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Self aligning idler is important parts in the making and providing of belts in different machines. It helps in making the belt components and especially when it comes to presentation and helping the belt to keep the right posture of alignment as it works. Self aligning idlers are thus important in the making of industries since they reduce the need to make constant adjustments in some machines. The following are the common types of self aligning idler based on their shapes and sizes as well as their different uses.
Cylindrical self aligning idler has a cylinder-like shape. It is the most basic of idlers and comes with a cylindrical body with a convex surface. This type of idler is common in the mining industry where heavy belts are used. They are used to maintain belt tension while ensuring that the belt has the correct alignment.
The spherical self aligning idler comes with a ball-like surface. It allows for movement in more than one angle. This provides better flexibility in the new and changing alignments. These types of idlers are mostly used in applications that require higher loads and where the belt tends to shift a lot.
These idlers have cone shaped ends. They help in turning the belt to a certain direction. Out of the three, these are the least flexible when it comes to self alignment. Just like the cylindrical type, the conical self aligning idler is also used in the mining industry.
This type of idler has a flat belt profile that provides support to the entire belt surface. This helps to prevent excessive wear and tear on the belt. They are mostly used in the packaging industry and even when carrying lighter loads as in the paper and pulp industry. Flat self aligning idlers help in the proper alignment of the belt during the production process.
Self aligning idlers are made from different materials depending on the industry they are being used in and what kind of loads they carry. Different materials offer different kinds of resistances against different kinds of forces such as tension, friction and pressure. The following are materials commonly used in making self aligning idlers.
Rubber is used in making self aligning idlers since it provides good friction. This helps in preventing slippage during the use of the idler. It is also resistant to many chemicals and absorbs shocks that may be detrimental to both the components as well as the carried materials. However, rubber wears out more easily especially when used in conditions with extremely high temperatures.
Stainless steel as discussed earlier requires minimal maintenance since it does not rust or get corroded by moisture or other chemical substances. Stainless steel also has a very long life span and may be used in industries that require high intensity work such as mining and construction. It is however expensive and is very inflexible, meaning it cannot be used in all settings.
Plastic self aligning idlers are made in cheaper plastic materials that may be reinforced with stronger materials such as fibres. They are very light and thus do not add to the overheads of the machines carrying them. Unfortunately, while they may be resistant to corrosion, most plastics have low tolerance for temperatures. Continuous exposure of plastics to high temperatures will weaken its structure and possibly lead to failure.
While pure metals such as aluminum and brass may be used to make self aligning idlers, usually they will be in the form of alloys. Alloys increase the strength of the metals and also prevent wear and tear thereby increasing the durability of the machines. They also allow the idlers to carry more loads without suffering from structural failure.
Self aligning idlers are important components not just because they serve a purpose but also because of how much they contribute to the efficiency of the different machines they are fitted in. This results to cost savings in repairs, less downtime and better productivity. They are therefore commercially favorable.
Both the cylindrical and spherical self aligning idlers are commonly used in the mining industry. The loads are usually very heavy and the belts need to be aligned to prevent slippage. Self aligning idlers here help to ensure the belts are supported and keep them from breaking down. This has translated into greater productivity with less machines breaking down. Less machines breaking down means less money spent on repairs and more money made in production.
They are used to manufacture large production belts used in farming equipment like tractors, combines and harvesters. The belts in these machines also carry heavy loads like crops, grains or even water. They use conical and cylindrical self aligning idlers to support these belts. Sometimes they also face the lighter loads in the packaging of agricultural products. In the packaging industry, flat self aligning idlers are used.
Belts in construction equipment like bulldozers and excavators also use self aligning idlers. The loads here can be quite variable depending on what is being carried. The idlers can be made of either rubber or plastic composites due to the environment they are used in. These materials reduce the noise level and also the vibration which can be uncomfortable to work in. The idlers in this instance help in keeping the belts aligned no matter the load.
Transporting goods over long distances requires the use of huge conveyor belts. These belts have to be made with durable materials such as metal alloys. Only strong idlers like the cylindrical self aligning idler work for them. The idlers help maintain the tension and prevent the long belts from sagging. This keeps the entire system running smoothly and safely so that no goods fall off or get damaged.
Self aligning idlers have different load capacities and they fit different kinds of belts. Some idlers have a wide range of applications meaning they can be used in more than one industry. Others have very specific uses and only work in certain belts. These are the main load capacities of self aligning idlers.
Light load idlers are suitable for jobs with lesser weights such as those in the packaging and food processing industries. They are usually made of lighter materials such as plastic or rubber composites. These materials are suitable as they do not add much weight to the already heavy machinery. This reduces the strain on the motor and other components. Despite being less load bearing, they come with features like bearings that are shielded from dirt and other particles to prevent them from entering and damaging the mechanism.
Medium load idlers are usually found in industries such as agriculture that have variable loads. Materials like stainless steel provide the right balance between flexibility and strength. This also prevents the equipment from rusting and breaking down. Designs like the conical self aligning idler provide good support to the belts stretched under medium loads. This helps in ensuring the belts do not wear out faster than normal.
These idlers are used in such jobs as mining and construction that have extremely heavy loads. They are made from the strongest materials such as metal alloys. The surface is usually increased to prevent excessive wear and tear either through texturing or coating with other stronger materials. As discussed, industries that have huge masses utilise cylindrical and spherical self aligning idlers to prevent slippage and maintain alignment. The bearings used here are also specially designed to handle high rotational forces.
A1: Yes. They are designed to provide maximum support to the belt and even out the tension across its length. This prolongs not just the life of the idlers but also that of the belts.
A2: The plastic idlers are used in less demanding industries like logistics and electronics manufacturing. They withstand environmental factors such as moisture and chemicals unlike metal idlers.
A3: Yes. It is advisable to replace them at the same time. This ensures consistent performance and reduces the likelihood of misalignment problems occurring due to age differences in the components.
A4: Regular cleaning prevents dirt and debris from building up which can cause excessive wear. Regular checks for damage or signs of fatigue ensure that the idlers are replaced before they fail and cause damage to the belts.
A5: The materials have a lower environmental impact than others. Also, the fact that they increase energy efficiency in machines helps to reduce carbon emissions. Less breakdowns also means less waste as fewer components need to be replaced.
