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The roller conveyors are systems for the movement of goods that are used in a variety of industries and companies: aggregates companies, mining, recycling plants, warehouses and logistics centers, courier companies, supermarkets, airports and ports, companies fruit and vegetables, chemical industry, pharmaceutical industry, etc.
The basic structure of the roller conveyors is simple, some rollers placed in parallel and anchored perpendicularly to a structure that acts as a guide and support for the entire system. The rollers can rotate on their anchors to the structures, which allow the products to move. However, this basic structure can be adapted through different modifications to all kinds of products and forms of movement; In addition to needing security systems and movement control; as well as specific protective systems according to the uses for the heads.
The fundamental parts of the rollers are:
The bearing axle. That goes inside the roller and is anchored to the structure.
The heads, which is where the bearings are located. Located at the ends of the shaft and allow anchoring and turning. It is also where traction is applied. It can be manufactured in different materials depending on their application; thus, for heavy structures, rollers with steel heads and steel sprockets or thermoplastic heads for light loads can be used. There are many options among these.
The cylinder or external structure of the roller, which will allow a large number of modifications adapted to each product or type of movement. It can be smooth or tapered.
From the basic structure described, it is possible to manufacture roller conveyors adapted to each type of function and classes of products, reaching a high degree of specialization. Thanks to all options for manufacturing, the roller conveyors can be used in many applications. Thus the rollers can be made of steel, aluminum, stainless steel, PVC, zinc plated and painted.
A first classification of roller conveyors is according to the load, they can be: light, medium or heavy load rollers. And the speed of movement of the load.
Also, if the movement of the roller is gravity or motorized. In certain sections of the roller conveyor circuits, the movement can be free turning by gravity, or also because they are at some point of classification or manipulation by workers. Most of the roller conveyors are usually motorized to move goods by traction. These can be manufactured for light, medium and heavy loads.
The manufacture of the outer part of the roller, the cylinder, allows one more step to adapt the roller to each type of product. The use of rubbers and different structures and shapes (for example, tapered rollers) ensure that the roller conveyor moves properly from packaged products (warehouses) to bulk products (for example in the food industry) in an optimal way.
The roller conveyors are also used for moving pallets, where there are also carriers of rotating rollers for pallets which allow redirection safely. For lighter loads we also have curved roller conveyors. In addition to the rollers themselves, the conveyors need accessory systems such as guides, safety systems and motion control systems.
Motorized roller conveyors are a type of material handling conveyor. An electric motor (often called an MDR motor) powers the rollers to move products quickly along the conveyor line.
Powered roller conveyors use 24-volt DC motorized rollers to control the movement of products. These MDR systems are ideal for heavy-duty applications and can handle loads up to lbs.
Live Roller 24v Conveyors use a series of powered rollers that are in line with each other. The rollers are powered by an electric motor which turns the rollers and moves the product down the line.
Motorized conveyors have control zones. Controller cards control these zones. The cards can be connected together via a plug-and-play interface. This interface is used to control the speed and direction of the conveyor.
The control zones are usually located at the beginning and end of the conveyor. The control zone at the front of the conveyor starts and stops the conveyor, taking advantage of run-on-demand technology. The control zone at the end of the conveyor is used to reverse the direction of the conveyor.
24V Motorized Roller Conveyors &#; MDR Overview
Motorized roller conveyors are a great choice for energy efficiency, low noise and easy maintenance. Use the abbreviation MDR (motorized driven roller) conveyors to refer to them.
MDR conveyors handle a multitude of products such as:
Packages
Tote Bins
Pallets
Tires
Cartons
Any product that will move on a roller conveyor
Planning MDR Conveyor Projects
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Firstly, powered roller conveyor using MDR rollers perform two functions:
Moving the product from location &#;A&#; to location &#;B&#;
Providing buffering or accumulation of product
The two different material handling functions are very important when used together. Buffering means that if the conveyor is full or product, it will stop. But if the conveyor is empty, it will move forward. Secondly, to make best use of MDR technology, the total conveyor length is divided into zones.
Importantly, size each zone according to the largest product you are moving. Add about 3 &#; 18&#; per zone for extra space. With at least one motorized roller per zone, MDR conveyor uses &#;zero pressure accumulation&#; (ZPA). In other words, ZPA basically means that the parts don&#;t crash into each other on the conveyor. Therefore loads continue moving along the MDR conveyor until they get close to (but do not touch) the product unit in front. Consequently there are no gaps in the assembly line. MDR conveyor systems have built in logic cards which automatically manage turning zones on and off. You can learn more about ZPA systems here.
Cutaway of Itoh Denki 24V DC motorized conveyor roller
You can buy straight sections of MDR conveyor from Ultimation in ready to run modules. In addition, curves and 90 degree pop-up transfer units move the product around corners and merges.
Similarly, a 90 degree pop-up transfer system can move packages from one lane to another. Parts move into the transfer on the MDR rollers. After that, a second motor raises the load about 1-2&#; up above the rollers on belts or chains. Finally, a third motor runs the belt or chains and the product moves off sideways.
Older style conveyor systems used chains to link the rollers. However, p
owered roller conveyors save space by eliminating traditional power transmission components.
For delivery applications multiple lines can be tiered up to take less vertical space. Above all, the quiet operation and space saving features make MDR conveyors very versatile.
Transportation and zero pressure accumulation are two typical applications of MDR. Therefore, w ith &#;Run only on Demand&#; feature, the rollers are off when no product is detected which results in saving energy.
Learn more about warehouse robots from Ultimation here.
Motorized roller conveyor systems and overhead conveyors are often used together with warehouse robots or Autonomous Mobile Robots. Warehouse robots can pick up and drop off loads from your existing conveyors and provide a flexible way to link all your conveyor styles together for maximum productivity and space utilization.from Ultimation here.
Depending upon the conveying application, different controls and accessories are available. Optional control cards make the MDR versatile for different accumulation activities. Load capacity can range from a few pounds to thousands of pounds per motorized zone.
15&#; &#; 60&#; between frame widths (i.e. the width of the conveyor)
Speeds ranging from 10 feet per minute (FPM) up to 200 FPM max speed. Please contact technical support for more information.
24 VDC brushless motor or 120/240 V AC motors
Roller spacing 3&#; up to 6&#; roller centers
Zero pressure accumulation with 18&#;, 24&#; or 30&#; or longer driven zones as part of a motorized roller conveyor
Variable speeds and reversible motion
Powder coat finishes and galvanized material available
No connection. In this setup, there are one or more motorized rollers. The other rollers are gravity (non-powered rollers). As an example, use this style where the conveyor is on a decline and you need low power transmission. Tire and wheel delivery conveyors use this system.
O-ring style belts. This is the most common system. For instance, the MDR rollers have two grooves. Connect these to adjacent gravity rollers (with grooves). The O-ring style belts are easy to install, and have a long life. They&#;re also very safe if personnel are nearby. Therefore, because MDR conveyors have small, distributed motors they are very safe. You can even stop them by hand!
Poly-V ribbed belts. Use these where you have heavier loads and need excellent power transmission. Poly-V belts are ribbed, and they connect to special caps on the end of the rollers. They achieve about 97% power transmission efficiency. As a consequence, Ultimation recommends placing the belts inside a finger guard to ensure safety.
Roller chain.
The heaviest duty MDR systems use sprockets on the rollers and chains between rollers. They&#;re just like CDLR (Chain driven live roller) conveyors. But there is no separate electric motor as the MDR motor provides the torque. We use MDR sprocket rollers for pallet conveyor and truck tire and wheel conveyors. Importantly, some of these loads are up to 250 pounds per zone. It&#;s common to use 2.5&#; diameter MDR motors with special internal gearing for these high loads.
MDR conveyors have some restrictions on environment applications:
Extreme Cold / Heat &#; Special models are available, but MDR motors are generally not suited for use in ovens
Corrosion resistance &#; Normal finish is galvanized. Stainless rollers and frames are available but very expensive
Food grade &#; Stainless available, but expensive. Dirt trapped in belts must be considered
Dirty conditions &#; special IP ratings with IP65 rated controllers available
Water resistance &#; available
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