roller conveyor
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Application Notes: Roller Conveyor
Rollers
Drive motor
Drivechain
Control
Guiding strand
Stopper
Detection, identification
Flat angle iron feet for attaching to floor
To move isolated loads of sufficient size with minimum friction butwith very small changes of level. Optimized flow for gain in timeand/or personnel.
Production, assembly, erection, packing and conditioning lines,work-station supply, transport, handling, distribution, storage, intermediate storage, accumulation storage, sorting, order preparation, picking, shipping, heating and cooling of elements.
A roller conveyor is used for routing isolated loads (pallets, containers, boxes, cartons, others). The rollers are driven by flat orcylindrical belts or by chains. The machine can accommodateswitches.
Rail and air freight in-feed, automatic postal package sorting, hospital logistics, transport and storage of documents and files,transfer of television sets on assembly line, routing of orders toshipping point, sorting of cartons by customer and round, weighingand labeling station, dynamic carton stock, manual work-station,food product packaging line (deep-frozen foods) and storage ofbooks, handling of bags and containers, reception of pallets(docks), deep freezing by blowing red berries and peas, automobilebody conveying, preparation of orders for mail order sales.
Pallet conveyor, pressureless accumulation conveyor.
Roller conveyor, roller table, heavy conveyor, light conveyor.
Machine purpose
Theory of operation
Several examples of use
© 2003 Schneider Electric All rights reserved.Doc. # 0105DB0301
HANDLING MACHINES
Names used
Names of machines related to application
Page 2
Table position, D1
Shipping ofspecific products Passage of load, D1
Jamming, D3
Chain transfer
Package returndefective labeling
Incoming productsfrom all production sources
Lack of product, D4
Identificationof the load, D6
Positioning ofload forstoppage, D5
Loadcounting, D2
Automaticpalletizing
Main types
Other typical machines or family
Conveyor with plastic, steel or aluminum rollers, free or motorizedroller conveyor, telescopic roller conveyor, roller conveyor for heavyloads, roller conveyor, 2-chain roller conveyor, fixed and flexiblecurves, taper roller curve, inclined roller conveyor.
Conveyor belt, belt conveyor, belt curve, chain conveyor (parallel orsupporting), telescopic roller or belt conveyor, flexible conveyor,turntable, turn-over, elevator, chain transfer, belt transfer.
Generally roller conveyors are located indoors. However, for agro-foodapplications, it can operate at negative temperatures (-40°C) with high relative humidity or harsh environments (dust, corrosive agents).Washing with a jet (or a high pressure jet) with or without detergentsis a practice that imposes a specific choice of material. Some applications call for electrostatic discharging of the conveyed parts.For a system, the electrical cabinet is generally isolated. For an “isolated” machine, the electric equipment must be designed to allowfor the environment and if necessary for explosive atmosphere.
Guides, guide strand, guide disk, link attachment, stop or buffer, stop-per, pneumatic stop, retracting lock, brake roller for mobile conveyor,flat angle foot for floor attachment, conveyor-turntable link, stepperfeed, roller or motor, disengagable, self-driven rollers, brake roller,brake plate, switch, automatic linear switch, automatic angle switch,parallel single output grouper, pusher, selection pusher, centeringpusher, pushing shoe, pop-up, turn-over finger, bin orientation device(pivot), automatic empty bin stacker, gate, weight control unit (static ordynamic), gauge tester, load identification (bar or magnetic code), testbench, electro-zinc finish or stainless steel for agro-food, anti-staticbelt, blower, fan, air conditioner, flow control software, PC, printer.
Conveyors of all types, chain or belt transfer at 45° or 90°, transfertruck, turntable, turntable with transfer, shuttle, turn-over, vertical, multiple level elevator, continuous vertical elevator, elevator table, scissors elevator table, elevator platform, transfer elevator, distributioncart (with or without friction wheel drive mechanism), wire guided cart,magazine, empty pallet magazine, transtorage, rotary storage.
Assembly, sorting, weighing, grading, counting, identification, packing, conditioning, palletizing, deep-freezing, treatment, painting, baking.
Associated systems
Upstream and downstream machines
Situation in environment
Process controland display station (if necessary).
E
Process cabinet
Turn-table
Belt Transfer
ERollerconveyor
Distributionbox or cabinet
D
Machine located within a process
HANDLING MACHINES
Related professions
Page 3
Distribution
D Mobile electric distribution of roller conveyorD General distributionD Mechanical protection of distribution
Equipment
E Mechanical protection of equipment and controlE Attaching electrical equipmentE Routing cablesE Distributing powerE Connecting cablesE Control power supply
Power control
E Roller conveyor energizingE Movement supply and safety cut-offE/M1 Starting motor(s) (if possible on load)E/M1 Changing motor running directionE/M1 Changing motor speedE Energizing variable speed controller powerE Brake release controlE/M1 Positioning the load
Protection
E Protecting motor(s) against short-circuitsE Protecting motor(s) against overloadsE Protecting the brake(s)E Protecting control power supply transformerE Lighting circuit, 220 V outlet and control circuitE Protecting and monitoring network and motor
Detection
D1 Top and bottom table positionD2 Passage of load (presence, absence)D2 Load countingD3 Jamming on conveyorD2 Product run-outD2 Positioning of load for stoppageD2 Load identification (automatic sorting)E Opening of electric equipment access door
Signalling (dialogue)
E Voltage presence on roller conveyorE Energizing roller conveyorE Roller conveyor in motionE Displaying coded messages, conveyor statusE Displaying plain messages: maintenance, productionE Displaying process, exchanges underwayE Resetting roller conveyorE Process supervision
Control (dialog)
E Starting and stopping roller conveyorE Emergency stopE Selecting automatic or manual modesE Manual rotation control (maintenance)E Selecting desired speed directionE Resetting roller conveyor after faultE Sending variable speed controller setpoint
Processing
E Start order sequenceE Time delaysE Power adaptationE Switching variable speed controller setpointsE Positioning of loadE Flow and stock managementE “Isolated” machineE Machine integrated into a processE Monitoring of emergency stop buttons
*refer to general catalog for complete details.
KN, KS xC60, NS, Masterpact, GS1, FA, KA, LA 1AA, AM, ACM 1
AA, AM, ACM, ACP, LG., XAP, DE8-B 1AM3, AM1, DZ6, LG. xAK2-G, AK2-L, LG. xAB3, AK5 xAB1, DB6, DZ5, ABS, ABE, LG., 9080G x9070T/TF 1
LS1D, GS1, Vario, NS, Compact, LG., FA, KA 1LC1, LP1, LU 1LC1, LC3, LD1, ATV6, LG., LU, ATV28/11 1LC2, LG8, LU, ATV28/11 1LC1, ATV6, LU xLC1, LU 1LC1, LU 1MSP, AV28/11 1
LS1D, GS1, GV2M-L, GV., LB1L, NS, LG., LU 1LRD, LT3, GV2M-P, GV7, LB1L, LG., ATV28/11 1GV2, LU 1DF6, GB2RT, GB2CB, C60, GV. 1DF6, GB2CB, C60, Vigi C60, GV2 3RH328AP, SM21, EM9T x
xXC, XS, XU depending on load type, XCW xXC, XS, XU depending on load type, XCW xXC, XS, XU depending on load type, XCW xXC, XU depending on load type, XCW xXC, XU depending on load type, XCW xXGV, XC, XS, XU, XGS, XCW xXC 1
XB4B 1XB4B 1XVB, audible signalling unit 1XBLA, XB4B xXBT 1TSX, XBT-N/G 1XB4B 1XBT 1
XB4BXB2B, XA2B, Vario, XY2C, XB4B, XALD 1XB4B 1XAD, XBT, XB4B, 9001K xXAD, XBT, XB4BXB4B 1SZ1RV, XBT, XB4B 1
CAD, LA1, RU, RX, RH, micro TSX xRE4, RE5, LAD, Twido, micro TSX 1RU, RX, RH xLA1, RU, RX, RH, Twido, microTSX xTSX7, micro TSX 1TSX7, micro TSX, XBT-N/G xmicro TSX, Momentum xmicro TSX, XBT-N/G xXPS-A 1
Electrical equipment associated with conveyor
Item Functions Solutions* Q.
1, 2
2, 1
HANDLING MACHINES
Page 4
CE marking
Low voltage directive73/23/CEE of 19/2/73, amended by directive93/68/CEE of 22/7/93.
SafetyThis machine is covered by machine directive No 89/392/CEE, amended.
Generally, this is one of the elements in anautomated installation for which safety isincorporated.
When this machine is accessible to the personnel, it is necessary to install emergency stop devices every 30 feet or trip wire emergency stop switches monitored by a Preventa module.
EMC (electromagnetic compatibility)89/336/CEE + amendments. When a variable speed controller is used, the radioperturbations must be attenuated by VW3Ainput filters, if necessary with VW3A linecoils or SinWave active compensators (MG)to reduce harmonic current.
Schneider servicesconsulting, training, research assistance,checks and measurements on site. It isadvisable to use interference supressors forcontactors (LA4).
Criteria for choice of machine user
The weight of the loads (influencing the choice of material and thediameter of the rollers): ultra light, <4 lbs. ; light, <110 lbs.;medium, <220 lbs.; heavy up to 2 T.
Size and shape of loads.
Speed of movement of loads : 3.2 feet/min to 393 feet/min
The length of the conveyor: up to several miles; generally in lengthsof 20 to 32 feet.
Conveyor width 4 inch to 6.5 feet.
Conveyor height.
Topology, logistics and transit conditions.
Environment/Applications : steel grades (stainless), route, accumulation, load identification, etc.
Cost of roller conveyor
A roller conveyor for light loads (<220 lbs.), 20 feet long, costs$46K before tax. A system can cost between $500K and $30 million.A roller conveyor is cheaper than a belt conveyor (belt guidance).The mechanism is simpler and the drive power is reduced compared to a conveyor belt of the same capacity.
The belt conveyor becomes essential as soon as elevation isnecessary.
Several application references in Europe
Germany: Mannesmann Demag
Austria :
Belgium :
Denmark:
Spain :
Finland :
France : Savoye, Samovie, Sydel, Atecmi, Matflex, NTS ,Manumeca,
Greece :
Italy: Conveyors, Peem, Papa, Montini
Norway:
Netherlands: Caljan
Portugal:
Sweden:
Switzerland:
UK : Shuttle worth
Critical points to be solved by manufacturer/know-how
Mechanical
Guidance of loads, loss of adhesion of loads during acceleration, noise, transportation offragile products, transportation of atypical shaped products.
Electric
Detection of jamming and anomalies, detection in difficult environments (cold: mist), identificationof products, synchronization with otherconveyors, positioning of loads, speedof logic control components in automatic sorting application (load follow-up).
HANDLING MACHINES
Motor dimensioning90% of light roller conveyors (<5 lb.) use arange of motors with power from 1/3 hp to3/4 hp. Conveyor belts for the same loadsrequire power ranging from 1 hp to 4 hp(high speed table).
Page 5
M1
M2
M3
D2
M2M2
D1
M3M2
D3M2
M2
Roller ConveyorMotor Starter
Detectionmain functions (...) optional product that
may be critical!
Mark Qty Motor starter function Recommended product Remarks
1 Forward/backward movement of the Type ATV28/11 starter with two The changing from low to highM1 chain conveyor on load: ATV28 running directions, low and high speed with acceleration and
• avoiding mechanical shocks, speed with acceleration, and delay or detection of the table• stopping at foreseen position. deceleration ramp times. position.
ATV11 P<1.5kW / 2 hp. @ 460 / 575 VAC
@ 115 / 230 VAC
>1 Forward/backward movement Type ATV28/11 starter with two The changing from low to highM2 of the pallet on the conveyor elements. ATV28 running directions, low and high speed can be realized by a time
--------- speed with acceleration and delay or detection of the tabledeceleration ramp times. position.
ATV11 P<1.5kW / 2 hp. @ 460 / 575 VACThe reverse motion is used @ 115 / 230 VACduring maintenance operations.
2 Lifting/lowering of chain transfer LC2 P<1.5kW / 2 hp. Standard motor switching withM3 overload protection
LU U-Line control Provide solid state overloadprotection and communicationscapability.
Mark Qty Detection needs Recommended product Remarks
2 Detecting the top and bottom position XS • Type XS1 inductive proximity Alternative: cylinder mountedD1 per of the table to authorize: or sensor, diameter 12 mm, sensors XS7-V12 on PADE
element • the arrival or the exit of the pallet, XC • XCK angular position switch cylinders.• the backward or forward movement of with roller lever.
the pallet on the arrival and exit conveyor.
>1 Detecting the pallet position on the XU Type XUL photo-electric sensor • For more precise sensing aD2 per arrival and exit conveyor. with background suppression. thru-beam system should be
element used,• For brilliant materials a sensor
with background suppressionor a polarized reflex sensorshould be used.
2 Detecting the passage and presence XU Type XUL photo-electric sensor Generally the sensors areD3 per of the pallet on the table. with background suppression. mounted between the rollers
element and detect towards the top.!
HANDLING MACHINES
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M2
D3
M1
D1D2
M2
D4
M1
M2
V
V2
Roller ConveyorMotor Starter
Detectionmain functions (...) optional product that
may be critical!
Mark Qty Motor starter function Recommended product Remarks
1 Forward movement of products on the LC1 Starter with one running See M3M1 per product separation element. direction, P < 0.75 kW / 1 hp.
element LU
1 Forward/backward movement Type ATV28/11 starter with two The conveyor rotation speedM2 per of products on the conveyor elements. ATV-28 running directions with variable can depend on the jamming
element speed, P < 3 kW / 4 hp. detection and only initiate theThe reverse motion is used stopping of the conveyor after
ATV-11 during maintenance operations. the time delay is elapsed.@ 460 / 575 VAC
@ 115 / 230 VAC
Mark Qty Detection needs Recommended product Remarks
2 Detecting the top and bottom position XS • Type XS1 inductive proximity Alternative: cylinder mountedD1 per of the table to authorize: or sensor, diameter 12 mm. sensors XS7-V12 on PADE
stopper • the arrival or the exit of products. XC • XCM angular position switch cylinders.with roller lever.
>1 Detecting the product position on the XU Type XUL photo-electric sensor Generally the sensors areD2 per arrival and exit conveyor. with reflex system. mounted between the rollers
stopper and detect towards the top.
1 Detecting a product jamming after the XU Type XU photo-electric sensor • For a more precise sensing a D3 per switching. with standard or delayed reflex thru-beam system should be
element system. used.• For brilliant materials a sensor
with background suppressionor a polarised reflex sensorshould be used.
1 Detecting a product jamming before XU Type XU photo-electric sensorD4 per the switching. with background suppression.
element!
HANDLING MACHINES
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