Optimized Upper Carrying Troughing Idlers

Upper carrying troughing belt conveyor idlers are designed to support belt sections where material is loaded and transported. There are two primary configurations using plain or impact rollers:

• A flat design featuring a single horizontal roller mounted on two fixed brackets;
• Troughed structure consisting of two or three rollers – one central and additional wing idlers- mounted within a supporting frame.

The troughed configuration is the best suited for bulk handling applications, as it allows a greater volume of material to be conveyed using the same belt width and speed. In particular, three-roller troughing idlers are used with unidirectional belts, with the side rollers slightly angled forwards to ensure self-centering belt tracking. On the other hand, the R version in which the side rollers have no forward inclination, is recommended for reversible belts.

Upper carrying troughing idlers support the conveyor belt by creating a “V”-shape formation, providing both structural stability and improved material containment. This angled configuration gently cradles the belt, ensuring even distribution of conveyed material along the structure. The inclined side rollers reduce the risk of spillage by preventing material from falling off the edges, while also enhancing belt tracking performance and load stability. The result is smoother operation, minimized material loss, and increased efficiency in bulk handling applications.

Designing the perfect belt conveyor idler

Selecting the correct rollers is crucial, as they are key components that directly impact the overall performance of upper carrying troughing belt conveyor idlers. They must be chosen based on the specific working conditions, considering factors such as belt width, speed, material flow rate, and lump size. Other important factors that can play a significant role in the choice are the material’s abrasive or corrosive properties, temperature and environmental conditions.

Additionally, the design of the transoms of belt conveyor idlers and their pitch (spacing) must to be calculated based on the total weight of the conveyed load. Proper design ensures that the belt receives adequate support during both loading and transport, preventing damage caused by sagging and strain.

Finally, the troughing angle—the inclination of the side rollers forming the “V” shape—must be selected according to the type of the material. A greater angle offers deeper containment for loose or fine materials, while a smaller angle is better suited for more stable loads, affecting both material stability and transport efficiency