Track rollers 101: Everything you need to know
Learn the basics of track rollers, including types, uses, and maintenance, in this comprehensive guide.
Get the information you need to make informed decisions.
Track rollers are essential components in various industrial applications, yet many people need to become more familiar with their workings.
With a projected global market size of $2.8 billion by 2027, understanding track rollers is crucial for businesses and industry professionals.
Track rollers are cylindrical components that are used to support and guide moving parts in industrial machinery and equipment.
Track rollers are typically used on conveyors, cranes, and other types of heavy machinery.
They are designed to carry heavy loads and to provide smooth, precise motion.
Track rollers are made from a variety of materials, including steel, plastic, and rubber.
To ensure a long service life, track rollers should be regularly checked for wear and tear, and should be replaced when necessary.
Proper maintenance and regular inspections can help to extend the service life of track rollers and reduce the need for costly repairs.
This article will not only provide you with a comprehensive understanding of track rollers.
Still, it will also give you the tools to make informed decisions about their use in your operations.
Please take advantage of the wealth of information we have to offer.
Definition of track rollers
Track rollers, also known as idler rollers, are mechanical components that work in conjunction with tracks in various material handling systems such as conveyor systems and cam drives.
They are crucial in maintaining smooth and efficient track and rail operations.
Proper selection, usage, and maintenance of track rollers can increase the speed and efficiency of the system.
Track rollers come in two types, those with outer ring running surfaces and those with cylindrical or flat outer ring running surfaces.
The best track roller will depend on the specific application, but outer ring running surfaces are generally considered the optimal choice.
Track rollers in tracked machines, such as excavators and road milling machines, are critical components that bear the total weight of the machine during standard operating procedures.
These rollers must be designed and constructed to withstand heavy loads without failure and to effectively dissipate the heat generated by continuous loading to protect other components, such as bearings and seals.
In particular, road milling machines,
like WIRTGEN, are known for their high advance rates, even at greater milling depths.
This puts the crawler units of these machines under extreme loads, which is why WIRTGEN utilizes high-quality track rollers specifically designed and manufactured for each machine model.
These rollers are essential for ensuring optimal performance and longevity of the machine.
Track rollers are an essential component in many industrial and heavy-duty applications, as they help to support and guide the movement of conveyor systems, vehicles, and other equipment.
Several different materials are commonly used to manufacture track rollers, each with its unique properties and advantages.
1.Carbon steel: This strong and durable material is often used in construction and manufacturing applications.
It is relatively inexpensive and can withstand heavy loads, making it a popular choice for track rollers.
Carbon steel is a ferrous metal containing iron and is known for its strength and durability.
It is commonly used in the construction of heavy machinery and equipment and in manufacturing industrial components such as gears, shafts, and bearings.
Carbon steel track rollers are typically made from low or medium-carbon steel, which has a lower carbon content than high-carbon steel.
This makes them less brittle and more ductile, making them more suitable for applications that require flexibility and high load-bearing capabilities.
2.Stainless steel: This material is known for its corrosion resistance, making it a good choice for track rollers exposed to harsh environments.
Stainless steel is an alloy of steel, which is composed of iron and at least 10.5% chromium.
Adding chromium to the steel creates a barrier against corrosion, making stainless steel highly resistant to rust and other forms of corrosion.
Stainless steel track rollers are typically made from type 304 or type 316 stainless steel, the most commonly used grade of stainless steel.
Type 304 is known for its excellent corrosion resistance, while type 316 is an even more corrosion-resistant alloy, making it suitable for use in harsh environments.
Stainless steel track rollers are also more expensive than carbon steel track rollers, but they offer a longer service life and require less maintenance.
3.Other materials: Track rollers can also be made from aluminum, brass, bronze, and plastic.
These materials are chosen for specific properties such as corrosion resistance, low weight, electrical conductivity, and low friction coefficient.
Aluminum is a lightweight, corrosion-resistant metal commonly used in aerospace and automotive applications.
Brass and bronze are known for their electrical conductivity and corrosion resistance, making them suitable for electrical and electronic applications.
Plastic track rollers are typically made from polyethylene, nylon, or other high-performance plastics and are known for their low friction, chemical resistance, and high impact resistance.
These materials are lightweight, corrosion-resistant, and have low friction, which is ideal for applications requiring high speeds and low load-bearing requirements.
Types of Track Rollers
1.Cylindrical track rollers: Cylindrical track rollers are the most common type of track roller characterized by their cylindrical shape.
They are typically made from carbon steel, stainless steel, or other durable materials and are designed for a wide range of applications.
Cylindrical track rollers are usually used in applications that require high load-bearing capabilities, such as in conveyor systems, material handling equipment, and heavy machinery.
They are also commonly used in machine tools and industrial robots. Cylindrical track rollers are available in various sizes.
Depending on the specific application, they can be fitted with different types of bearings, such as ball bearings, or needle bearings.
2.Cam followers: Cam followers are a track roller specifically designed to follow a cam or other type of rotating or linear motion.
They are typically made from hardened steel or other durable materials and are intended to be used in applications that require precise tracking and guidance.
Cam followers are commonly used in machine tools, robotics, and other automated equipment, where detailed movement is critical.
Depending on the specific application, they are available in various sizes and can be fitted with different types of bearings, such as ball bearings, roller bearings, or needle bearings.
3.Needle rollers: Needle rollers are a type of track roller characterized by their small size and high load-bearing capabilities.
They are typically made from steel or other durable materials and are designed to be used in applications that require high precision and low friction.
Needle rollers are commonly used in gear pumps, roller bearings, and other types of precision machinery. They are available in a variety of sizes.
Depending on the specific application, they can be fitted with different types of bearings, such as ball bearings, or needle bearings.
4.Spherical track rollers: Spherical track rollers are a type of track roller characterized by their spherical shape.
They are typically made from steel or other durable materials and are designed to be used in applications that require high load-bearing capabilities and high misalignment tolerance.
Spherical track rollers are commonly used in applications such as conveyor systems, material handling equipment, and heavy machinery, where the load may not be perfectly aligned with the roller.
Depending on the specific application, they are available in various sizes and can be fitted with different types of bearings, such as ball bearings, roller bearings, or needle bearings.
Key Features of Track Rollers
1.Use of tapered roller bearings or ball bearings: Track rollers are designed to handle radial and axial loads, which is achieved through tapered roller bearings or ball bearings.
These bearings can support and guide the movement of the track roller while also providing a low-friction surface for the track roller to move on.
Tapered roller bearings are designed to handle large radial and axial loads.
They are typically used in heavy-duty applications, while ball bearings are designed to hold smaller loads and are usually used in precision applications.
2.Special seals for extreme environments and operating conditions: Track rollers are often used in harsh environments and operating conditions, and to protect against dirt, sand, and moisture, special seals are used.
These seals are designed to withstand the extreme conditions of the environment while also providing a long-lasting and reliable seal.
The seals typically include lifelong seals and lubrication, which can withstand the harsh conditions of the environment and ensure that the track roller remains in good working condition for an extended period.
3.Availability in inch and metric sizes: Track rollers are available in a wide range of sizes, with options for both inch and metric sizes.
This allows for greater flexibility in selecting the appropriate size for the application. The rollers are also available in stud- or yoke-type varieties, allowing different mounting options.
Additionally, opportunities for larger sizes are available for heavier radial and thrust loads.
4.Inclusion of thru-shafts: Many track rollers include thru-shafts, which are designed to provide a secure and stable mounting option for the track roller.
The thru-shafts offer a safe and stable mounting option for the track roller and allow for easy installation and removal of the track roller when needed.
5.Integration of high-shear strength studs with a hex socket: Track rollers are often required to withstand high loads, and to ensure that they remain securely in place, many track rollers include high-shear strength studs.
These studs are designed to provide a secure and stable mounting option for the track roller and are integrated with a hex socket for easy installation.
The hex socket allows easy installation and removal of the track roller, making it a convenient option for maintenance and repairs.
Applications of Track Rollers
1.Architectural: Track rollers are often used in architectural applications, such as in the construction of skylights and other types of large glass structures.
They are used to support and guide the movement of the glass panels while also providing a low-friction surface for the glass to move on.
2.Automotive assembly: Track rollers are commonly used in the assembly of automobiles, as they can support and guide the movement of conveyor systems, robots, and other types of automated equipment.
They are also used to support and guide the direction of the car body and other components during the assembly process.
3.Fiberglass manufacturing: Track rollers are often used in manufacturing fiberglass products, such as boats and other types of watercraft.
They are used to support and guide the fiberglass material's movement while providing a low-friction surface for the material to move on.
4.Food and beverage production: Track rollers are commonly used in producing food and beverage products, as they can support and guide the movement of conveyor systems, robots, and other automated equipment.
They are also used to support and guide the movement of food and beverage products during production.
5.Foundries and mills: Track rollers are often used in foundries and mills, as they can support and guide the movement of conveyor systems, robots, and other automated equipment.
They are also used to support and guide the movement of metal and other materials during manufacturing.
6.Medical: Track rollers are commonly used in the medical industry, as they can support and guide the movement of conveyor systems, robots, and other automated equipment.
They are also used in the manufacturing of medical equipment and devices.
7.Metal processing: Track rollers are often used in metal processing, as they can support and guide the movement of conveyor systems, robots, and other automated equipment.
They are also used to support and guide the movement of metal and other materials during manufacturing.
8.Mining: Track rollers are commonly used in the mining industry, as they can support and guide the movement of conveyor systems, robots, and other automated equipment.
They are also used to support and guide the movement of the mined materials during the extraction process.
9.Pharmaceutical: Track rollers are often used in the pharmaceutical industry, as they can support and guide the movement of conveyor systems, robots, and other automated equipment.
They are also used to support and guide the movement of pharmaceutical products during the manufacturing process.
10.Pulp and paper: Track rollers are commonly used in the pulp and paper industry, as they can support and guide the movement of conveyor systems, robots, and other automated equipment.
They are also used to support and guide the movement of the pulp and paper materials during manufacturing.
11.Sand and gravel: Track rollers are often used in the sand and gravel industry, as they can support and guide the movement of conveyor systems, robots, and other automated equipment.
They are also used to support and guide the movement of sand and gravel materials during the mining and extraction.
12.Scientific research: Track rollers are commonly used in scientific research, as they can support and guide the movement of conveyor systems, robots, and other automated equipment.
They are also used in the movement of scientific equipment and materials during experimentation and research.
13.Shipbuilding: Track rollers are often used in the shipbuilding industry, as they can support and guide the movement of conveyor systems, robots, and other automated equipment.
They are also used to support and guide the movement of significant ship components during the assembly process.
14.Wood products: Track rollers are commonly used in the wood products industry, as they can support and guide the movement of conveyor systems, robots, and other automated equipment.
They are also used to support and guide the movement of wood materials during manufacturing, such as in sawmills, furniture factories, and many more.
Conclusion
In conclusion, track rollers are a vital component in track systems. Understanding the different types, key features,
and applications of track rollers will help you make informed decisions and ensure smooth operation in various heavy machinery.
Use the tips in this guide to make the most of your track rollers and keep your equipment running smoothly.