Conveyor Rollers

Conveyor rollers are cylindrical components that are essential for the operation of conveyor systems, which are used to transport materials from one point to another. They support the conveyor belt or directly carry items, facilitating smooth and efficient material handling in various industries.

Types of Conveyor Rollers

Based on Function:

Carry Rollers (Idlers): Support the loaded portion of the conveyor belt, keeping it trough-shaped (for bulk materials) or flat.

Return Rollers: Support the empty return side of the conveyor belt.

Impact Rollers: Located at loading points, they have rubber rings to absorb impact and protect the belt.

Training Rollers: Designed to keep the conveyor belt centered, preventing it from wandering off track.

Wing Rollers: Used at the edges of troughing idlers to help shape the belt.

Snub Rollers: Increase the wrap angle of the belt around pulleys for better traction.

Based on Design/Profile:

Straight Rollers: General-purpose, versatile, used with or without belts to convey products.

Crowned Rollers: Have a slightly larger diameter in the middle, used to keep thin sheets centered or on conveyor belt ends.

Grooved Rollers: Have grooves for centering workpieces or the conveyor belt itself.

Knurled Rollers: Provide increased friction for gripping workpieces or driving belts.

Based on Drive:

Gravity Rollers: Undriven, materials move by gravity or external push.

Driven Rollers: Powered by motors, chains, or belts to move materials actively.

Accumulation Rollers: Designed to allow products to accumulate without back pressure.

Applications in Various Industries

Mining & Aggregate: Transporting coal, ore, sand, gravel from excavation sites to processing plants.

Logistics & Warehousing: Moving packages, boxes, and goods in distribution centers, sorting facilities, and airports.

Manufacturing & Assembly: Transporting components and finished products along assembly lines (e.g., automotive, electronics).

Food & Beverage: Conveying raw ingredients, packaged goods, and waste materials (often with hygienic designs).

Agriculture: Moving grains, hay, silage, and other agricultural products.

Heavy Industry: Steel mills, cement plants, power generation (coal handling).

Material Selection Considerations

Roller Shell (Tube):

• Steel (Carbon Steel): Most common due to its strength, durability, and cost-effectiveness. Often coated or painted for corrosion resistance.
• Stainless Steel: For corrosive environments, hygienic applications (food, pharma), or cleanroom settings.
• Aluminum: Lightweight, good for certain applications where weight is a concern.
• PVC/HDPE: For lightweight applications, corrosive environments, or where non-sparking properties are required.

Shaft:

• Cold-Rolled Steel: For standard duty.
• Alloy Steel (e.g., 4140): For heavy-duty applications requiring higher strength.
• Stainless Steel: For corrosion resistance.

Bearings:

• Steel (Chrome Steel): Standard for most industrial bearings.
• Stainless Steel: For corrosive environments.

Lining/Coating (if applicable):

• Polyurethane: Excellent abrasion resistance, good oil resistance, versatile hardness.
• Silicone Rubber: Flexible, tear-resistant, electrical insulation, good for high temperatures.
• Nitrile Rubber: Good abrasion resistance, reasonable oil resistance.
• UHMWPE (Ultra-High Molecular Weight Polyethylene): Good wear resistance, low friction, self-lubricating.
• Chloroprene (Neoprene): Good resistance to weather, salt, diluted acids.
• Polyacetal: Strong impact resistance, good in low temperatures, self-lubricating.
• Polypropylene: Fatigue resistance, low density, good chemical resistance.

Seals:

• Nitrile, Viton, or other elastomers depending on operating conditions and chemical exposure.