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DESIGN GUIDELINES POWERED ROLLER CONVEYOR
DESIGN GUIDELINES
POWERED ROLLER CONVEYOR
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Table of contents
1. General information ................................................................................................................... 2
2. What are Powered Roller Conveyors used for? .................................................................. 3
3. Zero pressure conveying .......................................................................................................... 4
4. Modes of operation .................................................................................................................... 5
4.1 Singulation release ............................................................................................................ 5
4.2 Train release......................................................................................................................... 6
4.3 Gap train release ................................................................................................................. 7
5. Mechanical construction .......................................................................................................... 8
5.1 Standard zones ................................................................................................................... 8
5.2 Roller conveyor extrusion ................................................................................................ 9
5.3 Punches / holes ................................................................................................................. 10
5.4 Motor roller ........................................................................................................................ 11
5.5 Conveyor roller .................................................................................................................. 14
5.6 Poly-V belt .......................................................................................................................... 16
6. Controller .................................................................................................................................... 17
6.1 Advanced intelligence drive control ............................................................................ 17
6.2 Simple drive control ........................................................................................................ 19
6.3 Electrical connection plan .............................................................................................. 20
7. Sensors ........................................................................................................................................ 24
7.1 Standard sensor ................................................................................................................ 24
7.2 Alternative sensor ............................................................................................................ 25
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1. General information
• Safe and robust construction: The Powered roller conveyor design is robust and
potential danger areas are covered.
• Individual lengths and widths: Standard dimensions for box sizes are
300mm x 400mm and 400mm x 600mm are available. Other dimensions are
available on request.
• Ambient temperature: The temperature range between +2°C and +40°C must
not be exceeded (avoid thermal shocks).
• Humidity range: < 90%
• Shocks: < 0,5g
• Conductivity: The frame and rollers are designed to be electrically conductive.
The poly-V belts are anti-static.
• Extensions: Stands and leveling feet can be directly attached to the frame
construction.
• Catalog: Additional information can be found in the current Robotunits catalog.
3
2. What are Powered Roller Conveyors used for?
• Zero pressure accumulation (non-contact) conveying of goods
• Plug & Play solutions
• Energy efficient solutions
• Gentle handling of goods
Properties of suitable goods
• Smooth, closed or uniformly ribbed bottom surface
• A robust bottom for the transported weight
• Maximum 50kg per zone
• Even load distribution across the box
• Center of gravity is centered and below one third of the height
(to ensure stability during acceleration / deceleration)
Properties of unsuitable goods
• Curved bottom surface (convex or concave )
• Raised edges / ribs underneath the goods
• Recesses in which the rollers may get caught in
• Blister packaging
Typical conveyed goods
Plastic boxes Robust cardboard boxes
4
3. Zero pressure conveying
The Powered Roller Conveyor with zero pressure accumulation logic (ZPA) is divided
into individual zones and each zone has a sensor. ➍
The individual zones are connected and communicate with each other.
When goods approach an occupied zone ➍ they will be stopped on the previous
unoccupied zone ➌. When occupied zones become free ➍, upstream zones ➌ follow
automatically.
• Advantages
+ Plug & Play solution with decentralized controller = no higher-level controller
required (it can be accessed at any time with a control system - PLC)
+ Only the required rollers turn = energy efficient
+ Zero pressure accumulation conveying
Tip: The zero pressure accumulation (ZPA) logic can only be configured with the
ConveyLinx-Controller using the software "Easyroll".
The MotionLinx-Controller must be configured by the customer using a control system
(PLC).
➊ ➋ ➌ ➍
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4. Modes of operation
4.1 Singulation release
The goods ➌ are released when the downstream zones ➍ are free, i.e. the sensor is no
longer occupied.
• Advantages
+ Each zone (motor roller) starts individually = no accumulation of starting currents
• Disadvantages
- Slower emptying of zones
➊ ➋ ➌ ➍
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4.2 Train release
All goods ➋ ➌ are released when the downstream zone ➍ is free, i.e. the sensor is no
longer occupied. All upstream zones convey the goods in unison.
• Advantages
+ Fastest possible emptying of zones
• Disadvantages
- All zones (motor rollers) start in unison = accumulation of starting currents
➊ ➋ ➌ ➍
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4.3 Gap train release
All goods ➋ ➌ are released when the downstream zone ➍ is free, i.e. the sensor is no
longer occupied. All upstream zones convey the goods with a time delay (standard
setting is 0.3 seconds). As a result, not all motor rollers start at the same time and
current peaks can be avoided.
• Advantages
+ Due to the short time delay, there is no accumulation of starting currents
+ Fast emptying of zones
➊ ➋ ➌ ➍
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5. Mechanical construction
5.1 Standard zones
If the number of rollers changes, the sensor is placed between the 2nd and 3rd last
roller in the conveying direction. The motor roller is assembled in the middle of the
zone (odd number of rollers) or is positioned one roller from the middle in the
conveying direction (even number of rollers).
Motor
roller
Conveyor
roller
Zone
sensor
Poly-V
head Poly-V
belt
⭢
9
Frame
Option without side guides Option with side guides
5.2 Roller conveyor extrusion
Cover
Cable
conduit
T-Slot
10
5.3 Punches / holes
All punches and holes are machined per order. This means no unnecessary openings.
Straight without side guide
Straight with side guide
Curve
Inside radius Outside radius
11
5.4 Motor roller
• The delivery time for standard motor rollers is approximately 1 week.
Standard dimensions
Conveyed goods width
[mm] Inside clearance [mm] Installed length [mm] Roller diameter [mm]
300 310
Inside
clearance
-0.5
-1.0 Ø50 400 410
600 610
Alternative dimensions
Minimum 300 –
Maximum 1200
Minimum 310 –
Maximum 1210
Inside
clearance
-0.5
-1.0 Ø50
Performance data
Speed Code
ECO PLUS (40W) BOOST (50W)
Speed [m/min]
Current [A]
Speed [m/min]
Current [A]
During Start During Start
15 (Alternative)
2.0 – 9.9
2.5 4.1
2.0 – 6.9
3.5 5.0 20 (Standard)
10.0 – 28.0 7.0 – 20.0
35 (Alternative)
28.1 – 48.0 20.1 – 35.0
Life expectancy
Conveyed goods weight [kg] Operating hours [h]
15 75,000
25 47,000
35 37,000
50 29,000
Mounting thread
M12X1.25
Motor roller connection
M8 socket, 4-poles
Motor cable, 1m
Brushless
24V DC - motor
Steel tube galvanized
Spring loaded axle,
hexagonal open-end
(wrench size 11)
Finger guard
Poly-V head
12
TIP: Motor rollers with custom dimensions (with a speed up to 130m/min) can be
ordered with a delivery time of approximately 3 weeks.
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Motor roller attachment
Design type Drive side Belt side
Straight without side guide
Straight with side guide
Curve
Tube materials (Roller Conveyor Straight)
Standard Alternative
Steel galvanized
Stainless steel
PVC rubber coated (2mm – 3mm thickness)
PU rubber coated (2mm – 3mm thickness)
SKMM012X1.25
(wrench size 14)
Torque support
Spring loaded
axle, hexagonal
(wrench size 11)
Hexagonal nut
with flange
(wrench size 17)
Spring loaded
axle, hexagonal
(wrench size 11)
Hexagonal nut with
flange (wrench size 17)
BLSM008 +
IBSM08X016EXNIKO
ISK (wrench size 4)
14
5.5 Conveyor roller
• The delivery time for standard conveyor rollers is approximately 1 week.
TIP: Conveyor rollers with custom dimensions can be ordered with a delivery time of
approximately 3 weeks.
Standard dimensions
Conveyed goods width
[mm] Inside clearance [mm] Installation width [mm] Roller diameter [mm]
300 310
Inside
clearance
-0.5
-1.0 Ø50 400 410
600 610
Alternative dimensions
Minimum 300 –
Maximum 1200
Minimum 310 –
Maximum 1210
Inside
clearance
-0.5
-1.0 Ø50
Poly-V head
Spring loaded
axle, hexagonal
(wrench size 11)
Steel tube galvanized
Finger guard
15
Conveyor roller attachment
Design type Drive side Belt side
Straight without side guide
Straight with side guide
Curve
Roller materials (Roller Conveyor Straight)
Standard Alternative
Steel galvanized
Stainless steel
PVC
PVC rubber coated (2mm – 3mm thickness)
PU rubber coated (2mm – 3mm thickness)
Spring loaded
axle, hexagonal
(wrench size 11)
Spring loaded
axle, hexagonal
(wrench size 11)
Spring loaded
axle, hexagonal
(wrench size 11)
BLSM008 +
IBSM08X016EXNIKO
ISK (wrench size 4)
BLSM008 +
SKMM008FLA
(wrench size 13)
Spring loaded
axle, hexagonal
(wrench size 11)
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5.6 Poly-V belt
Standard poly-V belts are labeled as shown below.
Pitch
Standard Alternative
Conveyed goods length
[mm] Pitch [mm] Ribs
Conveyed goods length
[mm] Pitch [mm] Ribs
- 63 (Curve)
Minimum 200
60
300 80 70
90
400 105 120
133
600 160 175
200
• Material: Chloroprene with PA tension members, anti-static
• Recommendation: Roller pitch = Conveyed goods length
3.75
Robotunits article number
Manufacturer article number
17
6. Controller
6.1 Advanced intelligence drive control
Motor roller
connector M8 plug,
4-pole
Sensor connection
M8 socket, 4-pole
Replacement
button Motor roller
connector M8 plug,
4-pole
Sensor connection
M8 socket, 4-pole
Network cable
connection RJ45
24V (Logic) 24V (Motor roller)
0V
Network cable
connection RJ45
Network
cable RJ45
Motor roller
connector M8
plug, 4-pole
PIN (4) zone sensor
PIN (2) additional I/O
connection via Y-connector PIN (1) 24V
PIN (3) 0V
Sensor connection
M8 socket, 4-pole
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Control systems
Controller PLC protocol ZPA logic
(Robotunits) Other logics
(Customer via
PLC)
CONVEY LINX
✔ ✔ (e.g. Siemens) (e.g. Schneider) (e.g. Allen Bradley) (e.g. Mitsubishi)
MOTION LINX
✘ ✔ (e.g. Beckhoff)
TIP: Files required by the control technician for programming can be found here:
www.indsoft.bg/downloads.php (Additional Files).
Y- Connector for advanced intelligence drive control
Sensor connector
M8 plug, 4-poles
2
1
PIN (3) 0V PIN (1) 24V
PIN (4) Zone
sensor
PIN (4)
additional I/O connection
Sensor connection
M8 socket, 3-poles
PIN (1) 24V PIN (3) 0V
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6.2 Simple drive control
24 V
0V
Motor roller
connector M8
plug, 4-pole
Error output
Run A
Run B
Reverse direction
Common
(connection not
required)
Speed
Direction
Acceleration / Deceleration
20
6.3 Electrical connection plan
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22
23
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7. Sensors
7.1 Standard sensor
• Manufacturer / type: Wenglor / OPT1507
• Article number: SUP10025
• Light source: Infrared light
• Working range: 900mm
• Opening angle: 3°
• Supply voltage: 12V – 30V
• Current consumption sensor: < 16mA
Switching point adjustment
Turning the potentiometer counterclockwise decreases
the sensor range.
Turning the potentiometer clockwise increases the
sensor range.
Connection
M12 socket, 4-pole
Potentiometer
25
TIP: The standard sensor OPT1507 can cause problems with the following goods.
• Black objects (ESD boxes)
• Glossy objects (stainless steel containers)
• Wire mesh frames and similar materials
In such a case the sensor P1KY102 can be used.
7.2 Alternative sensor
• Manufacturer / type: Wenglor / P1KY102
• Article number: SUP10101 (Mounting plate PRO10393)
• Light source: Infrared light
• Working range: 1500mm
• Light spot diameter: 14mm – 42mm
• Supply voltage: 10V – 30V
• Current consumption sensor: < 15mA
Teach-In button
Cable connections
M12 socket, 4-pole
