Roller conveyors are a significant part of streamlining the efficiency and productivity of material handling operations. In this article, we&#;ll look at the three basic types of roller conveyors and explore their construction, function within various industries, common applications, and additional criteria for consideration.
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The roller conveyor uses a series of rollers in a frame to transport material from one point to another within a manufacturing setting. The driving force may either be gravity or electrically powered, and the entire system is designed to move large volumes of heavy goods with minimal effort. Compared to other types of conveyors, roller conveyors offer flexibility to handle assorted sizes and shapes of goods, scalability for use within different operations, and efficiency in energy consumption and space utilization.
The three basic types of roller conveyors have their own structural features.
The gravity roller conveyor has a simple, non-motorized design that comes in a horizontal plane or gently sloped decline.
The belt-driven live roller is essentially a gravity roller powered by a belt running in the opposite direction of the rollers, capable of stopping or stalling the product while the belt continues to move.
Finally, the chain-driven live roller conveyor uses motorized sprockets and loop-to-loop chains to move its rollers. All designs are formed from welded heavy-gauge steel, boasting a durable system that can withstand the harshest conditions, toughest environments, and most abrasive applications.
The function of roller conveyors is to reliably transport heavy-duty items in even the most rigorous conditions. Due to their versatility and robust design, they are optimal for moving boxes, cases, drums, and totes of varying weights within a single operation.
The operational mechanism of roller conveyors can vary depending on the specific type. The manual function requires goods to be pushed by hand, the gravity-fed option has the system set at a slight incline to move items, and the powered type includes motors to turn the rollers.
In the case of motorized conveyors, the choice of power supply depends on the specific requirements for the operation, including the weight of goods and the desired speed of movement.
As conveyor technology advances, more innovative methods are used to boost production. Roller conveyors&#; efficiency, safety, and adaptability are constantly improving, with automation and artificial intelligence (AI) functions especially being in high demand.
For example, current inventions emphasize smarter conveyor systems that predict maintenance needs, adapt to varying load requirements, and integrate seamlessly with other automated systems. Future trends are expected to push the boundaries further, with more sustainable materials and energy-efficient designs in the pipeline.
The most fundamental type of roller conveyor, this kind, is exactly as its name states&#;operating by gravity to move goods over free-spinning rollers. It is a simple, cost-effective option that is easy to install and perfectly relocatable. The only limitation is that gravity conveyors require a slight incline or manual adjustments for speed control. It is most economical for moving flat boxes, containers, and related products through packing areas and assembly lines on its own or in a connected system.
The belt-driven live roller conveyor (BDLR) is ideal for handling a wide variety of goods in different shapes and sizes. It has a quiet operation and is versatile for accumulating, diverting, merging, and transporting various shapes, sizes, and weights. The BDLR&#;s limitation is the type of goods it can move, based on avoiding wear and tear on the belt driving the rollers. Typically used in applications for warehousing, distribution, and order fulfillment, the standard BDLR model can be adjusted to fit the exact needs of any operation.
The chain-driven live roller conveyor (CDLR) is a motorized conveyor with chains driving the rollers, being particularly robust and reliable for heavy loads. Designed to move bulky products like machinery, filled drums, loaded pallets, and more, the CDLR moves products at a consistent rate of speed over a long distance. Its limitations are the noise factor and regular maintenance, yet its ability to handle the toughest jobs within a wide spectrum of industries makes up for any shortcomings.
Roller conveyors are versatile for every warehousing, manufacturing, and distribution application type. They excel in environments requiring streamlined processes and reduced handling times, such as assembly lines, packaging stations, and shipping areas.
More specific purposes apply to each of the three types of roller conveyors. For example, CDLRs are best suited for transporting totes and pallets being sideloaded, unloaded, and accumulated over a certain distance. At the same time, gravity conveyors are ideal for moving packages of different weights and sizes in conjunction with a system containing mechanically powered conveyors.
Selecting the right roller conveyor requires careful consideration of several key areas. First, the materials&#; weight, size, shape, and condition affect the type of conveyor best suited for the operations. Next, the environment&#;s temperature and humidity must be considered to guarantee that the right mechanism can withstand any harsh environment. Finally, the conveyor is designed and engineered according to key specifications like load capacity, roller diameter, material, and speed to ensure it is suited to the operational demands.
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When working with a conveyor designer and manufacturer, you have the option to add accessory features to provide you and your labor force peace of mind when moving goods. Each conveyor system can be tailored to fit your exact criteria to guarantee that any particular transport challenges you may face are effectively handled.
Choosing the conveyor for your operation is crucial for future industry success. Whether you require a simple gravity conveyor to supplement your existing system or a custom-built CDLR to replace an antiquated process, roller conveyors are an optimal blend of efficiency, adaptability, and cost-effectiveness to easily handle all your industrial needs.
As you seek an experienced team to help meet your unique material handling needs, consider Power Pack Conveyor Company as your trusted conveyor solutions partner. With our extensive knowledge and commitment to customer satisfaction, we invite you to contact us to further explore how our roller conveyors can transform your operations.
Our experts are on hand to provide insights and guide you through selecting the ideal automation system that meets your specific needs.
Stokman are experts in conveyor rollers, mainly for the transport of bulk goods. But what is a conveyor roller and how do conveyor rollers work? We are happy to share our knowledge and that&#;s why we explain the basics in this blog; the hows, whats and whys of conveyor rollers. After reading this blog, you will understand what a conveyor roller is, what it is used for and how a conveyor roller works. We also explain the differences between top rollers, bottom rollers and side rollers.
Let&#;s start at the beginning; what are conveyor rollers used for? Conveyor rollers are parts of a conveyor belt which is used to move products or loose bulk goods such as coal, sand or iron ore. The conveyor rollers are part of this installation and are essential to enable transport.
The conveyor belt is the carrier of the materials and passes around the pulleys and rollers as a loop. The conveyor pulleys drive the belt, tension it and guide it in the required direction. In our blog about conveyor pulleys, you can read more about the function and operation of conveyor pulleys. The conveyor rollers carry the conveyor belt from drum to drum. They serve purely to support the belt.
Conveyor rollers are therefore an essential part of the conveyor belt. How does a conveyor roller work? As described above, the conveyor roller is responsible for supporting the conveyor belt. Because the conveyor belt revolves around the pulleysas an endless loop, the conveyor belt has an outward section and a return section.
For a proper understanding of the operation and functionality of conveyor rollers, we first identify a number of components of a conveyor belt. This starts at the feed point, where the materials are poured onto the belt. The purpose of the conveyor belt is to transport this material to the discharge point, where the material leaves the belt again. The outward section of the conveyor belt moves with the material from the feed point to the discharge point and is called the upper or carry section. The bottom or return section moves back from the discharge point to the feed point without material.
As can be seen in the drawing below, the belt conveyor is a closed loop. The conveyor rollers support and guide the conveyor belt at various points.
In drawing 1, we see the different conveyor rollers; these rollers have different functions depending on their position in the system. In the upper section, at the feed point, we place buffer rollers; these mainly serve to protect the belt when material is poured onto it. Many materials, such as coal or iron ore, are heavy, coarse and angular. The buffer rollers are fitted with rubber support rings. These rings dampen the shock loads on the belt when material is poured onto it. In order to prevent the belt from sagging (deflecting) too much between the rollers, the rollers are positioned closer together at the feed point.
The top rollers are also called carry rollers. These are the rollers that carry the belt and the material. The carry rollers are not lined and are placed further apart than at the feed point. The space between the various carry rollers partly depends on the weight of the conveyor belt and the amount of load on it per metre in length. The maximum permissible distance between top rollers is 1,500 millimetres.
The rollers that guide the lower part of the belt back to the feed point are the bottom rollers. Bottom rollers can be manufactured with or without lining, with the choice depending partly on the material to be transported. If the belt is carrying sticky materials, the bottom rollers will, to a greater or lesser extent, wipe this material from the belt, resulting in unwanted soiling underneath the installation. The following criteria determine which type of lining can be used for a bottom roller:
We also want to prevent material falling off the belt during transport. To this end, the outer rollers, also known as the side rollers, are positioned at a certain angle, the trough angle. This is clearly shown in the drawings below.
We have been helping our customers put together the best possible conveyor belts for different goods, locations and sectors for decades. If you are interested in what we can offer or you have any questions about the operation and options of Stokman conveyor rollers after reading this blog, please contact us. Want to request a quote right away? Create your own conveyor roller in our configurator and we&#;ll send you a personal quote within 2 days.
If you want to learn more, please visit our website Joyroll Conveyor Machinery.