Optimizing Conveyor Efficiency and Longevity with Strategic Idler Placement
When installing two or more cradles, it is advisable to use intermediate idlers placed between each adjacent cradle. Placing an idler set between two cradles (or positioning each cradle between two idlers) reduces the drag of the conveyor belt over the bars. This reduction in drag leads to lower power consumption for the conveyor. Additionally, it minimizes heat buildup in the bars, thereby extending the life expectancy of both the bars and the belt.
It is recommended to specify idlers both before and after each 1200-millimeter (4 ft) cradle. The number of idler sets required for a given transfer point equals the number of cradles required plus one. To maintain a uniform belt line, all idlers should be from the same manufacturer and have the same size roller.
For areas under the loading zone between cradles, impact idlers should be used, while conventional idlers can be used outside this zone. Track-mounted idlers between cradles facilitate maintenance.
In some impact areas, such as long loading zones or locations prone to unpredictable impacts that could damage rollers, it may be acceptable to place intermediate idlers up to 2.4 meters (8 ft) apart. These applications include transfer points under quarry and mine dump hoppers, at pulp and paper mills where logs are dropped onto belts, or at recycling facilities handling heavy objects like car batteries and truck engines on conveyors.