Impact Beds for Reducing Impact Zone Problems

In a standard conveyor arrangement, a top conveyor feeds material onto a lower conveyor by dropping it into an impact zone. At this point, impact rollers and frames are often installed to absorb the impact forces created by the falling material, which helps protect the bottom conveyor belt from damage.

Impact idler rollers and frames are designed to handle small, crushed, and granular material, improving the longevity of roller bearings and mechanical joints. However, if the forces become too great, impact idlers typically suffer premature bearing failure or excessive loading at the connection between the roller shaft and frame. This results in bearing stress failure on the bottom of the shaft and the mating surface of the frame slot.

impact bed for belt conveyor

Moreover, extreme wear and tear can occur if the crushing process doesn't adequately reduce oversized material from entering the chute, limit the amount of fugitive material (such as bucket teeth and pins), or if there is a significant fall height. In huge heap leaching system, our impact can be installed in radial telescopic stacker conveyor.

Because impact rollers and frames are often fitted in areas prone to frequent damage or wear, they can break under constant and heavy impact. In such situations, impact beds should be considered as a replacement, as they have a higher impact rating and a longer service life than impact rollers.

What is a Conveyor Impact Bed?

An impact bed is a piece of equipment used in conveyor systems to help the belt and structure absorb impact damage caused by large rocks and fugitive material. Designed to absorb high-impact forces, an impact bed also helps eliminate spillage and scattering of material, increasing productivity and lowering clean-up costs.

Typically located under a conveyor belt at the base of a chute, conveyor impact beds use shock-absorbent bars and a strong support frame to reduce shock transfer. They are often fitted in place of impact rollers to eliminate damage to impact-roller bearings and other moving parts.

How Do Impact Beds Compare to Impact Rollers?

If a conveyor system is wearing through impact idlers too quickly or they are outright breaking, an impact bed might be the solution. Impact beds are a cost-effective way to minimize the replacement of damaged impact idler rollers and frames. They can be designed to fit almost any position and should ideally be considered during the design phase of your conveyor system.

Compared to impact beds, impact rollers have more limitations on impact rating and service life, as impact idler frames cannot absorb the same amount of energy as impact beds. In high-impact zones, impact beds usually last much longer. Another added advantage is the minimal gap between the impact bars, which helps prevent conveyor belt deflection and denting.

impact bars for impact bed

Types of Impact Beds

Standard Impact Beds: Suitable for most applications, these beds provide general protection for the conveyor belt.
Heavy-Duty Impact Beds: Constructed from heavy-gauge material to withstand the impact from oversized, large, and heavy products. This design incorporates a fully welded, heavy-gauge steel plate frame, large diameter pins, and highly absorbent impact bars. This impact bed can be applied in mobile stacker conveyor system.
Hybrid Impact Beds: These incorporate impact rollers in the design, adding additional support from the side bars. This design offers greater control along the edge of the belt, which assists in maintaining the seal between the skirting rubber and the conveyor belt. It also helps reduce belt sag and movement associated with load shifts.
Custom Impact Beds: Custom-designed and manufactured to suit any specific application.

Impact beds play a crucial role in protecting conveyor belts and enhancing the efficiency of material handling systems, especially in high-impact zones. Their design and construction provide excellent impact absorption, reduce maintenance costs, and extend the lifespan of conveyor components. If you have specific needs or further questions about impact beds, feel free to ask!