Jun. 05, 2024
Roller Conveyors Our gravity roller conveyors can transport light, medium, and heavy duty loads that gave firm flat bottoms such as cartons, totes, cases, skids, drums, etc. Ashland's line of roller conveyors includes models with the roller from 1-3/8" to 2-5/8" diameter and various frame styles. Our roller conveyor sections come in 5' and 10' lengths as well as 45 and 90 degree curves. Some models can be installed permanently or used for temporary set-ups. Although we cannot meet every roller and frame combinations, take a look through this guide to learn how to choose the right roller conveyor for your application.
Roller Conveyor Model Summary We have many combinations of frames and rollers that are described by their short description. Refer to the model below to see how we abbreviate our roller conveyors.
Choosing Your Conveyor The best place to start when choosing a roller conveyor is to determine the weight and dimensions of the product you wish to convey. This will narrow down the roller, frame, width, and roller centers that you will need for your conveyor. Once you determine the conveyor model needed for your application, you can filter through our roller conveyor section here.
Frame Capacity, Style, and Couplings We have different frame styles that can provide different options for your application. Ultimately the frame style will be determined by the capacity requirements of your application. Options include material, frame height, shaft holes, roller position, construction, and capacity. The frame must be capable of supporting both the conveyed items in addition to the frame and rollers. Each roller conveyor will have the capacities listed in the construction. These capacities are based on 10' support centers and 5' support centers. Having supports located every 5' will increase the frame capacity, whereas having supports every 10' will decrease the frame capacity. All of our conveyors are equipped with couplers. These are used to connect multiple conveyor units together to form a run and give stability to the system. The conveyors will either have Hook and Rod couplers (HR) or Butt Plate couples (BP) The coupler style will be noted at the end of the conveyor short description. All couplers are bolted or welded into the frame depending on the frame model. Curves Often curves will determine the width of the conveyor system, as the product requires additional space to negotiate the turn. The additional space depends upon the length and width of the product. Take a look at this link from our catalog for information on choosing the correct between frame dimension.
Roller Centers and Roller Position A minimum of three rollers should be in contact with the load at all times. Roller centers man also need to be closer together to reduce the load per roller. If you are moving a light and longer product, you can increase the roller centers to reduce the weight and cost of the roller conveyor. Looking to match the roller centers of an existing conveyor? Measure the distance between the center of one roller axle/shaft to the next roller shaft. Depending on the model of conveyor, our roller centers are 1.5", 3", 4.5", and 6" centers. As a standard, all of our rollers will be set high in their frame. This will allow for some overhand of product if needed for your application. If you need to make sure your products will not slide off the sides of the conveyor, you can attach guards to your frames. You can also purchase our conveyors with the rollers set low in the frames. This option is not available on our website and will have an additional cost and lead time. You can make this request through a sales representative.
Supports Our conveyors do not come with the supports. Supports come in different styles and heights. It is possible to use our conveyors without supports and lay them directly on a flat, even surface. When pairing your conveyor with supports, you will need to match the between frame dimensions (except for tripod and low profile supports). To learn how to select the correct supports for your conveyor click here.
Accessories Our conveyors are compatible with many accessories that can tailor your application to your needs. Not all accessories will work with your conveyor. Make sure to read the product descriptions to see which conveyor model each accessory will work for. To see a list of accessories that we can supply, click here.
Related VideosRoller conveyors play a vital role in various industries, allowing for the smooth and efficient movement of goods and materials. However, to ensure their optimal performance and extend their lifespan, regular maintenance is essential. In this comprehensive roller conveyor maintenance guide, we will delve into the world of preventive and scheduling best practices. By implementing these strategies, you can minimize downtime, reduce costly repairs, and maximize the efficiency of your roller conveyors. So, let’s dive in and discover how to keep your roller conveyors in top shape with the help of preventive maintenance software.
To understand how to effectively maintain roller conveyors, let’s start with the basics. A typical roller conveyor consists of several key components, including rollers, frames, belts, and supports. These components work together to transport items along the conveyor line. Routine maintenance is necessary to keep each component in optimal condition. First and foremost, it’s important to inspect the rollers regularly. Check for any signs of wear and tear, such as uneven surfaces, damaged bearings, or misaligned rollers. Replace any worn or damaged rollers promptly to prevent further issues. Next, examine the frames and supports for any signs of damage or misalignment. Ensure that they are securely fastened and aligned correctly. Any loose or misaligned frames can cause instability and affect the overall performance of the conveyor system. Lastly, pay attention to the belts or chains that connect the rollers. Look for signs of fraying, stretching, or excessive tension. Tighten or replace any loose or damaged belts to maintain proper functionality.
Regular field service maintenance is not just a good practice; it is essential for the smooth operation and longevity of roller conveyors. Neglecting maintenance can lead to a range of problems, including increased downtime, decreased productivity, and higher repair costs. By conducting routine maintenance, you can identify and address potential issues before they escalate. This proactive approach minimizes unexpected breakdowns and ensures that your roller conveyors operate at peak performance. Moreover, well-maintained conveyors contribute to a safe working environment and reduce the risk of accidents.
Performing daily inspection and maintenance checks is a fundamental part of roller conveyor maintenance. These checks help identify and address minor issues before they become major problems. Here are some key tasks to include in your daily maintenance routine: Clean the conveyor: Remove any debris, dust, or residue that may accumulate on the rollers, belts, or frames. This ensures smooth operation and prevents contamination. Inspect rollers: Check each roller for signs of wear, misalignment, or damage. Replace any worn or damaged rollers promptly to prevent disruptions. Examine belts or chains: Inspect the belts or chains for signs of wear, tension, or damage. Adjust or replace them as necessary to maintain proper operation. Lubricate moving parts: Apply lubrication to the rollers, bearings, and other moving parts as recommended by the manufacturer. Lubrication reduces friction and prolongs the lifespan of the components. Check safety features: Ensure that all safety guards, emergency stops, and sensors are functioning correctly. Address any malfunctions immediately to ensure a safe working environment. By incorporating these daily maintenance tasks into your asset management, you can prevent potential issues and keep your roller conveyors running smoothly.
In addition to daily checks, it’s crucial to establish a comprehensive maintenance schedule for your roller conveyors. A well-planned schedule ensures that maintenance tasks are performed regularly and systematically. Here are some key steps to consider when creating a maintenance schedule: Determine maintenance intervals: Assess the manufacturer’s recommendations and industry standards to determine the frequency of maintenance tasks. Factors such as conveyor usage, load capacity, and operating conditions may influence the intervals. Create a checklist: Develop a detailed checklist of maintenance tasks to be performed during each maintenance cycle. Include items such as roller inspection, belt replacement, lubrication, and safety checks. Assign responsibilities: Clearly define who is responsible for each maintenance task. Assigning specific roles ensures accountability and helps streamline the maintenance process. Document maintenance activities: Keep a record of all maintenance activities performed, including dates, tasks completed, and any issues encountered. This documentation serves as a valuable reference for future maintenance and troubleshooting. By adhering to a well-designed maintenance schedule, you can stay proactive in keeping your roller conveyors in optimal condition and minimize the risk of unexpected breakdowns.
Preventive maintenance is a proactive strategy that focuses on identifying and addressing potential issues before they cause disruptions. Implementing a preventive maintenance program for your roller conveyors offers several benefits: Enhanced equipment lifespan: Regular maintenance prevents premature wear and extends the overall lifespan of your roller conveyors. Reduced downtime: By identifying and addressing potential issues early on, you can minimize unplanned downtime and maintain productivity. Cost savings: Preventive maintenance helps avoid costly repairs and replacements by addressing minor issues before they escalate. To implement a preventive maintenance strategy, consider the following steps: Conduct regular inspections: Perform comprehensive inspections at scheduled intervals to identify any signs of wear, misalignment, or damage. Replace worn components: Promptly replace any worn or damaged rollers, belts, or chains to prevent further issues. Lubricate as needed: Apply lubrication to the moving parts as recommended by the manufacturer to reduce friction and ensure smooth operation. Monitor performance: Regularly monitor the performance of your roller conveyors, including factors such as speed, noise levels, and overall efficiency. Any deviations from normal operation should be investigated promptly. By adopting a preventive approach to roller conveyor maintenance, you can maximize the lifespan and performance of your equipment while minimizing disruptions.
Cleaning and lubrication are critical aspects of roller conveyor maintenance. Proper cleaning ensures the removal of debris, dust, and contaminants that can hinder performance, while lubrication reduces friction and prevents premature wear. Here are some key tasks to consider: Cleaning the rollers and belts: Regularly clean the rollers and belts using a mild detergent or cleaning solution. Remove any accumulated debris, dust, or residue to maintain smooth operation. Inspecting and cleaning bearings: Check the bearings for signs of dirt, debris, or lack of lubrication. Clean and lubricate them as needed to prevent damage and ensure optimal performance. Lubricating moving parts: Apply lubrication to the rollers, bearings, and other moving parts as recommended by the manufacturer. Use the appropriate lubricant and follow the recommended intervals to ensure proper lubrication. Remember, excessive lubrication can attract more debris, so it’s essential to strike the right balance. Follow the manufacturer’s guidelines and consult with maintenance experts if needed.
Despite regular maintenance efforts, roller conveyor mechanism parts may encounter common issues. Knowing how to identify and address these problems promptly can help minimize downtime and prevent further damage. Here are a few common issues and troubleshooting tips for your roller maintenance: Roller misalignment: Misaligned rollers can cause items to veer off course or create uneven movement. Use a level or laser alignment tool to realign the rollers as needed. Belt tracking problems: If the conveyor belt starts to veer to one side, it can cause jams and disruptions. Adjust the tracking mechanism or consult the manufacturer’s guidelines for corrective actions. Excessive noise or vibration: Unusual noise or excessive vibration may indicate loose or worn components. Inspect and tighten any loose parts or replace worn components as necessary. Conveyor jams: Items getting stuck or jammed on the conveyor can disrupt the workflow. Identify the cause of the jam and address it promptly, ensuring the safe removal of any obstructions. If you encounter persistent or complex issues, it’s advisable to consult with a professional technician or contact the manufacturer for assistance.
Maintaining accurate and detailed records of maintenance activities is crucial for effective roller conveyor maintenance. A comprehensive maintenance log provides valuable information and insights for future maintenance, troubleshooting, and decision-making. Here are the key aspects of record keeping: Maintenance schedule and tasks: Document the scheduled maintenance tasks and intervals in your maintenance log. This ensures that tasks are performed on time and allows for easy tracking and planning. Task completion and observations: Record details of each maintenance task performed, including dates, tasks completed, and any observations made during the process. This information helps identify patterns, track performance, and troubleshoot recurring issues. Repairs and replacements: Document any repairs or component replacements carried out, along with the reasons and dates. This log serves as a reference for future maintenance and helps identify any recurring issues or problematic components. Equipment performance: Record any notable observations regarding the performance of your roller conveyors, such as changes in speed, noise levels, or efficiency. This data can help detect emerging issues and guide maintenance decisions. By maintaining detailed records, you can establish a comprehensive maintenance history, make informed decisions, and enhance the overall efficiency of your roller conveyor maintenance efforts.
Safety should be a top priority during roller conveyor maintenance. Working with heavy machinery and moving parts can pose risks if proper precautions are not taken. Here are some essential safety measures to follow: Lockout/Tagout (LOTO): Implement a lockout/tagout procedure to isolate the conveyor system from its power source before conducting any maintenance tasks. This ensures that the equipment cannot be started accidentally during maintenance. Personal protective equipment (PPE): Wear appropriate PPE, such as safety glasses, gloves, and protective clothing, to protect against potential hazards. Training and awareness: Ensure that maintenance personnel are properly trained in operating and maintaining roller conveyors. Regularly update their knowledge and provide safety refresher training. Clear communication: Establish clear communication protocols between maintenance personnel and operators to ensure everyone is aware of maintenance activities and potential hazards. Regular inspections: Regularly inspect the safety features of the roller conveyor system, such as emergency stops, safety guards, and sensors. Repair or replace any faulty safety equipment immediately. Always prioritize safety and encourage a safety-conscious culture in your maintenance practices to protect both personnel and equipment.
To streamline and optimize your roller conveyor maintenance processes, consider leveraging maintenance management software like FieldInsight. FieldInsight offers a comprehensive solution for organizing and tracking maintenance tasks, managing schedules, and generating reports. Here are some key benefits of using FieldInsight: Streamlined task management: Assign and track maintenance tasks, set reminders, and receive notifications for upcoming tasks, ensuring nothing falls through the cracks. Maintenance history and documentation: Store and access detailed maintenance records, including task completion dates, observations, and repairs. This enables easy tracking, analysis, and decision-making. Preventive maintenance scheduling: Set up preventive maintenance schedules within FieldInsight, ensuring that routine maintenance tasks are performed on time and consistently. Avoid debris buildup, excessive wear, structural damage, material spillage, belt slippage, and more with regular planned preventative maintenance. Real-time updates and collaboration: Facilitate seamless communication and collaboration among maintenance teams, allowing for real-time updates and efficient coordination. Data-driven insights: FieldInsight provides analytical reports and performance metrics that can help identify trends, optimize maintenance strategies, and improve overall equipment reliability. Ensure you have all the right tools for conveyor belts, roller bearings, and more. With a field service software you can save time in your conveyor maintenance plan to ensure normal conveyor operation is consistent.
Regular and proactive maintenance is the key to ensuring the smooth operation and extended lifespan of your roller conveyors. By implementing preventive and scheduled maintenance practices, performing daily inspections, and incorporating cleaning and lubrication tasks, you can prevent major issues, reduce downtime, and enhance overall efficiency. Remember, proper record keeping, prioritizing safety measures, and utilizing maintenance management software like FieldInsight can significantly streamline your maintenance processes and help you achieve optimal results. So, don’t wait! Start implementing these best practices today and explore the benefits of FieldInsight as a comprehensive solution for your roller conveyor maintenance needs. Your roller conveyors will thank you with extended service life and reliable performance. What You Should Do Now Book a Demo. You’ll be in touch with an automation expert who has worked in this space for over 5 years, and knows the optimal workflow to address your needs. If you’d like access to free articles about managing HVAC workflows, go to our blog. If you know someone who’d enjoy reading this page, share it with them via email, Linkedin, Twitter, or Facebook.
Posted by Stephanie on March 27, 2023 A conveyor is a type of material handling system that simplifies the process of transporting products. These items can include everything from bulky items to products with complex geometries. Conveyors are essential for most warehouses because of their ability to safely and efficiently handle sizable volumes of materials. When you’re selecting a conveyor for your warehouse, there are several types that you can consider. However, they all work by moving objects from one destination to another with a frame that’s comprised of buckets, belts, rollers, or other types of moving parts. While all types of conveyors have their benefits, the roller conveyor is among the most effective solutions that you can add to your facility. Roller conveyors are available in numerous designs and styles. The following guide goes into detail about roller conveyors and the advantages you can obtain from them.
The Importance of Roller Conveyors To better understand what roller conveyors are, you should first know what material handling is. This process involves the protection, movement, control, and storage of products and materials in warehouses, distribution centers, or manufacturing facilities. Material handling can include many different manual and automatic systems that are meant to support logistics and facilitate the supply chain. Effectively using material handling in your facility can help with: Production planning Forecasting Resource allocation Inventory management Flow management Customer delivery After-sales support These systems are put into place to reduce inventory, lower handling costs, enhance customer service, and shorten delivery time. A roller conveyor is a highly popular conveyor belt that’s designed to allow objects to move along the surface with the use of rollers. These rollers are equally spaced cylinders that revolve constantly while the conveyor is operational. Roller conveyor systems can transport items from one destination to another with small engines or gravity, which is an integral aspect of the material handling process. Once you’ve installed the right roller conveyor in your facility, you should notice efficiency improvements throughout the entire facility.
How Roller Conveyors Work As mentioned previously, roller conveyors use rollers to move items from one location to the next. While there are numerous types of roller conveyors, they are all equipped with similar components, which include everything from rollers to bearings.
Overview of Roller Conveyor Mechanisms When you use a roller conveyor mechanism, the materials that are being transported need to have a relatively rigid surface that’s supported by at least three rollers. These systems are most effective when paired with accumulation applications. It’s possible for the roller to reduce product inertia at higher speeds, which makes it useful when placed after high-speed sorting equipment. Over the years, several advancements have been made to the construction of these systems to ensure that they remain relevant for the modern industrial setting. For instance, the drive roller conveyor is a somewhat new upgrade that allows each individual roller to be affixed to a motor in a manner that improves system control. The inclusion of this technology helps to equalize the material velocity, which makes it possible for the conveyors to be put in reverse at low or high elevations. You can also use these specific roller conveyors for any application that requires a bi-direction focus. All you need to do is change the direction of the motor.
Roller Conveyor Parts Roller conveyors are comprised of four distinct parts, which include: Rollers Frames Bearings Shafts The rollers that are outfitted on conveyors are cylindrical parts that are positioned along the upper portion of a conveyor frame to accommodate the movement of various goods. These conveyors make the transportation of goods between at least two areas of a warehouse more efficient. Rollers are typically paired with AC motors, of which there are numerous types. For instance, AC induction motors allow for continuous operation in a single direction. The roller frame can be made from either steel or aluminum. The exact material you choose depends on the frame’s capacity and the amount of loading that you intend to perform. Steel is invariably more durable than aluminum, which means that it has a higher weight capacity. Rollers can be covered in rubber or plastic to increase the amount of friction that occurs. There are several different types of non-precision bearings that can be found in a roller conveyor. For instance, angular ball bearings are made to support rolling shafts. This is a lengthy structure that makes up the primary portion of the conveyor. Pillow block bearings are pedestals that support spinning shafts with the use of numerous accessories. This assembly consists of a mounting block that contains the bearing. The purpose of these ball bearings is to reduce friction and support axial and radial loads. Roller conveyor shafts are made to transmit torque and rotation between separate conveyor screw sections. They also deliver radial support and are made from carbon steel or stainless steel.
Types of Roller Conveyors There are many types of roller conveyors, the primary of which include: Gravity roller conveyors Powered roller conveyors Belt-driven live roller conveyors Chain-driven live roller conveyors Motorized roller conveyors Custom roller conveyors
Gravity Roller Conveyors A gravity roller conveyor is the most basic type of conveyor at your disposal. It uses free-rotating rollers that slide materials down the line via gravity. This type of system can transport lightweight and medium weight items that don’t need a motor. You can add accessories to these systems, which extend to slide rails, pop-up stops, curves, and hanging brackets. It’s possible for them to be made with plastic, steel, or aluminum.
Powered Roller Conveyors Powered roller conveyors are a more advanced form of roller that’s powered by a motor. This power propels the items forward. An internal motor is used to power one out of nine rollers in the system. This type of roller conveyor is ideally suited to transporting lighter and smaller products.
Belt-driven Live Roller Conveyors Belt-driven live roller conveyors use a motorized belt to provide power to every roller, which means that this conveyor controls how materials move as they’re being transported. When you use this conveyor, you can set specific control points where items can stop momentarily. These conveyors are also recommended when you perform a large amount of side loading. The belt that’s included with a belt-driven roller conveyor can be either straight or in a V-shape, the latter of which allows for a curved conveyor. The rubber belt that’s positioned below the roller can’t come into contact with debris, excess heat, or moisture. If it does, the system can quickly degrade. These conveyors are commonly used to transport medium and heavy loads.
Chain-driven Live Roller Conveyors Chain-driven roller conveyors are similar to the belt-driven alternative but will use chains to power the rollers. They’re typically used to convey heavy-duty items. You might also want to use this system if you’re facing adverse conditions and are unable to safely operate a standard belt-driven conveyor. These systems work well with extremely heavy loads as well as reversible operations. The amount of power available with a chain-driven conveyor is high.
Motorized Roller Conveyors Motorized roller conveyors are relatively modern systems that pair smaller DC motors with the rollers. This type of motor is commonly built inside the roller and will be spread at different intervals throughout the conveyor system. Every motor acts as a type of accumulation zone. Controller cards provide the operator with complete control over the system’s direction and motor speed. These cards often come with photo-eye inputs to assist with controlling zone accumulation. There are several benefits of using this type of conveyor system instead of an AC motor conveyor, the primary of which is that they are highly effective at handling accumulation because of their smaller size.
Custom Roller Conveyors A custom roller conveyor can be practically anything you want it to be. By selecting a custom solution, you can design the entire system from scratch, which allows you to match the finished conveyor with the exact application you’d like to use it for. Since you have complete control over how the conveyor is customized, it’s possible to include numerous features and accessories in the final design.
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