuring the smooth transportation of materials. Trough idlers are widely used in various industries, including mining, agriculture, and manufacturing, where bulk material handling is a critical operation.

What is the function of an idler roller?

The primary function of an idler roller is to provide support to conveyor belts and the materials being transported on them. Idler rollers help to distribute the weight of the materials evenly across the belt, preventing sagging and ensuring smooth operation. They also play a significant role in maintaining the belt’s alignment and tension, which are vital for the efficient functioning of the conveyor system. In addition to supporting the belt, certain types of idler rollers, such as impact idlers and return idlers, have specialized functions like absorbing the impact of falling materials at loading points and supporting the return side of the belt, respectively.

How many types of idler rollers are there?

There are several types of idler rollers, each designed to fulfill specific functions within a conveyor system. The most common types include:
Troughing Idlers: Designed to support the belt in a trough shape, ideal for carrying bulk materials.
Flat or Return Idlers: Used on the return side of the belt to support it as it travels back to the loading point.
Impact Idlers: Positioned at loading zones to absorb the shock of falling materials and protect the belt and structure from damage.
Guide or Training Idlers: Used to help the belt maintain its path and prevent misalignment issues.
Spiral or Rubber Disc Return Idlers: Help to clean the belt and prevent material buildup on the return side.
Each type plays a crucial role in the conveyor’s overall functionality and efficiency.

What is the standard size of an idler roller?

The standard size of an idler roller can vary depending on the conveyor belt width and the specific application requirements. However, common diameters for idler rollers include 76 mm (3 inches), 89 mm (3.5 inches), 102 mm (4 inches), and 127 mm (5 inches). The length of the idler roller is typically matched to the width of the conveyor belt, with standard sizes ranging from 500 mm to over 2000 mm. It’s important to select the appropriate size based on the load capacity, belt speed, and material characteristics to ensure optimal performance and longevity of the conveyor system. Manufacturers often provide a range of standard sizes but can also customize idler rollers to meet specific operational needs.

Jordan Smith, a seasoned professional with over 20 years of experience in the conveyor system industry. Jordan’s expertise lies in providing comprehensive solutions for conveyor rollers, belts, and accessories, catering to a wide range of industrial needs. From initial design and configuration to installation and meticulous troubleshooting, Jordan is adept at handling all aspects of conveyor system management. Whether you’re looking to upgrade your production line with efficient conveyor belts, require custom conveyor rollers for specific operations, or need expert advice on selecting the right conveyor accessories for your facility, Jordan is your reliable consultant. For any inquiries or assistance with conveyor system optimization, Jordan is available to share his wealth of knowledge and experience. Feel free to reach out at any time for professional guidance on all matters related to conveyor rollers, belts, and accessories.

Roller Conveyors: Types, Applications, Benefits, and Design

Roller Conveyors

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Introduction

This article takes an in-depth look at roller conveyors.

You learn details on topics such as:

  • What is a Roller Conveyor?
  • Construction of Roller Conveyors
  • Types of Roller Conveyors
  • Applications for Roller Conveyors
  • Benefits of Roller Conveyors
  • And Much More…

Chapter 1: What is a Roller Conveyor?

Roller conveyors are part of material handling systems that use a series of evenly spaced cylindrical rollers to move boxes, supplies, materials, objects, and parts across an open space or from an upper level to a lower level. The frame of roller conveyors is at a height that makes it easy to access and load materials manually. Items transported by roller conveyors have rigid, flat surfaces that allow materials to move smoothly across the rollers.

The uses for roller conveyors include accumulation applications, reduction of product inertia, and high speed sorting. Drive roller conveyors have rollers attached to a motor by a chain, shaft,or belt. The use of drive rollers equalizes the velocity at which materials are moved, can be reversible, and can have the capability of moving goods from a lower level to a higher one. They are used in bi-directional applications where the conveyor’s motor can change a product's directional movement.

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Chapter 2: Construction of Roller Conveyor

Roller conveyors have design features that enable them to serve the needs of specific applications. Although roller conveyors vary according to their structure, mode of movement, and other manufacturer features, all roller conveyors have the same basic characteristics.

Powered roller conveyors have small belts and plastic spools that give traction to the rollers. Friction belts or chains placed beneath the conveyor of a powered roller conveyor are used to power its heavy duty rollers and are connected to a shaft that spans the length of the conveyor's frame, which is linked to an electric motor that drives the rollers.

Rollers

Rollers for roller conveyors are metal cylinders fitted into its frame with sets of bearings on either end of the cylinder. There are several types of conveyor rollers each of which is designed to fit the needs of the product being transported. Rubber and plastic rollers increase friction while steel and aluminum rollers have a smooth surface. Rollers are selected for their ability to keep products on the conveyor, and their ability to maintain the integrity of products.

Plastic Rollers

Plastic conveyor rollers are an economical roller and are designed to handle light loads. They are easy to install and require little maintenance. Plastic conveyor rollers meet the noise standards of the Occupational Safety and Health Administration (OSHA). Since plastic does not corrode, rust, and is resistant to the effects of moisture, they have a longer useful life. Plastic conveyor rollers are easy to clean and are used to transport food packaging in the food industry.

Nylon Rollers

Nylon rollers are used for medium to heavy loads and have the durability and strength that enables them to withstand constant use. They are made of synthetic polymers that are resistant to abrasion, chemicals, and corrosion. Nylon conveyor rollers, like plastic conveyor rollers, are lightweight, easy to install, and produce limited noise due to their low vibration.


Rubber Coated Rollers

Rubber coated rollers have a rubber coating placed over steel, stainless steel, or solid plastic rollers. The rubber layer improves the grip of the roller and provides protection for the roller and products. The types of rubber coatings vary in accordance with the industry where they are used. Rubber coated rollers are resilient, soft, and have the ability to grip smooth materials.

As with all rubber products, rubber coated rollers are anti-static, chemical resistant, customizable and durable. They are used by the automotive industry, printing, and packaging and fabrication. Rubber coated rollers have increased friction between the roller and materials that prevents slippage.

Steel and Stainless Steel Rollers

Steel and stainless steel rollers are the most popular conveyor roller materials due to their durability and smooth surface. They are simple to clean, long lasting, strong and capable of moving heavy materials. Steel and stainless steel are used as the core for plastic, nylon, and rubber rollers due to their smooth surface and exceptional strength.

Stainless steel rollers are compatible with any material, can accommodate smaller diameters, have precision bearings or are fixed shafts and can be adjusted to meet shipping needs.

Structure of a Roller Conveyor

The frames of roller conveyors can be permanently positioned or temporarily placed and are made of steel, stainless steel, or aluminum. The convenience of temporary roller conveyors makes it possible to assemble and disassemble them for repositioning. Of the choices of structural metals, aluminum roller conveyors are lighter and are used for moving lighter loads.

Support legs for roller conveyors come in different sizes, materials, and styles to meet the needs of the conveyor and its loads. They can have a tripod design or “H” design with “H” design legs categorized as light duty, medium duty, and heavy duty. Support legs are made of channel and capable of accommodating different diameter rollers.


Roller Conveyor Motor

Roller conveyor motors are 24 volt DC motors that use less energy and have less torque, which makes them safer. A motorized roller conveyor is divided into zones with each zone having a motor driven roller (MDR) that is connected to the other rollers in the zone. The DC motors are built inside a roller in a zone and are controlled by an operator that determines the speed and direction of the movement of the conveyor.


Non Precision Bearings

Non precision bearings, such as sleeve bearings and bushings, have a looser tolerance and lower accuracy. They are made of the same materials as precision bearings and are used for smaller loads and lower speeds. The term “non precision” refers to their lack of accuracy and precision. They are used in applications where tight tolerances are not necessary.

Angular Contact Ball Bearings

Angular contact ball bearings make contact with the line of action of the load at an angle to the bearing's load. The inner and outer ring raceways of angular contact ball bearings are designed and developed to be positioned close to each other in the bearing axis' direction. This enables them to handle combined radial and axial loads. Types of angular contact ball bearings include single row, double row, and four point contact ball bearings.


In power roller conveyors, angular contact ball bearings support the conveyor line shaft, a long cylindrical rotating shaft that is connected to the rollers by belts and drive spools. When the shaft is powered, it moves the load by powering the rollers. Angular contact ball bearings, shaft, belts, and drive spool make the operation of a roller conveyor quiet and efficient.

Pillow Block Bearing

Pillow block bearing, also known as plummer block bearing, are means for supporting the shaft. They are commonly used with conveyor systems and have a single bearing that is mounted parallel to the conveyor. Pillow block bearings have a mounting block that houses the bearing and is bolted to a support surface.

The purpose of pillow block bearings is to handle misalignments and deflections of the shaft. They are widely used due to their ability to handle axial and radial loads.

Roller Conveyor Sprockets

Roller conveyor sprockets are gears that mesh with conveyor chains to transfer rotary motion to the rollers of a powered roller conveyor. The sizes of roller conveyor sprockets vary according to the number of teeth in their gears, power transmission, diameters, and the length of their bore. They can have plastic hubs, which are only used with light to medium loads. Steel hubs provide more strength and are able to handle heavier loads.

Roller Conveyor Curves

Roller conveyor curves are included in a roller conveyor system to change the direction and flow of materials without changing the orientation of the materials. They are designed to move items around corners, curves, and obstacles or equipment. Curve design is influenced by its angle, which needs to be at least 30° and no more than 90° with curve angles of more than 90° requiring special engineering.

Rollers for roller conveyor curves are conical or cylindrical shaped to be able to adjust the radius of the curve. They are designed to handle cardboard boxes, plastic crates, tires, and lightweight items. Roller conveyor curves are adjusted for the size and weight of the goods being transported and have support rollers on their frame.

Additional features of roller conveyor curves include side guides that can have a fixed or adjustable design. Although single curves are the traditional type of roller conveyor curve, S designs are also used as a floor space saving configuration. Spiral roller conveyors spiral from one level of a system to another level and are used in systems that have limited space. Other roller conveyor curves are split, multi-track, and double deck.

Chapter 3: Types of Roller Conveyors

There are several forms of roller conveyors, which are differentiated between powered or motor driven roller conveyors and gravity roller conveyors. Of the two types, gravity roller conveyors are the simplest form and operate by products being manually pushed along the surface of the rollers. The term motor driven or powered roller conveyors covers a number of roller conveyors with each type having a different power system.

Gravity Roller Conveyor

Gravity roller conveyors are the most basic form of roller conveyor and consist of a frame with rotating rollers, support legs, and the use of gravity to move materials. They transport light to medium weight loads and do not have a motor, which makes them the most cost effective material movement choice.


Made of steel, aluminum, and plastic, gravity roller conveyors can have curves, slide rails, supports and hanging brackets, sensors, and pop up stops. They are used as temporary conveyors and replacements for skate wheel conveyors in heavy duty applications where stacking loads do not need special scheduling. One of the features of gravity roller conveyors is their ability to be positioned during loading and unloading of products to make the process more efficient and less time consuming.

Belt Driven Live Roller Conveyor (BDLR)

Belt driven live roller conveyors have a motor that powers each roller with a motorized belt that allows for control of the movement of materials. Loads can be halted, turned and side unloaded or slide loaded, and reversed. The power driven belts of BDLR conveyors make it possible to move materials vertically and around curves. Some versions have a shaft that runs perpendicular to the rollers that positions and moves the belts that move the rollers.


Some belt driven live roller conveyors have their rollers set higher than the frame to support goods that are wider than the frame. BDLR conveyors are used to transport clean and dry medium to heavy loads and can be paused or reversed.

Chain Driven Roller Conveyor

Chain driven roller conveyors are powered by a chain drive connected to each roller. The configuration of chain driven roller conveyors is different from a single chain driven roller conveyor that powers the rollers with one long chain. The rollers on a chain driven roller conveyor have sprockets attached to each roller that powers and turns the roller.

Power transfer is high in chain driven roller conveyors, which makes them suited for medium to heavy loads. As with other powered roller conveyors, the power on a chain driven roller conveyor can be reversed allowing movement of materials in both directions.

Applications for chain driven roller conveyors include palletizing, filling, load staging, and strapping. Chain driven roller conveyors are not as powerful as roll to roll powered roller conveyors. They are very durable and provide optimal performance in harsh and hazardous conditions.


Line Shaft Roller Conveyor

Line shaft roller conveyors are driven by a rotating shaft that is attached to the rollers by drive spools and belts with one spool for each roller. The belts for each roller run from the shaft to the spool that turns the roller. When the shaft is powered, it turns the belts that turn the spools that turn the rollers.

A programmable logic controller (PLC) controls the electric motor that turns the shaft. With the absence of chains and sprockets, line shaft roller conveyors operate quietly and smoothly. The shaft runs the length of the roller conveyor and is placed below the rollers to one side of the frame.


A line shaft can power over 100 feet of straight and curved rollers, boosting the conveyor system's efficiency. They are used for accumulation, sorting, low back pressure, and medium to light duty loads

Line shaft roller conveyors are not suitable for hostile or harsh environments and should never be used in wet, oily conditions, at slow speeds, or on inclines. Materials being moved must be able to make contact with three rollers at all times.

Zero Pressure Roller Conveyor

With traditional accumulation conveyor systems, materials on the conveyor are allowed to bump into each other and stack up, a condition that creates pressure between materials that can damage the quality of products. In those types of conveying systems, material movement is uncontrolled and continues regardless of products being stopped and stationary.

Zero pressure roller conveyors or pressureless accumulating conveyors have zones driven by 24 volt DC motors controlled by photoelectric sensors. A central controller receives feedback from the sensors that lets it know if the zone ahead for a product has anything in it. If it does, the controller stops movement preventing the build up of back pressure.

Each zone of a zone pressure roller conveyor has a powered roller, sensor, and three or four slave rollers. The powered roller is connected to the controller, which determines when products can leave or enter the zone. The rollers are powered by an internal motor linked to non-powered slave rollers by O-rings.


Zero pressure roller conveyors are available as kits to repurpose older conveyor systems and are used for automation applications requiring timing, rate of movement, and consistency. While more complex and electronically actuated than past roller conveyors, zero pressure roller conveyors are efficient, regulate material flow, and provide a smoother transfer of goods.

Motor Driven Live Roller (MDR)

Motor driven live roller conveyors have slave drive transportation rollers with small 24 volt DC motors built into the rollers. The conveying system is divided into zones that have a motor powered roller and three or four slave rollers with each zone serving as an accumulation zone. Controller cards control the movement of products and the motors of the rollers using photoelectric sensors.


Motor driven roller conveyors are ideal for accumulation due to their small size. They eliminate the need for PLCs or complex pneumatic systems. The transportation rollers of the system are slave driven using bands that are easily replaced. In order to function with declines, inclines, or speed changes, belts are used with the MDR rollers.

Merge Roller Conveyors

Merge roller conveyors, or combiner roller conveyors, capture products that are flowing from multiple feed lines. They are normally used for collecting products from upstream lines into a single product stream. They are used for light and medium loads with live roller conveyors used to combine two to four lines. The design of merge live roller conveyors includes fixed or powered rollers to combine the infeed.

The major benefit of merge roller conveyors is to reduce the need for manual manipulation of products and their ability to combine upstream and downstream processes. They improve warehouse product flow and further minimize the use of labor for product placement and movement. Merge roller conveyor designs make it possible to easily reposition and reorient them.

Chapter 4: Applications for Roller Conveyors

Since their introduction in 1908, roller conveyors have become an essential part of product movement, assembly, and supply chain operations. They are versatile and adaptable pieces of equipment capable of handling any size load. Over the years, the use and sizes of roller conveyors has radically changed as new designs and functions are constantly being introduced.

The uses for roller conveyors includes:

  • Moving products across large areas with less labor
  • Transportation of heavy and cumbersome goods and materials
  • Saving labor costs by moving products while other activities are completed
  • Prevent injuries to workers from the stress of lifting to items falling
  • Ensure the safe transport of products with damaging them
  • Integral parts of robotic functions and actions.

Custom Designs

Every application for roller conveyors requires a specially designed roller conveyor that precisely fits the needs of an application. The most efficient use of a roller conveyor requires that it be engineered to fit the location where it will be used. Custom designed roller conveyors include various modular units, such as straight segments, curves, transitions between conveyors, mergers, types of power, and separators. Each of these factors has to be carefully considered and worked into a total roller conveyor system.

One of the challenges of developing a custom designed roller conveyor is the determination of whether the system will be a single unit stand alone system or be a more inclusive design with intertwined assets and components. Additionally, it is necessary to examine whether the system will be powered as well as the type of power such as chain, belt, or roller.

Airport Roller Conveyors

Airports make extensive use of roller conveyors, which include check in conveyors, baggage handling systems, and baggage loading. The types of roller conveyors include gravity and powered roller conveyors depending on the type of baggage or package handling.

Assembly Roller Conveyors

There are several types of assembly roller conveyors that vary between overhead conveyors, belt conveyors, and roller conveyors. Conveyor systems can be noisy, distracting, and uncomfortable for workers, which is the reason that, when possible, manufacturers use roller conveyors due to their reliability, durability, and smooth and quiet operation.

Supply Chain Roller Conveyors

An important tool of the supply chain and warehousing is the forklift that can quickly move products and goods. Many supply chain managers use roller conveyors to avoid the use of forklifts in product movement since roller conveyors are less expensive, relieve the workload for workers, and make product movement quicker.

Packaging Roller Conveyors

The packaging industry has high demand for conveying systems that move packages and for the process of stacking and sorting of packages. Depending on the application, either gravity or driven roller conveyors are used for package processing.

Food and Beverage Roller Conveyors

Roller conveyors for the food and beverage industry are challenging to design due to the regulations, restrictions, and standards placed on the industry. In many cases, roller conveyors have to meet three levels of cleanliness to qualify as possible for food and beverage use.

Metal Working Roller Conveyors

One of the main uses for metal working roller conveyors is the separation and identification of scrap. They are ideal for this purpose due to their heavy construction and versatility.

The few industries listed above are a small sample of the many industries that use and depend on roller conveyors as an essential part of their operation. From automobile manufacturing to robotics, roller conveyors are an important part of product movement.

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    Chapter 5: Benefits of Roller Conveyors

    The popularity of roller conveyors is due to their versatility and ability to adjust to different conditions. Temporary roller conveyors can be moved to where they are needed while permanent roller conveyors are long lasting and sturdy. Since their introduction in the early twentieth century, roller conveyors have found use in a varied number of industries with conventional and unconventional applications.

    • Speed - Roller conveyors are a safe and fast transport system, which reduces the risk of damage to goods due to mishandling.
    • Reliability - One of the reasons for the continued use of roller conveyors is their reliability as a long lasting logistics solution.
    • Cost Effectiveness - Roller conveyors are long lasting due to their toughness and durability. The initial investment in their cost is amortized over their many years of use.
    • Efficiency - The speed at which roller conveyors can move goods enhances and improves material movement.
    • Maintenance - Roller conveyors require limited maintenance due to their simple design and few moving parts, which reduces material handling downtime.
    • Safety - The continued use of roller conveyors has significantly reduced injuries due to the removal of the need to lift and move products by hand. This is one of their main benefits since workers no longer need to lift heavy packages or containers, a process that can be completed using various lifting mechanisms.
    • Customizable - The versatility, structural flexibility, and conformability of roller conveyors makes it possible to place them in any space where product movement is required. Every roller conveyor has to be engineered to fit the conditions where it will be used.

    Chapter 6: Regulations Regarding Roller Conveyors

    Safety Requirements of Conveyors

    The Occupational Safety and Health Administration (OSHA) has guidelines for the operation of conveying systems. The American National Standards Institute (ASNI) has safety considerations for conveyor design based on the American Society of Mechanical Engineers (ASME) guidelines. Both organizations continually review and update their standards and requirements to reflect new developments and technological advancements.

    OSHA Guidelines

    • 1926.555(a): General requirements.
    • 1926.555(a)(1): A motor stop switch should be found at the operator’s position. The system must have a pilot light with a sound that rings when the system is powered on.
    • 1926.555(a)(2): Remote operations should have a stop switch at the motor.
    • 1926.555(a)(3): The emergency stop button avoids reactivation of the system until the emergency button is reset to "ON."
    • 1926.555(a)(5): Overhead conveyors should have a protective covering below the conveyor. If the position of the conveyor is far from employees, this can be ignored.
    • 1926.555(a)(6) & 1926.555(a)(6): Warning signs must be put on aisles, crossovers, and passageways.
    • 1926.555(a)(7): Conveyors should have warning signs or be locked out during regular maintenance.
    • 1926.555(a)(8): Conveyors should be made and maintained according to ANSI B20.

    ASME Guidelines

    Conveyor safety standards are incorporated in:

    • ASME B11.0-2020, which mentions safe use of machines and mentions several safety devices that must be part of the construction and installation process.
    • ASME B20.1-2018: ASME B20. 1 -2018 has the design requirements, maintenance, construction, and operation of a conveying system concerning hazards. It’s a set of general safety guides. ASME B20. 1-2018 is for industrial use conveyors and not those which are designed to mobilize people.
    • ASME B20. 1-2018 is part of the specifications in ASME B20.1, ANSI B11.19, ANSI A1264.1, ANSI 244.1, which mention safety guides for conveyors.
    • ASME B20.1 and ANSI B11.19: These are in ASME B20. 1-2018 that explains the requirements for installation, construction, inspection, maintenance, and operation of a conveyor system.
    • ASME B20.1, ANSI B11.19, ANSI B11.0: These are more details concerning safety processes for temporary, permanent, and portable conveyors.

    Chapter 7: Roller Conveyor Maintenance

    Conveying systems are machines with interacting pieces that rely on one another to function properly. The various types of roller conveyors are pieces of equipment that necessitate a maintenance schedule to ensure proper performance. To effectively maintain a system and avoid problems, it is important to schedule regular examinations of a conveyor’s components that contribute to its overall performance.

    Conveyor Maintenance Steps

    The drive chain and sealed roller bearings must be oiled. Operators should be trained as to the proper inspection procedures in regard to bearings, rollers, shafts, belts, and DC motors.

    Driver rollers need to be cleaned to avoid system blockages. Residue or debris collected during material movement must be wiped from the surface of the rollers. Cleaners used on rollers have to be products designed for the specific roller. Stainless steel rollers, for example, must be sprayed with water then washed with a detergent. Preventative maintenance can address minor issues before they become major ones and ensures proper equipment performance

    Preventative Conveyor Maintenance

    Preventative maintenance involves examining conveyor rollers for flexible and smooth movement, drive chain or belt wear, and how level rollers are. Rollers should move in one direction and the same direction. Wobbling or non-movement of rollers is an indication of a problem, which should be addressed immediately. Since bearings fail due to wear, they should be regularly checked.

    As with any tool, roller conveyors that operate continuously endure wear and degradation due to the conditions of the environment where they are used. High temperatures and humid conditions have a negative effect on roller conveyors, which necessitates an increase in the number of times they should be examined. A key to the continued successful performance of a roller conveyor is intervals of downtime that allows the system to cool.

    Chapter 8: Considerations When Choosing Roller Conveyors

    A conveying system can be integrated into an operation in a variety of ways to improve efficiency and speed. There are several factors to consider before installing a roller conveying system in order to customize it to the needs of the application.

    Available Space

    Conveying system manufacturers consider the available space while designing a system. This step necessitates the identification of interaction sites, clearances, impediments, or any other areas that may impede material movement. Though automated systems are the most popular, whether the system is motorized or manual is determined by how it is used.

    Roller Frame Material

    The frame is often made of aluminum or steel, depending on the amount of loading on the system and the value of the rated frame's capacity. Rollers are substantially more variable in composition because they come into direct contact with products and can influence their movement. Some rollers are covered in plastic or rubber to increase friction, while others are just aluminum or steel drums. A properly selected roller keeps products on the line while not compromising its integrity.

    Roller Sizer and Orientation

    The size of the material on the conveyor, as well as the ideal layout of the conveyor, must be determined so that it does not impede the movement of products. Individual roller sizes are determined by the load and loading conditions. Heavy, high impact loads, for example, necessitate large rollers, whereas slow, low impact loads use smaller rollers.

    The spacing of rollers is determined by estimating the length of the load touching the conveyor surface and calculating the spacing so that three rollers are at all times in contact with this surface. High set rollers are used for loads that are wider than the width of the conveyor frame. Low set rollers are used to contain products inside the roller conveyor frame.

    Load Capacity

    Once the system has been set out and given a pattern, the quantity of material it can carry must be established. Overloading a system can lead to malfunctions or work stoppages. The overall length, bed breadth, and drive system have an impact on load capacity. Gravity roller conveyors are ideal for flat-bottomed, light to medium weight goods like totes, boxes, and bags but cannot be used with extremely delicate and cumbersome geometries like electronics and manufacturing parts.

    System Speed

    A conveying system's speed is measured in feet per minute (fpm). The average speed of most conveying systems is 65 feet per minute, which is how fast a person walks when carrying a 50 pound load. Although this is average, the speed of a roller conveying system can be adjusted to suit the application.

    Roller Conveying System Configuration

    Roller conveying systems are available in a wide range of shapes, styles, sizes, and configurations. They might be straight, angled, horizontal, or curved with pockets or slats as well as z-frames. If hundreds of feet must be crossed, a more efficient design, such as a line shaft roller conveyor, should be considered as a means to conserve energy. Roller conveyors can be installed in any facility or structure as long as careful consideration is given to each of the factors related to its use.


    Drive System

    The drive system moves materials on an automated conveying system and has counter bearings to keep goods moving. The convenience of drive systems is their ability to move goods in both directions and be positioned in the middle of the system, its beginning, or its end.

    Depending on the design of a drive system, it can have single or variable speeds that are driven by a 24 V DC motor attached to gears, rollers, or a shaft. Variable speed drives allow variations in material flow rates.

    Behavior, Control, and Environment

    Product mobility, control, and the placement of a roller conveyor are additional critical factors that are examined when designing a roller conveyor. The function of a roller conveyor can be affected by heat, dust, dirt, and moisture, which may require the use of more durable designs such as shaft driven or chain driven models. Zero pressure models with precision timing are ideal for conditions where there is possible back pressure. Although gravity models have a simple structure, they are susceptible to the same effects of deterioration that more complex roller conveyors are.

    Conveying System Safety

    The Occupational Safety and Health Administration (OSHA) regulates conveyor systems, which must meet federal safety standards. The regulations are known and followed by all conveyor manufacturers. Conveying systems are a preventative strategy that keeps personnel from having to lift and transport heavy objects.

    Disadvantages of Roller Conveyors

    Aside from the need for constant maintenance, which is common with any piece of equipment, there are disadvantages to roller conveyors that can limit their selection and use. These factors should be considered such that the chosen type of conveying system meets the needs of the application.

    • Damage to Goods - Gravity conveyors have little control over the movement of goods, which can lead to goods being damaged.
    • Weight - Roller conveyors are very heavy and get heavier as they get longer.
    • Conveyor Speed - Roller conveyors that are not power driven do not have any control over the rate of speed at which goods are moved.
    • Cleaning - Keeping roller conveyors clean is difficult due to the number of rollers and its constant use. In locations with multiple roller conveyors, a janitorial staff is assigned to cleaning rollers. In all cases, keeping the rollers clean and free of debris is essential for optimum performance.
    • Space - All forms of conveying systems take up a great deal of space, which is calculated into the customized design of roller conveyors. When the decision is made to install a roller conveying system, it must be noted that large areas of a facility will be devoted to it.

    Conclusion

    • Roller conveyors are part of material handling systems that use a series of evenly spaced cylindrical rollers to move boxes, supplies, materials, objects, and parts across an open space or from an upper level to a lower level.
    • Each roller conveyor system is designed to meet the needs of a specific application.
    • Though gravity roller conveying systems are the most well-known, other types include belt driven rollers, chain driven rollers, line shaft rollers, and zero pressure rollers.
    • Roller conveying systems, like any other type of machine, require routine maintenance and cleaning.
    • OSHA and ASME provide regulations and guidelines for the use and design of conveying systems.

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      For more information, please visit Idler Roller Manufacturer.