Impact rollers provide additional support and absorb shock stresses at loading and transfer points on conveyor belts. They have a smaller core and thicker rubber coating with grooved surfaces for superior strength. They can be arranged in standard or suspended frames and spaced no more than 17 inches apart.
An impact roller is one of the supporting and guiding elements used in flat and channel conveyor belt systems. The specific function of a striker roller is to provide the conveyor with additional support at transfer and loading points where the belt is subjected to significant shock stresses. While similar in general construction to other roller elements, the hammer roller features a smaller diameter core element and a thicker grooved rubber tread. The thicker coating and grooved surface offer superior strength over conventional rollers. Percussion rollers can be arranged in standard, stationary or garland suspended frames, depending on belt configurations.
Conveyor belts use a large number of rollers along the unloaded surface of the belt. These roller arrangements ensure that the belt is supported and runs straight. They can also be configured to allow the belt to deflect sideways around curves while maintaining an adequate load area. Impact rollers have the specific purpose of helping absorb intense impact to the belt at the loading and transfer points.
Conveyors carrying large aggregates such as raw coal and iron ore are constantly jolted where belt is loaded or where one belt unloads onto another. These repeated impacts can severely wear out a conveyor and ultimately lead to belt failure. Rows of impact rollers are positioned here to absorb much of the force and prevent accelerated wear. The row frequency of impact roller sets at a point load is typically greater than for normal guide rollers along its length.
Conventional idler and guide rollers would not offer the same degree of protection as the impact roller as they usually feature large diameter shells with thin rubber lining. Impact rollers differ in design in that they have a much smaller center shell and a much thicker rubber lining. This coating is normally designed as a set of concentric rings which form a grooved surface to the roller. The typical percussion roll has an inner core diameter of approximately 3.5 inches (90 mm) and an overall diameter of 6 inches (152 mm).
The mandrels of the rollers are flattened in the same way as normal idlers, thus allowing the roller to fit into standard fixed frames. This gives the impact rollers logistical flexibility as they can be used on standard frames. The reels can also be suspended on garland-shaped stands if the ribbon configuration requires it. Typical impact roller spacing rarely exceeds 17 inches (450 mm) to allow for the maximum amount of belt support.
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