Impact idlers are critical components in conveyor systems designed to handle high-impact scenarios. Their core functions include:
Impact Absorption
When materials drop at high speed from heights (e.g., crushers, discharge chutes) onto the conveyor belt, impact idlers use elastic structures to absorb instantaneous impact forces, preventing direct damage to the belt.
Belt Protection
The idler surface is typically covered with cushioning materials like rubber or polyurethane, which reduce kinetic energy from falling materials. This minimizes rigid collisions between the belt and hard objects (e.g., ores, metal chunks), preventing belt tearing, abrasion, or delamination.
Stable Conveying
In high-impact zones (e.g., loading stations, transfer points), impact idlers maintain belt stability through flexible support, reducing belt bounce or deviation caused by shocks.
Extended Equipment Lifespan
By mitigating impact transmission, these idlers reduce mechanical stress on belts, drums, and bearings, thereby extending the overall lifespan of the conveyor system.
Typical Applications
Material drop points in mining crushers
Underneath unloading funnels in ports
Stone loading areas in quarries
Coal bunker outlets in power plant coal-handling systems
Design Features
Roller bodies wrapped in high-density elastic materials (Shore hardness 60-80A)
Internal bearings usually sealed deep-groove ball bearings for dusty environments
Common diameters: 108–159 mm (length customized per belt width)
Maintenance Tips
Regularly inspect wear on the cushioning layer (replace if worn beyond 1/3 of original thickness)
Ensure free rotation of idlers to avoid localized stress concentration
Perform quarterly bearing lubrication in dusty environments
Proper selection of impact idlers significantly reduces conveyor failure rates. In metallurgical industry tests, conveyor belts at loading points with impact idlers showed a 2–3 times longer lifespan compared to standard idlers.
