Wedge Belt Electric Roller Conveyor System

1. Core Structure and Working Principle

This equipment consists of an electric roller drive module, multi-wedge belt transmission system, driven roller set, frame structure, and electrical control system. The overall design is compact and easy to install, making it suitable for space-limited workstation layouts and flexible conveyor configurations.

1. Electric Roller Drive Module

The electric roller serves as the power core of the system, integrating a built-in motor and gearbox inside the roller body. This integrated design ensures a compact structure, high transmission efficiency, and low noise operation.

Common specifications include roller diameters of Φ38 / Φ42 / Φ50 / Φ60 / Φ70mm, with customizable lengths from 230mm to 1400mm. Power options range from AC 90W to DC 10–150W, supporting stepless speed regulation from 0–120 m/min. DC24V brushless models are especially suitable for applications requiring frequent start-stop cycles and higher safety control requirements.

2. Multi-Wedge Belt Transmission System

The system uses a PJ-type multi-wedge belt (pitch 2.34mm) to transmit power from the drive roller to multiple driven rollers. The belt engages through multiple grooves, forming a multi-point contact transmission structure.

This design provides strong load capacity and stable torque transmission without slippage. Each conveyor unit can typically handle loads from 5 to 50kg, making it suitable for light to medium-duty material handling applications.

3. Driven Roller Set

The driven rollers are available in carbon steel galvanized, stainless steel, or PU-coated materials, depending on application requirements. Standard roller center distance options include 75 / 100 / 125mm. A shorter pitch provides smoother and more stable conveying performance.

Both ends of each roller are equipped with precision ball bearings and sealed end caps, ensuring low noise, dust resistance, and water resistance. The system operates reliably in environments ranging from 0 to +40°C.

4. Accumulation Control (Zero-Pressure Accumulation)

Each conveyor unit can operate independently with its own drive, enabling modular accumulation control.

By combining sensors and physical blocking mechanisms, products can be stopped, buffered, and released sequentially without pressure buildup. This prevents product collisions and damage, making it ideal for value-sensitive goods and synchronized production processes.

2. Key Performance Advantages

1. High Torque and Stable Load Capacity

The multi-wedge belt system provides multi-groove engagement, ensuring strong torque transmission without slipping. The system supports up to 50kg per unit, delivering stable and continuous conveying performance for regular-shaped goods.

2. Low Noise and High-Speed Operation

The transmission system operates with low vibration and low noise, typically ≤65dB overall. The electric roller design ensures smooth operation, making it suitable for environments with strict noise or cleanliness requirements such as electronics, pharmaceutical, and food industries.

The conveyor can reach speeds up to 120 m/min, meeting the demands of high-speed sorting and packaging lines.

3. Flexible Configuration and Strong Adaptability

The system supports multiple layouts including straight lines, curves, inclines, and side transfers. Conveyor units can be freely combined to form complex production lines.

Frame materials can be selected from carbon steel, aluminum alloy, or stainless steel, allowing adaptation to different industrial environments and production requirements.

4. Easy Maintenance and Long Service Life

The structure is simple and modular, allowing easy disassembly and replacement of rollers and belts. Daily maintenance mainly involves cleaning debris from the belt and rollers and checking belt tension.

All key components are standardized, reducing spare parts cost and downtime. The overall system is designed for long operational life with minimal maintenance requirements.

5. Energy Efficient and Space Saving

The direct-drive electric roller eliminates secondary transmission losses, improving energy efficiency.

Its integrated structure removes the need for external drive units, significantly reducing footprint. This makes it highly suitable for compact workstations and high-density warehouse layouts.

3. Typical Industry Applications

1. E-commerce Logistics and Express Warehousing

Ideal for high-speed sorting, buffering, and conveying of cartons, parcels, and totes. Supports zero-pressure accumulation, significantly improving sorting efficiency in large-scale logistics and fulfillment centers.

2. Food and Pharmaceutical Industry

Stainless steel structures and food-grade belts ensure hygienic operation. The system supports clean, low-noise conveying for packaged food, pharmaceutical boxes, and medical containers, meeting strict industry compliance standards.

3. Electronics and Home Appliance Manufacturing

Used for assembly line material handling of electronic components and small appliances. Low noise operation ensures no interference with precision assembly, while accumulation functions support synchronized multi-station workflows.

4. Retail, E-commerce, and Apparel Industry

Suitable for carton, shoe box, and retail packaging distribution systems. Flexible configuration allows rapid adaptation to changing production layouts and multi-category handling requirements.

4. Selection and Maintenance Guidelines

1. Key Selection Factors

• Material Characteristics: Determine weight, size, and fragility of products. For light-duty loads, standard rollers are sufficient; for fragile or heavier loads, PU-coated rollers are recommended.

• Layout Requirements: Choose single or multi-unit configurations based on conveyor length and production layout. DC24V brushless rollers are recommended for high-frequency start-stop applications.

• Environmental Conditions: Stainless steel and IP67-rated systems are recommended for food, pharmaceutical, or high-moisture environments.

2. Daily Maintenance

• Clean belt and roller surfaces daily to remove dust and debris

• Check belt tension and roller rotation condition weekly

• Inspect electric roller temperature and noise levels regularly

• Ensure sensors and control signals remain stable and unobstructed

• Replace worn belts or rollers promptly to avoid downtime

3. Routine Servicing

• Lubricate transmission components periodically

• Recalibrate sensors and accumulation timing logic monthly

• Inspect safety devices including emergency stops and overload protection

• Replace heavily worn parts during quarterly maintenance cycles