The trough roller is the core component of the load-bearing section in belt conveyors. It forms a "V-shaped trough structure" through the combination of multiple sets of rollers, supporting the conveyor belt and bulk materials (such as coal, ore, sand,
The trough roller is the core component of the load-bearing section in belt conveyors. It forms a "V-shaped trough structure" through the combination of multiple sets of rollers, supporting the conveyor belt and bulk materials (such as coal, ore, sand, and gravel), guiding the materials to concentrate on the center of the conveyor belt for conveyance, and reducing the sagging of the conveyor belt and operational resistance. Its core positioning is "high-efficiency load-bearing + material guidance". It is widely used in various bulk material conveying scenarios, with its core value lying in enhancing the load-bearing capacity of the conveyor belt, reducing material spillage, and ensuring stable operation of the conveying system. It is a "standard component" for long-distance, high-flow conveyor lines.
1. Structural design: The core logic of slot-shaped load-bearing
The structural design of the grooved roller revolves around "enhancing load-bearing capacity and optimizing material guidance". The core components and design features are as follows:
Roller unit: Consists of 1 set of central rollers + 2 sets of side rollers (some special models include transition rollers). The central rollers are arranged horizontally, while the side rollers are inclined to both sides, together forming a trough-like structure. The roller body can be made of carbon steel, stainless steel, ceramic, or polymer materials, with its surface undergoing wear-resistant treatment (such as chrome plating, plastic spraying). The diameter ranges from φ89mm to φ219mm, and the length is matched according to the width of the conveyor belt.
Support structure: The core component connecting the roller unit and the conveyor frame, which is welded or stamped from steel plates and has its surface treated with anti-corrosion measures (galvanizing, plastic spraying); the strength of the support must be suitable for the load it bears. For heavy-duty conditions, thicker steel plates (thickness ≥6mm) are used to ensure no risk of deformation or fracture.
Bearing and Sealing: The roller is equipped with a deep groove ball bearing or a self-aligning roller bearing, paired with long-lasting lubricating grease (high temperature/low temperature resistant options available), to reduce rotational resistance. The sealing system adopts a dual sealing of "labyrinth type + contact type", with a protection level of IP65 or above, isolating dust and moisture, thereby extending the bearing life.
Slot angle design: The inclination angle of the side roller (i.e., the slot angle) is a core parameter. Conventional slot angles are 15°, 30°, and 45°. The larger the slot angle, the larger the cross-sectional area of the conveyor belt to accommodate material (under the same belt width, a 45° slot angle increases material capacity by more than 30% compared to a 30° slot angle). However, it needs to match the slot forming property of the conveyor belt (to avoid excessive stretching of the belt edges).
II. Core Advantages: The Key Value of Bulk Material Conveying
Enhance carrying capacity and accommodate high-flow conveying: The trough-type structure forms a "U-shaped" cross-section for the conveyor belt, with a material capacity 50%-80% higher than that of flat idlers (under the same belt width), meeting the high-flow conveying needs of hundreds to thousands of tons per hour (such as ten-thousand-ton conveyor lines in mines).
Reduce material spillage and lower loss costs: The trough-type structure confines the material to the center of the conveyor belt, preventing material spillage caused by vibration and tilt during conveying. This reduces the material loss rate to below 1% and simultaneously decreases the workload of on-site cleaning.
Protect the conveyor belt and extend its service life: Multiple sets of idlers evenly support the conveyor belt, reducing its sag (sag ≤1%) and avoiding local stress concentration; the buffer-type grooved idlers can absorb material impacts, preventing the conveyor belt from being scratched by sharp materials, thereby extending its service life by 20%-30%.
Reduce operational resistance and achieve energy saving and consumption reduction: The idlers are designed with precision bearings and low-friction seals, achieving a rotational resistance coefficient of ≤0.02. This design reduces the driving power consumption by 15%-20% compared to ordinary flat idlers, resulting in significant electricity cost savings over long-term operation.
Strong adaptability and compatibility with multiple working conditions: Different materials of idlers can be selected according to the characteristics of the material (temperature, corrosivity, hardness) (such as metal idlers for high temperatures, stainless steel/polymer idlers for corrosion resistance). The groove angle and length can be customized, and it is compatible with conveyor belts of all specifications ranging from 500-2400mm.
Easy to install and maintain, with high cost-effectiveness: The structure is highly standardized, eliminating the need for complex debugging during installation. Routine maintenance simply involves regular inspection of the bearing rotation and sealing conditions, resulting in low maintenance costs. The service life of a single set of idlers can reach 2-5 years under conventional working conditions.
III. Applicable Industries and Typical Application Scenarios
The grooved roller is the "basic component" for bulk material conveying, and is widely used in the following industries:
Mining industry: mining and conveying lines for ores such as coal, iron, and copper (such as underground raw coal conveying and surface concentrate powder conveying), suitable for heavy loads and high flow demands;
Building materials industry: cement, sand and gravel, ceramic raw materials, gypsum powder conveyor lines, deep groove type idlers can improve the conveying efficiency of cement clinker and sand and gravel;
Power industry: coal conveyor lines in thermal power plants, raw material conveyor lines for biomass power generation, and buffer groove type idlers suitable for coal dropping impact scenarios;
Port and dock: Bulk cargo (coal, ore, grain) loading and unloading conveyor belts, with deep groove type idlers meeting the port's "high throughput" conveying needs;
Metallurgical industry: sintered ore and blast furnace slag conveyor lines in steel plants, high-temperature resistant metal trough rollers suitable for high-temperature materials (≤120℃);
Chemical industry: Conveyor lines for chemical powder and granular materials (such as fertilizers and soda ash), with stainless steel/polymer groove-type idlers capable of withstanding corrosive materials;
Food processing industry: For grain conveyor lines such as wheat, corn, and soybeans, ordinary trough-type idlers can reduce grain spillage and ensure conveyor hygiene;
Infrastructure industry: Conveyor lines for sand, gravel, and concrete aggregates in construction projects, equipped with mobile conveyors to meet the flexible conveying needs of construction sites.
IV. Selection Guide: Precisely matching the needs of the conveyor system
According to the conveyor belt parameter selection:
Conveyor belt width: The length of the roller should be 100-200mm greater than the belt width (for example, if the belt width is 1200mm, the roller length should be 1400mm) to ensure that the conveyor belt fully covers the roller;
Groove performance of conveyor belt: Ordinary canvas conveyor belts are suitable for groove angles below 30°, while high-strength nylon conveyor belts can accommodate deep groove angles up to 45°, avoiding excessive stretching of the belt edges;
Conveying speed: For low speeds (≤2m/s), choose ordinary bearings; for high speeds (>2m/s), choose high-precision self-aligning roller bearings to reduce rotational heating.
Selecting the model based on material characteristics:
Material hardness/impact: For high-hardness materials (such as ore), metal rollers are selected; for high-impact material feeding, buffer groove rollers are chosen;
Material temperature: For normal temperature (-20℃~80℃), choose ordinary materials; for high temperature (80℃~120℃), choose metal rollers; for low temperature (<-20℃), choose cold-resistant polymer rollers;
Material Corrosivity: For corrosive materials (such as acid and alkali solutions, salt spray environments), stainless steel or polymer rollers should be selected.
Select the model based on the load capacity:
Light load (≤5kN): Select φ89-φ108mm idlers, with a support steel plate thickness of 4-5mm
Medium load (5-15kN): Select φ133-φ168mm idlers, with support steel plate thickness of 5-6mm
For heavy loads (>15kN), select φ168-φ219mm idlers, with a support steel plate thickness of 6-8mm, and use self-aligning roller bearings.
Select the model based on the installation location:
Regular load-bearing section: Select ordinary/deep groove type idlers;
Near the drum/curved path: choose a transition groove type roller;
Below the discharge opening: choose a buffer groove type roller;
For sections prone to deviation: Select self-aligning groove-type idlers.
V. Key points of installation and maintenance
Installation specifications:
Spacing settings: The spacing for ordinary load-bearing sections is 1-1.5m, while for heavy-load sections, it is 0.8-1m. The spacing for buffer rollers near the discharge port is 0.5-0.8m
Horizontal alignment: The roller bracket needs to be installed horizontally, with the center roller axis parallel to the centerline of the conveyor belt. The groove angle deviation of the side rollers should be ≤1°, to avoid belt deviation caused by uneven loading;
Secure fixation: The connecting bolts between the bracket and the frame must be tightened (with a torque set according to the bolt specification, such as 30-40N·m for M12 bolts) to prevent loosening during operation.
Routine maintenance:
Weekly inspection: check the flexibility of the roller rotation (no jamming or abnormal noise), clean the material adhering to the surface, and check whether the groove angle of the side roller is deformed;
Monthly inspection: check the bearing temperature (≤60℃ during operation) and inspect the seals for any damage. If oil leakage or dust ingress is detected, replace the seals promptly;
Quarterly maintenance: replenish lubricating grease for the bearing (use lithium-based grease, with a filling amount of 1/3-1/2 of the internal space of the bearing), remove rust from rusted parts and repaint anti-corrosion paint;
Fault replacement: In case of jamming of the roller, wear of the roller body ≥3mm, or deformation of the bracket, it is necessary to replace it in a timely manner to avoid damage to the conveyor belt.
Storage requirements:
Store in a dry and ventilated warehouse to prevent rusting of the roller body and bracket;
Store single sets of idlers upright, with a stacking height not exceeding 5 layers, to prevent deformation of the supports due to pressure;
For long-term storage (>6 months), it is necessary to rotate the roller regularly to prevent the bearing grease from solidifying.
