Types of roller conveyors and how to choose effectively
02-04-2022 907
A roller conveyor is a type of conveyor that uses rollers, the rotating posts are spaced apart to allow an object to slide over its surface.
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Conveyor belts are material handling systems that enable the easy transport of products, from powders to bulks to complex geometries. They are indispensable in all types of systems, as they provide a fast and safe method for handling large volumes of material. There are many types of conveyor belts, but their principle of operation remains the same in each type; move an object by gravity or mechanical energy from one point to another using belt holders, rollers, or other moving parts.
The roller conveyor is the focus of this article and is one of the most commonly used conveyors. Types, designs and uses of roller conveyors will be explored, as well as how to specify one of these systems for any application.
A roller conveyor is a type of conveyor that uses rollers, the rotating posts of which are spaced apart to allow an object to slide across its surface. They move matter from one place to another, and often take advantage of gravity or implement small engines to do so. The material being transported must have a sturdy surface supported by a minimum of three of the rollers.
Since the design of these conveyors is so simple, many advancements have been made to allow roller conveyors to keep up with industry trends. The biggest innovation is the drive roller or live roller conveyor, where each roller is connected to the motor via belt, chain, shaft for increased controllability. This equalizes the speed with which the material moves down the path and also allows these conveyors to have reverse usage limits, i.e. from low to high heights. They can work well in two-way applications, as the rollers can direct the material in either direction by changing the direction of the motor.
This section details the important types of roller conveyors currently in the industry. We are highlighting the main designations here, but know that more types exist and that there is a lot of overlap between these different types. Additionally, these roller conveyors can be a combination of multiple designs, depending on the manufacturer.
The simplest on this list, a gravity roller conveyor is a frame that contains rollers that rotate freely and use gravity to slide material down the line. They are used to transport light to medium weight products that do not require a motor, which is an economical solution for designers.
Gravity roller conveyors can be made from steel, aluminum and plastic. They are often implemented as temporary conveyors, alternatives to roller skates, heavy duty applications and cumulative loads that do not require any specialized timing.
Conveyor rollers use a belt to increase the motor power of each roller, to control the movement of the materials being transported. Some belt-driven roller conveyors can support products wider than the frame width, thanks to the rollers being higher than the frame. In any arrangement, the rubber belt underneath the rollers should not be exposed to moisture, extreme heat or debris as these conditions can rapidly degrade the system. These conveyors are typically used to handle medium to heavy loads that are dry and clean.
Like a belt driven conveyor, but instead of using a belt, it implements a chain to power each roller. They are used when the transport of heavy loads is required and when adverse conditions preclude the use of typical belt-driven conveyors.
They are best suited for reversible operations and extreme loads, because of the high power transfer capacity in these designs. This is different from a single chain driven roller conveyor, where the rollers are driven by a single loopless continuous chain through the sprockets on the rollers.
Regardless of the type of roller conveyor chosen, there are some general specifications that must be determined before purchasing the right model for the job. Here are some typical conveyor specifications you will encounter when sourcing the right conveying system.
The first required specification will be the material used to build the frame and the rollers. The frame is usually aluminum or steel, but this depends on how much load will be carried on the system and the value of the rated frame capacity.
Rollers have a much more diverse composition, as they come into direct contact with your product and can impact its behavior as it moves. Some rollers are coated with plastic or rubber to increase friction, while others are simply aluminum or steel. Choose a roller to keep your product on the line and it won't negatively affect the integrity of your product. Likewise, choose a frame that can support the weight of the material being transported as well as the weight of the rollers.
Determine the mass of the material on the conveyor, then determine the optimal arrangement of the conveyor so that it does not degrade or impede the movement of the object. This first means determining the dimensions of the individual rollers, this is done by considering the load and the loading conditions. For example, heavier and high impact loads require larger rollers, while slow, low impact loads will benefit from smaller rollers.
Next, calculate the distance of each roller by finding the length of the load in contact with the conveyor surface and determining the distance so that the three rollers are always in contact with this surface. Finally, find out if the product is protruding from the conveyor belt; if so, purchase a roller conveyor that is set high so it can overhang.
The type of load and the accumulation depend on the product being held. How much does the product weigh? Is it fragile, or could it come in contact with other items on the line? The answer will be more detailed about the type of roller conveyor used. Gravity roller conveyors are optimal for flat bottomed, low to medium weight objects such as boxes, but they should not be used with overly delicate and unwieldy geometries such as electronics and production parts.
Determining the span and curvature of the conveyor will also help narrow down your search. For example, flat belt roller conveyors cannot be used if there is a curve, so you should not buy this design if you need a curve. Similarly, if you have hundreds of feet to cross, consider a more efficient design such as a road roller conveyor to save energy if possible.
Finally, consider the desired material movement, the degree of control that should be allowed, and the environment in which the conveyor will operate. If extreme heat, dirt and moisture are present, choose a sturdier design such as a chain roller conveyor. If precise timing and zero pressure are needed, investigate the high-tech roller conveyor options that will give you the precision you need. If you just need a quick, low-tech way to get an object from point A to point B, you may need to look no further than traditional gravity or roller conveyors.
This article presents an understanding of roller conveyors, their different types, and their main uses. For more information on related products, please refer to our other guides at www.intechvietnam.com
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The roller conveyor is the focus of this article and is one of the most commonly used conveyors. Types, designs and uses of roller conveyors will be explored, as well as how to specify one of these systems for any application.
What is a roller conveyor?
A roller conveyor is a type of conveyor that uses rollers, the rotating posts of which are spaced apart to allow an object to slide across its surface. They move matter from one place to another, and often take advantage of gravity or implement small engines to do so. The material being transported must have a sturdy surface supported by a minimum of three of the rollers.
Since the design of these conveyors is so simple, many advancements have been made to allow roller conveyors to keep up with industry trends. The biggest innovation is the drive roller or live roller conveyor, where each roller is connected to the motor via belt, chain, shaft for increased controllability. This equalizes the speed with which the material moves down the path and also allows these conveyors to have reverse usage limits, i.e. from low to high heights. They can work well in two-way applications, as the rollers can direct the material in either direction by changing the direction of the motor.

Commonly used roller conveyors
This section details the important types of roller conveyors currently in the industry. We are highlighting the main designations here, but know that more types exist and that there is a lot of overlap between these different types. Additionally, these roller conveyors can be a combination of multiple designs, depending on the manufacturer.
1 - Gravity Roller Conveyor
The simplest on this list, a gravity roller conveyor is a frame that contains rollers that rotate freely and use gravity to slide material down the line. They are used to transport light to medium weight products that do not require a motor, which is an economical solution for designers.
Gravity roller conveyors can be made from steel, aluminum and plastic. They are often implemented as temporary conveyors, alternatives to roller skates, heavy duty applications and cumulative loads that do not require any specialized timing.
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2 - Belt driven roller conveyor
Conveyor rollers use a belt to increase the motor power of each roller, to control the movement of the materials being transported. Some belt-driven roller conveyors can support products wider than the frame width, thanks to the rollers being higher than the frame. In any arrangement, the rubber belt underneath the rollers should not be exposed to moisture, extreme heat or debris as these conditions can rapidly degrade the system. These conveyors are typically used to handle medium to heavy loads that are dry and clean.
3 - Chain driven roller conveyor
Like a belt driven conveyor, but instead of using a belt, it implements a chain to power each roller. They are used when the transport of heavy loads is required and when adverse conditions preclude the use of typical belt-driven conveyors.
They are best suited for reversible operations and extreme loads, because of the high power transfer capacity in these designs. This is different from a single chain driven roller conveyor, where the rollers are driven by a single loopless continuous chain through the sprockets on the rollers.

How to choose the right roller conveyor
Regardless of the type of roller conveyor chosen, there are some general specifications that must be determined before purchasing the right model for the job. Here are some typical conveyor specifications you will encounter when sourcing the right conveying system.
- Rollers and frame materials
The first required specification will be the material used to build the frame and the rollers. The frame is usually aluminum or steel, but this depends on how much load will be carried on the system and the value of the rated frame capacity.
Rollers have a much more diverse composition, as they come into direct contact with your product and can impact its behavior as it moves. Some rollers are coated with plastic or rubber to increase friction, while others are simply aluminum or steel. Choose a roller to keep your product on the line and it won't negatively affect the integrity of your product. Likewise, choose a frame that can support the weight of the material being transported as well as the weight of the rollers.
- Roller size and direction
Determine the mass of the material on the conveyor, then determine the optimal arrangement of the conveyor so that it does not degrade or impede the movement of the object. This first means determining the dimensions of the individual rollers, this is done by considering the load and the loading conditions. For example, heavier and high impact loads require larger rollers, while slow, low impact loads will benefit from smaller rollers.
Next, calculate the distance of each roller by finding the length of the load in contact with the conveyor surface and determining the distance so that the three rollers are always in contact with this surface. Finally, find out if the product is protruding from the conveyor belt; if so, purchase a roller conveyor that is set high so it can overhang.
- Loading and Accumulating Type
The type of load and the accumulation depend on the product being held. How much does the product weigh? Is it fragile, or could it come in contact with other items on the line? The answer will be more detailed about the type of roller conveyor used. Gravity roller conveyors are optimal for flat bottomed, low to medium weight objects such as boxes, but they should not be used with overly delicate and unwieldy geometries such as electronics and production parts.
- Distance and curvature
Determining the span and curvature of the conveyor will also help narrow down your search. For example, flat belt roller conveyors cannot be used if there is a curve, so you should not buy this design if you need a curve. Similarly, if you have hundreds of feet to cross, consider a more efficient design such as a road roller conveyor to save energy if possible.
- Behavior, control and environment
Finally, consider the desired material movement, the degree of control that should be allowed, and the environment in which the conveyor will operate. If extreme heat, dirt and moisture are present, choose a sturdier design such as a chain roller conveyor. If precise timing and zero pressure are needed, investigate the high-tech roller conveyor options that will give you the precision you need. If you just need a quick, low-tech way to get an object from point A to point B, you may need to look no further than traditional gravity or roller conveyors.
Summary
This article presents an understanding of roller conveyors, their different types, and their main uses. For more information on related products, please refer to our other guides at www.intechvietnam.com
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