Electric Roller Merging and Diverting Conveyor

I. Core Structure and Working Principle

The equipment consists of six core modules: electric roller drive unit, merge & divert guide mechanism, roller conveyor section, frame structure, sensing system, and electrical control system. The overall design is compact, easy to install, and suitable for various production line layouts. It can flexibly realize both merging and diverting operations, and can be integrated into existing conveyor systems without major modifications.

1. Electric Roller Drive Module

As the power core of the system, the electric roller integrates the motor and gearbox inside the roller body, providing a compact structure, high transmission efficiency, and low noise operation. No external drive frame is required, saving installation space.

• Roller diameter: Φ38 / Φ42 / Φ50 / Φ60 / Φ70 mm

• Power range: AC 90W / DC 10–150W

• Speed range: 0–100 m/min variable speed control

• DC24V brushless motor available for high-frequency start/stop and precision control applications

Cooling options:

• Oil-cooled

• Oil-immersed

• Air-cooled

The system is highly sealed and suitable for dusty, humid, and demanding industrial environments.

2. Merge & Divert Guide Mechanism

This is the key functional module responsible for material routing.

It includes:

• Adjustable guide plates

• Turnover rollers or pneumatic diverter arms

• Synchronized conveyor control structure

Functions:

• Divert products from the main line to branch lines (diverting mode)

• Merge multiple branch lines into the main conveyor (merging mode)

The guide angle is adjustable from 0° to 90°, allowing flexible adaptation to different layout designs.

The surface is made of wear-resistant and low-friction materials to prevent scratching, deviation, or product damage, ensuring smooth and stable material transfer.

3. Roller Conveyor Section

The roller conveyor consists of powered rollers and idle rollers.

Material options:

• Galvanized carbon steel

• Stainless steel

• PU-coated rollers

Standard roller pitch: 75 / 100 / 125 mm
The design ensures that at least three rollers maintain contact with the product during transport, ensuring stability and smooth conveying.

Both ends use precision ball bearings with sealed caps, offering low friction, dust resistance, and water resistance. The system operates reliably in environments from 0°C to +40°C.

4. Sensing and Electrical Control System

The system is equipped with photoelectric sensors and proximity switches installed at key positions such as branch lines, merging zones, and main line entry points.

Functions:

• Real-time detection of product position, speed, and quantity

• Accurate triggering of merging/diverting actions

• Prevention of misoperation and missed detection

The control system is based on PLC programming with a touchscreen interface.

Features:

• Manual / automatic / synchronized operation modes

• Pre-set merge/divert logic and timing control

• Compatible with Profinet, Modbus, and other industrial communication protocols

• Seamless integration with AGV systems, sorting machines, and scanning systems

5. Frame Structure

The frame is made of carbon steel, aluminum profiles, or stainless steel, treated with coating, anodizing, or polishing for corrosion resistance and durability.

Key features:

• Adjustable height design

• Modular structure for flexible expansion

• Optional side guards and safety rails to prevent product falling

• Suitable for different conveyor heights and layouts

6. Working Principle

Diverting Mode:

Products are conveyed along the main line via electric rollers. When the sensor detects a product, the signal is sent to the PLC system. The system activates the diverter mechanism and directs the product to the designated branch line, where it is smoothly transported to the target workstation.

Merging Mode:

Products from multiple branch lines are transported into the merging zone. Sensors detect incoming products and trigger the guide mechanism. The system synchronizes speed between branch lines and the main conveyor, ensuring smooth and collision-free merging.

The entire process is fully automated, continuous, and highly efficient without manual intervention.

II. Key Performance Advantages

1. Accurate Merge & Divert, Smooth Operation

High-precision sensors and PLC control ensure accurate timing and positioning, preventing product collision, blockage, or misalignment. The system achieves stable and efficient material transfer between multiple lines.

2. Compact Structure, Space-Saving Design

Integrated electric roller drive eliminates external motors and drive units, significantly reducing footprint. Modular design allows flexible adjustment of width, length, and angle, suitable for complex production layouts.

3. Stable Operation, Low Noise, Energy Efficient

Low-noise operation (≤65 dB) ensures a comfortable working environment. Direct-drive electric rollers reduce energy loss, improving efficiency and reducing operating costs. Designed for 24/7 continuous operation with low failure rates.

4. Wide Application Compatibility

Handles products from 5–50 kg, including cartons, totes, trays, electronic parts, food packages, and automotive components. Easily integrates with roller conveyors, belt conveyors, lifting systems, and sorting equipment.

5. Easy Maintenance and Long Service Life

All key components are standardized, ensuring easy replacement and low maintenance cost. Daily maintenance only requires cleaning rollers and checking sensors. Sealed design prevents dust and moisture intrusion, extending service life.

6. Safe and Reliable Operation

Equipped with emergency stop, overload protection, limit switches, and safety guards. Protection level can reach IP54 or higher (customizable to IP67), suitable for dusty, humid, cleanroom, and industrial environments.

III. Typical Industry Applications

1. E-commerce Logistics & Warehousing

Used for high-speed sorting and distribution, enabling efficient merging and diverting of parcels across multiple sorting lines. Supports barcode scanning integration for automated routing.

2. Food & Pharmaceutical Industry

Stainless steel structure and food-grade rollers ensure hygiene compliance. Suitable for clean environments with strict sanitary requirements, ensuring safe and contamination-free handling.

3. Electronics & Home Appliance Manufacturing

Used for precise routing of electronic components and appliance parts between assembly, testing, and packaging lines. Low-noise operation supports precision manufacturing environments.

4. Automotive Parts Manufacturing

Handles high-volume transport and distribution of small automotive components and trays, reducing manual handling and improving production efficiency.

IV. Selection and Maintenance Guidelines

Selection Considerations

• Product size, weight, and material

• Required merging/diverting mode (single or dual function)

• Layout of main and branch conveyors

• Speed and synchronization requirements

• System integration needs (PLC, AGV, WMS compatibility)

• Environmental conditions (clean, dusty, humid, etc.)

Daily Maintenance

• Clean rollers and guide surfaces

• Check fasteners and mechanical stability

• Ensure sensors are unobstructed and functioning properly

Weekly Maintenance

• Inspect electric roller for abnormal noise or heating

• Check lubrication condition (oil-cooled models)

• Inspect guide mechanism wear and alignment

• Verify electrical connections

Monthly Maintenance

• Lubricate transmission components

• Calibrate sensors and control timing

• Test safety protection devices

Quarterly Maintenance

• Replace worn rollers and guide components

• Backup PLC programs and parameters

• Perform full system inspection and debugging

• Check sealing performance of electric rollers