Roller Conveyors: Types, Applications, Benefits, and Design

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Introduction

This article provides a comprehensive overview of roller conveyors.

You'll learn about topics including:

• What is a Roller Conveyor?
• Construction of Roller Conveyors
• Types of Roller Conveyors
• Applications for Roller Conveyors
• Benefits of Roller Conveyors
• And Much More...

Chapter 1: What is a Roller Conveyor?

Roller conveyors are integral parts of material handling systems, utilizing an array of evenly spaced cylindrical rollers to transport boxes, supplies, materials, objects, and parts across open spaces or downward gradients. These conveyors are elevated to a convenient height, allowing for easy manual loading and access. Items transported must have flat, rigid surfaces for smooth movement across the rollers.

Applications for roller conveyors encompass accumulation tasks, product inertia reduction, and high-speed sorting. Roller conveyors powered by motors via chains, shafts, or belts offer consistent velocity, reversibility, and the ability to move goods from lower levels to higher levels. They are particularly beneficial for bi-directional tasks where the motor can alter the product's directional movement.

Chapter 2: Construction of Roller Conveyor

Roller conveyors' unique design features are tailored to specific application needs. While structural forms, movement modes, and other manufacturer-specific characteristics vary, fundamental attributes remain consistent.

Powered roller conveyors utilize small belts and plastic spools for roller traction. Friction belts or chains beneath the conveyor enhance the heavy-duty rollers and link to a length-spanning shaft driven by an electric motor.

Rollers

Conveyor rollers, made from metal cylinders with bearings on both ends, come in various types to match different product requirements. Rubber and plastic rollers increase friction, while steel and aluminum rollers offer smooth surfaces. Roller selection focuses on keeping products on the conveyor and maintaining product integrity.

Plastic Rollers

Plastic conveyor rollers, known for their economy, are designed for light loads. Easy to install and maintain, they meet OSHA noise standards. Their corrosion, rust, and moisture resistance extend their lifespan, making them perfect for food packaging transport.

Nylon Rollers

Nylon rollers handle medium to heavy loads, boasting durability and strength for constant use. These synthetic polymers resist abrasion, chemicals, and corrosion. Lightweight and low-noise, nylon rollers are easily installed.

Rubber Coated Rollers

Rubber coated rollers feature rubber layers over steel, stainless steel, or plastic cores for enhanced grip and roller/product protection. They excel in automotive, printing, packaging, and fabrication industries, resisting chemicals and providing anti-static, customizable, and durable performance.

Rubber coated rollers increase friction between rollers and materials, preventing slippage.

Steel and Stainless Steel Rollers

Steel and stainless steel rollers are preferred for their smooth, durable surfaces. Easy to clean and long-lasting, these rollers handle heavy materials and serve as cores for various roller types, owing to their strength and smoothness.

Stainless steel rollers, adaptable to various materials, allow for smaller diameters and precision bearings or fixed shafts for shipping needs.

Structure of a Roller Conveyor

Roller conveyor frames, made from steel, stainless steel, or aluminum, can be temporary or permanent. Temporary roller conveyors offer assembly and disassembly flexibility, while aluminum frames cater to lighter loads.

Support legs in various sizes, materials, and styles accommodate conveyor needs. Designs like tripod or "H" shapes cater to light, medium, and heavy-duty loads.

Roller Conveyor Motor

Modern roller conveyors use 24V DC motors for energy efficiency and safety, dividing zones where motor-driven rollers (MDR) control speed and direction.

Non Precision Bearings

Non-precision bearings, such as sleeve bearings and bushings, offer lower accuracy but suffice for smaller loads and lower speeds. They fit applications not requiring tight tolerances.

Angular Contact Ball Bearings

Angular contact ball bearings, designed for axial and radial loads, support conveyor line shafts for quiet and efficient operation.

They feature single-row, double-row, and four-point contact designs.

Pillow Block Bearing

Pillow block bearings, or plummer block bearings, support shafts, provide alignment flexibility, and handle axial and radial loads in conveyor systems.

Roller Conveyor Sprockets

Roller conveyor sprockets, gear-driven, provide roller motion. Available with varied tooth counts, power ratings, diameters, and bores, these sprockets use plastic hubs for light loads and steel hubs for heavier loads.

Roller Conveyor Curves

Curves in roller conveyor systems change material direction without altering orientation. Curve design considers angles (30-90 degrees), with special engineering for angles over 90 degrees.

Rollers in conveyor curves, conical or cylindrical, handle various items, incorporating side guides and structural adjustments for specific loads.

Chapter 3: Types of Roller Conveyors

Roller conveyors come in various forms—powered (motor-driven) and gravity types. Gravity roller conveyors, the simplest, move items manually across roller surfaces. Powered roller conveyors utilize different power systems.

Gravity Roller Conveyor

Gravity roller conveyors, cost-effective and versatile, transport light to medium loads using frames, rotating rollers, and support legs.

Typically steel, aluminum, or plastic, gravity conveyors can have curves, supports, sensors, and pop-up stops for enhanced efficiency during loading/unloading.

Belt Driven Live Roller Conveyor (BDLR)

BDLR conveyors use motorized belts for roller movement, allowing efficient load control for activities like halting, turning, side loading, and reversing. Suitable for clean, dry, medium to heavy loads, some BDLR rollers support wider goods by sitting higher than the frame.

Some BDLR versions feature perpendicular shafts driving belts to move rollers collectively

Chain Driven Roller Conveyor

Chain driven roller conveyors employ chain drives connected to individual rollers for medium to heavy-duty tasks in palletizing, filling, load staging, and strapping.

These conveyors offer high power transfer, durability, and reversible movement for bi-directional material handling.

Applications include palletizing, filling, load staging, and strapping—optimal in harsh/hazardous conditions.

Line Shaft Roller Conveyor

Line shaft roller conveyors feature rotating shafts driving rollers via spools and belts, offering smooth, quiet operations without chains/sprockets.

Motorized shafts, controlled by programmable logic controllers (PLCs), power extensive straight and curved parts of the system, enhancing efficiency for medium to light-duty loads.

However, line shafts may struggle in wet, oily, or harsh conditions, requiring consistent roller contact.

Zero Pressure Roller Conveyor

Zero pressure roller conveyors, driven by 24V DC motors and photoelectric sensors, prevent product accumulation pressure, ensuring smoother transfers.

These conveyors use powered rollers, controllers, and slave rollers for precise product movement, applicable in automation for timed, consistent processes.

Zero pressure systems improve upon uncontrolled traditional conveyors for safer, more efficient material handling.

Motor Driven Live Roller (MDR)

MDR conveyors, with built-in 24V DC motors, divide into accumulator zones for effective movement control without PLCs or complex pneumatics.

Zone controllers and photoelectric sensors manage small, easily replaced transportation rollers, facilitating various load movements, including incline/decline transitions.

Merge Roller Conveyors

Merge roller conveyors streamline product flows from multiple lines into a single stream, using fixed or powered roller configurations for optimized warehouse operations and labor efficiency.

These systems minimize manual handling, simplify repositioning, and combine upstream/downstream processes.

Chapter 4: Applications for Roller Conveyors

Since their inception in 1908, roller conveyors have become indispensable in product movement, assembly, and supply chains. Their adaptable design suits diverse loads and applications, continuously evolving to meet new demands.

Uses include:

• Efficient coverage of large areas with minimal labor
• Transporting heavy, cumbersome goods/materials
• Saving labor costs and completing other tasks during product movement
• Preventing injuries from lifting and falling objects
• Ensuring safe transportation without damage
• Supporting robotic functions and operations

Custom Designs

Customized roller conveyors cater to specific application needs, designed to fit the operation location. They include modular units, straight/curved segments, transitions, mergers, power types, and separators.

Designing custom roller conveyors involves determining whether the system will be standalone or integrated with other assets, powered by chain, belt, or roller mechanisms.

Airport Roller Conveyors

Airports extensively use roller conveyors, including gravity and powered types for baggage check-in, handling, and loading.

Assembly Roller Conveyors

Assembly lines employ overhead, belt, and roller conveyors, with roller systems preferred for reliability, durability, and quieter operation.

Supply Chain Roller Conveyors

Roller conveyors, offering quick, efficient product movement, are a cost-effective alternative to forklifts in supply chain management, reducing worker workloads.

Packaging Roller Conveyors

Packaging industries use roller conveyors for package movement, stacking, and sorting, with gravity or driven types employed as needed.

Food and Beverage Roller Conveyors

Meeting stringent industry standards, roller conveyors in food and beverage industries require specific cleanliness levels and regulatory compliance.

Metal Working Roller Conveyors

Heavy-duty and versatile, metal working roller conveyors excel in scrap separation and identification, highlighting their robustness.

These industries exemplify roller conveyors' essential role across various sectors, from automotive to robotics, enhancing product movement efficiency.

Chapter 5: Benefits of Roller Conveyors

Roller conveyors' versatility and adaptability contribute to their sustained popularity across different applications. Temporary versions permit mobility, while permanent iterations offer durability.

• Speed: Safely and quickly transports goods, reducing handling risks.
• Reliability: Long-lasting solutions ensure consistent productivity.
• Cost Effectiveness: Durability and longevity balance initial investments.
• Efficiency: Fast-moving systems optimize material handling.
• Maintenance: Simple design minimizes downtime for repairs.
• Safety: Reduced manual lifting lowers injury risks; mechanical aids handle heavy loads.
• Customizable: Flexible structures fit diverse spaces and needs.

Chapter 6: Regulations Regarding Roller Conveyors

Safety Requirements of Conveyors

OSHA and ANSI establish guidelines for conveyor safety and design, with updates reflecting technological advances:

OSHA Guidelines

• 1926.555(a): General requirements.
• 1926.555(a)(1): Operator position requires a motor stop switch and pilot light with sound activation.
• 1926.555(a)(2): Remote operations should feature stop switches at motors.
• 1926.555(a)(3): Emergency stop buttons prevent reactivation until reset to "ON."
• 1926.555(a)(5): Overhead conveyors need protective coverings, barring distant placements.
• 1926.555(a)(6) & 1926.555(a)(7): Warning signs required for aisles, crossovers, and passageways.
• 1926.555(a)(8): ANSI B20 compliance for conveyor construction and maintenance.

ASME Guidelines

Conveyor safety outlined in:

• ASME B11.0-2020: Machine safety, including required safety devices for construction and installation.
• ASME B20.1-2018: Design, construction, maintenance, and operation guidelines for industrial conveyors, integrated with ASME B20.1, ANSI B11.19, ANSI A1264.1, ANSI 244.1 safety standards.
• ASME B20.1, ANSI B11.19, ANSI B11.0: Detailed safety processes for temporary, permanent, and portable conveyor systems.

Chapter 7: Roller Conveyor Maintenance

Regular maintenance ensures effective performance for interacting components of roller conveyors. Scheduling examinations for drive chains, sealed roller bearings, rollers, shafts, belts, and DC motors is essential.

Conveyor Maintenance Steps

Lubricate drive chains and sealed roller bearings. Train operators for proper inspection procedures. Clean driver rollers to prevent blockages and address minor issues to avoid major problems.

Preventative Conveyor Maintenance

Regularly check bearings to prevent wear-related failures. Examine rollers for smooth and flexible movement, belt or chain wear, and level alignment. Address wobbling or non-movement issues promptly.

Harsh conditions like high temperatures and humidity necessitate frequent checks. Allow downtimes for system cooling to maintain performance.

Chapter 8: Considerations When Choosing Roller Conveyors

Integrating a conveyor system streamlines operations, but careful consideration of various factors ensures customization to application needs.

Available Space

Identify interaction sites, clearances, and impediments to design an efficient conveyor system. Manual or motorized systems depend on usage patterns.

Roller Frame Material

Frame materials (aluminum/steel) depend on loading. Roller materials vary—plastic, rubber, aluminum, or steel—for friction and movement. Proper roller selection retains product integrity.

Roller Size and Orientation

Determine load size and conveyor layout. Individual roller sizes depend on load conditions—large for heavy, high-impact loads; smaller for slow, low-impact loads.

Optimize roller spacing to maintain multiple contact points with the load surface. High set rollers support wide loads; low set rollers contain products within the frame.

Load Capacity

Establish material quantity limit to prevent overloads and malfunctions. Consider overall length, bed breadth, and drive system impacts. Gravity conveyors suit light to medium-weight, flat-bottomed goods.

System Speed

Measure system speed in feet per minute (fpm). Customize speed to suit application requirements.

Roller Conveying System Configuration

Available in various shapes, sizes, and styles—straight, angled, curved, pockets, slats, z-frames. Designs like line shaft conveyors conserve energy for long distances.

Install with careful consideration of related factors for efficiency.

Drive System

Drive systems move materials with counter bearings for controlled flow, supporting bi-directional and middle/beginning/end placements.

Types include single or variable speed models, driven by 24V DC motors attached to gears, rollers, or shafts for adjustable flow rates.

Behavior, Control, and Environment

Product mobility, control, and conveyor placement influence design. Various conditions (heat, dust, moisture) may necessitate durable designs (shaft/chain driven models).

Zero pressure models with precision timing handle back pressure conditions. Gravity models, though simple, can deteriorate under adverse conditions.

Conveying System Safety

OSHA-regulated conveyor systems meet federal safety standards, ensuring safe transport without heavy lifting for personnel.

Disadvantages of Roller Conveyors

Despite maintenance requirements, roller conveyors may face drawbacks:

• Damage to Goods: Gravity conveyors lack movement control, risking product damage.
• Weight: Roller conveyors get significantly heavier with length.
• Conveyor Speed: Non-powered conveyors lack speed control.
• Cleaning: Multiple rollers complicate cleaning, requiring dedicated janitorial efforts.