Idler Rollers - Converter Accessory Corporation

It is important that all of your idler rollers function properly in your machine. If your idler rollers are designed poorly or require maintenance, web wrinkles, poor tension control and web defects will occur. Some things to consider regarding idler rollers when your web behaves poorly in your process are:

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1. Remember the web handling principle: A web will seek to align itself perpendicular to a roller in its entry span to that roller. What that means to you is your web will actually move to stay at a 90 degree angle to each idler roller in your machine. Idler rollers which are skewed to each other throughout a machine will affect the web because the web will bend to stay perpendicular to each idler roller. If your rollers are not level and parallel to each other web wrinkles and web guiding problems will occur. Check that all of your idler rollers are level and parallel in your machine. Laser alignment of rollers may be required to achieve optimum positioning.


2. Idler rollers should be balanced. Each time an idler roller revolves, unbalance will cause tension fluctuations in the web. In extreme cases machine vibration may occur. Dynamically balance all of your idler rollers, especially in high speed applications.


3. Bearing maintenance is critical. The web handling principle (stated in number 1 above) only applies when webs are in traction with rollers. Improper bearing operation can cause idler rollers to slow or stop spinning. When your web loses traction with idler rollers, web handling, tension control and web guiding problems will result. Check that all of your idler rollers spin freely.


4. Low inertia rollers, either thin wall or engineered shape, can help with traction, balancing and tension issues. Lighter weight rollers will start faster, spin freer and stop easier.


5. Idler roller mounting blocks should be designed to allow for level and parallel adjustment while also providing rigid mounting. Idler rollers can move to become skewed to each other over time. If there is no provision for this occurrence, idler roller alignment can become difficult, time consuming and expensive.


6. Idler roller surface should be flat. Any imperfections, such as diameter fluctuations across the rollers face, or taper can affect your web. Web wrinkles and other web defects can occur. Idler rollers can be designed with a concave profile to assist with wrinkle removal, albeit a passive effect.


7. Idler roller surface should be smooth. A smoothness finish should be specified. Idler rollers can be designed with grooves to allow air to exhaust from between the web and rollers face. This is extremely beneficial to assist with keeping smooth, non-porous webs in traction with idler rollers, especially in high speed applications. However, be careful when considering the groove design, it may cause defects in your web if it is too extreme or aggressive for your web.


8. Idler rollers can be covered with a variety of coatings. Plasma coatings can assist where traction is required and where adhesives must be handled. Rubber coverings can provide very high coefficient of friction between the web and roller face to assist with traction. Chrome and nickel plating can offer extremely smooth finish. Be aware of your options when it comes to idler roller coverings and coatings and consider how they can assist your web handling and operation.


9. Consider idler roller placement in your machine. Consider the number of idler rollers, as well. Idler rollers have two functions: to route your web through your process and to support the web. Oftentimes, long unsupported web lengths can cause issues with web handling and wrinkles will occur, due to insufficient web support.

Written By: Jeffrey Damour, Sales Manager, Converter Accessory Corporation, Wind Gap, PA, - 800-433-

Excavators are essential machines in construction, with key components—the “track roller” and “idler”—often causing confusion. Today, we’ll explore the differences between these two parts(Track Rollers and Idlers) and their significant roles in the performance and longevity of excavators.

Functions of Track Rollers and Idlers

Track rollers are located on both sides of the excavator’s chassis and support the machine’s weight directly. During operation, they work with the track system to manage the load, ensuring smooth movement over various challenging terrains, from muddy sites to rocky landscapes. Track rollers are vital for maintaining the excavator’s stability and balance.

Idlers, on the other hand, are designed to guide. Positioned at the front or rear of the track, they help keep the track aligned and maintain proper tension. While they do not bear the excavator’s weight directly, idlers ensure the track system stays on course, which is crucial for directional control. We supply many models of idlers like CX250D front idler for you to choose.

Structural Differences

Though both track rollers and idlers are part of the excavator’s mobility system, they differ significantly in structure. Track rollers are usually more numerous and are arranged evenly beneath the tracks, distributing the machine’s weight effectively. Because they frequently contact the ground, they need to be highly abrasion-resistant and robust, typically made from high-strength alloy steel or other durable materials. Their design must also ensure effective sealing and corrosion resistance due to exposure to mud, water, and debris.

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Idlers, while fewer, have a more complex design. They are generally larger and positioned at the track’s ends. Their primary role is to guide the track, requiring adequate tension adjustment capabilities and lightweight yet durable materials. Additionally, idlers help clear debris from the track, protecting the system from damage.

Lifespan Differences

Given their differing functions, track rollers and idlers have varying lifespans. Track rollers experience more wear due to their constant contact with the ground and the heavy loads they support, necessitating more frequent inspections and maintenance, as well as eventual replacement. Also, a good quality track roller is more durable and reduce the cost of replacement. Thus we recommend DH55 track roller to fit your DOOSAN/DAEWOO excavator.

Conversely, idlers, while important for track alignment, do not bear the excavator’s weight directly, resulting in less wear and a longer lifespan. However, neglecting their maintenance can lead to operational issues, as their condition directly affects the track’s performance. Regular checks and maintenance are essential for both components.

Importance of Monitoring Track Rollers and Idlers

Some may assume that a excavator’s performance relies solely on its engine, but track rollers and idlers are equally critical. Problems with track rollers can compromise stability, while idler failures can cause the track to misalign, hindering operation. Thus, keeping an eye on these components not only extends the excavator’s lifespan but also minimizes downtime and repair costs.

To ensure optimal operation of your excavator, it’s crucial to regularly replace and maintain the track rollers. We offer high-quality services that enhance the stability and durability of your machinery. Whether in mining, road construction, or challenging environments, the track rollers and idlers are vital components that require attention. If you need any help or have any questions, please feel free to contact us.