roller conveyor

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

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

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

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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).

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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roller conveyor

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