Conveyors and rollers
Conveyors are the most commonly used means of automated material handling. Depending of the method of use, the materials and packages to be conveyed, it can be found in countless layouts. Typically fixed conveyors, purposefully implemented consciously between two points, or even as a network connection multiple points. Implementation of conveyor systems is always preceded by thorough logistical planning.During conveyor system design the layout of the current warehouse building or production hall, the potentially planned addition and above all the target task, for which the conveyor system is built must be taken into consideration.
Main types and components of conveyors:
- roller conveyors (pallet conveyor, mini load conveyor)
Among horizontal material handlers, roller conveyors are the most widely used systems. The conveyors are typically units mounted with two sidewalls and conveyor rollers.
With respect to their operating principles, there are two main types:
- driven roller conveyor
- non-driven free-wheel roller conveyor
Driving solution for driven tracks, can be analyzed at length, but the most important thing is that is should be decided by the current problem to be solved. Driven conveyors can be typically divided into two groups:
- congested conveyor
- congestion-free conveyor, with frictional roller or controlled motor-driven roller
Congested roller conveyors are in most cases driven directly, as a result of which, congestions may form in the nodes of the conveyor system. In congestions have to eliminated, they can be eliminated using sorter systems. There a countless possible layouts of congestion-free conveyors. Frictional rollers can be found in the product range of Zenit Kft. as top-quality solutions. Using these rollers, stable systems can be created with the adequate driving solutions. Besides frictional rollers, our company also offers engine-driven rollers, which we can implement with versatile engine-driven roller control units.
- Conveyor belts
Due to their continuous operation, belted conveyors are versatile, usually continuously operated material handling equipment. Their continuous operation is typical for energy management, in case of longer route sections. Belted conveyors used for shorter target tasks can also be of intermittent operation. The principle of intermittent operation is due to fact that materials are placed on them with differences in time.
They are relatively frequently used due to their favorable cost price, stable material handling between different levels, and packages of different size and shape. In is a broadly applied solution in logistics systems.
- Plastic conveyor belts
The plastic belt solution is a modern form of logistic systems conveyor belts. It is most widely used in the field of bottling technology, but this solution should be considered for every belted conveyor, where durable implementation is a basic expectation.
- Overhead conveyors
Overhead conveyors are also typical solutions for fixed-track material handling. It is a solution widespread in manufacturing, and lately it has been strongly present in logistics, as well. Space utilization is a great advantage of overhead conveyors. They do not use the floor levels of the halls, so they do not have a negative impact on their utilization. On the other hand, they are intermittently operating equipment, which means that their efficiency is lower, than that of their continuously operating counterparts. With respect to their operation, they come with:
- constant-sequence carriers
- ad-hoc carriers
Conveyor systems are mostly fixed conveyor tracks, and they are mostly driven by
- carrier powered by power supply integrated into the conveyor system
- forwarding chain carrier integrated into the conveyor system
- conveyor system without power supply, with carrier driven by its own power supply.
Reversing conveyor elements (arches, 90° switches, pushers, ejectors, etc.)
Reverser and intervention elements are key components of the conveyors. Extent and direction of the directional change, later orientation of the product, and the reversing speed considerable impacts their layout. The list of directional change methods is lengthy, manufacturers try to offer novelties every year. Novelties are mainly due to the changing and increasing production needs, as well as to the increase of competitiveness and surpassing the market standards.
- Sorting and commissioning systems
Sorting systems are intra-logistical process elements created in a highly important place.hey are parts of manual commissioning processes integrated into the automated process, the operating principle of which serves as basis for a large number of solutions (commissioning robots, distribution tracks, etc.).They are complex units with variable load bearing capability depending on the dynamics of manufacturing and warehousing processes, and their operation is usually extremely complex. Sorting solutions are in each case designed depending on the currently arising processes to be implemented. Sorting, commissioning and automation is a rather comprehensive topic, easy to get lost in. Once the appropriate intention of the client has been formulated, the expectations from which the most adequate method can be developed, must be formulated accurately. Selection of assets and systems, similarly to warehouse automation requires careful planning and thorough process survey.
Rollers - NDW
NDW offers conveyor rollers for all areas in various industries. Extraordinary quality and price/performance ratio of the rollers ensures a distinguished market position. Their products can meet any challenge.NDW offers its passion, expertise and experience to You: Zenit Kft. is the exclusive Hungarian distributor of NDW. We can deliver parts that resist the problems of any conveyor system. Our knowledge related to the internal material handling go beyond the sales and delivery of conveyor rollers.
Have you ever wondered what the world would look like without conveyor rollers? First of all, it would be much emptier, because everything that surrounds us started its life on a conveyor: your plate and the food on it, the chair and the computer, the car and its key. Without conveyors nothing would ever reach its destination. This method of transportation has an increasing popularity, so the relevance of using conveyors and rollers continues to increase.
Driven rollers
New engine-driven rollers of NDW are the result of a more than two-year period of development. This development made possible full control of conveyors and conveyor systems in terms of efficiency, durability and of course logistic installation. Engine rollers are driven by NDW controls, which come in four versions, starting from the simple controls of individual driven rollers to the complex conveyor controls that communicate with each of them, this way the system is set for optimal efficiency. Naturally, NDW constantly works on improving and upgrading these controls. Engine-driven rollers are the result of far-reaching research and continuous improvement. It can be safely said that NDW and its exclusive Hungarian partner, Zenit Kft. offer engine-driven rollers of outstanding performance and high quality.
NDW connect application
With the help of the unique NDW connect application you may view, control and monitor every switch-off and switch-on of the conveyor roller.
The application provides broad insight to the performance of conveyor systems. The entire conveyor control runs on a single Wi-Fi system, which allow global remote access and monitoring.
24V driven roller
The NDW E rollers are brushless DC motors, integrated in a conventional ø50 / 60mm NDW cylinder; their primary purpose is to drive the unproven rollers in the conveyor belt systems.(max. speed 1 m / s ø50mm).
| Power supply voltage: | 24V DC |
| Operating power consumption: | 2A |
| Starting current: | 2A |
| Performance: | 50W |
| Operating conditions: | 0°C - 40°C dehumidifying environment |
| engine coupling head: | stainless hex head 11m, fixing M12 |
| Cylinder diameter: | base version Ø50mm (versions,50,60,63,5,70,80,89mm) |
| Protection: | IP54 |
| Noise impact. | 55dB |
| Minimal length: | with 275mm installation poly-V head |
| Compatible drive controller: | BC 50, BP120 |
Speed ranges, torques:
- 0,05-0,25m/s 4,07-2,57Nm (6,88Nm starter)
- 0,1-0,5m/s 2,11-1,26Nm (3,84Nm starter)
- 0,2-1m/s 1,03-0,55Nm (2,09Nm starter)
- 0,6-3m/s 0,3-0,18Nm (0,63Nm starter)
Possible driving layouts:
- circular belt pressed into the cylinder,
- double circular belt head,
- Poly-V belted head
- Ribbed belted head
- double sprocket head
24V pallet driven roller
The NDW pallet E rollers are brushless DC motors, integrated in a conventional ø63,5 / 70/80/89 mm NDW cylinder ; their primary purpose is to drive the unproven rollers in the conveyor belt systems. (max. speed 0.35 m / s).
| Power supply voltage: | 24V DC |
| Operating power consumption: | 2A |
| Starting current: | 2A |
| Performance: | 50W |
| Operating conditions: | 0°C - 40°C dehumidifying environment |
| engine coupling head: | stainless hex head 11m, fixing M12 |
| Cylinder diameter: | Ø63,5mm basic layout (versions 63,5,70,80,89mm) |
| Protection: | IP54 |
| Noise impact. | 55dB |
| Compatible drive controller: | BC 50, BP120 |
Speed ranges, torques:
- 0,06-0,45m/s 4,1-2,6Nm (6,9Nm starter)
- 0,04-0,23m/s 6,5-4,9Nm (12,7Nm starter)
- 0,02-0,14m/s 11,0-7,8Nm (19,4Nm starter)
Possible driving layouts:
- Poly-V belted head
- double sprocket head
BC50
The BC 50 controller is for the application of a single motor, a simple motor controller at affordable priceless complex, without integrated sensor.
The BC50 motor controller is designed to drive motor-driven E-rollers. Speed and direction of the E-roller can be regulated over a user-friendly interface, or using an external I/O controller. Control settings can be adjusted in the user-friendly interface. Settings can be changed using the graphic user interface (UI) and simple buttons. As a result of this, no DIP switches are necessary on this controller. The BC50 is supplied with surge protection against the induced surge of engine driven E-rollers, when it operates as a generator. As a permanent protection, the control has jam protection to protect the E-roller. When this occurs, the control attempts to start the jammed drive a couple of times. When the engine stops, the control sends an error message on the screen, and sends an I/O error signal.
The BC50 can be controlled in two modes:
In manual and in I/O mode. In manual mode, the user can simply operate the entire E-roller (Running, Direction, Speed) using the integrated buttons and the control interface. In I/O mode, operating settings of the E-roller can be regulated via an external l/O.
BP120
The BP 120 controller has sensor integration with two motor controllers for complex programming and system communication. Thanks to its built-in transformer, it can instantly be switched over to 230V, so it is an excellent Plug & Play solution. It is suitable for larger systems, operates in both independent and intelligent mode.
The BP120 controller is designed to drive and control two NDW motor-driven E-rollers.BP120 has two integrated sensor connection, this way is suitable for a number of intra-logistic applications.BP120 controls, when interconnected, may create a system that is capable of entirely independent operation. With the point-to-point communication and due to the integrated logic of the controller, no external computer or PLC is necessary. After setting the regulatory parameters, the system can be used in a highly flexible manner. No external power supply is required. Thanks to the integrated transformers, the BP120 controller can instantly be connected to the electric network (110-130 V), so it is an excellent Plug & Play solution.
The BP120 controller offers a user-friendly solution that simplifies and facilitates setting or adjusting the controller. This user interface (UI) consists of an LCD display, combined with simple buttons.BP120 controllers have pre-programmed settings for simple installation and testing. Each BP120 controller is able to communicate with their neighbors, with the left-side and right-side controller. This allows system upgrade and integration of more complex tasks. Fully autonomous Zero Pressure Accumulation ZPA can be created. With the help of the integrated logic of the controllers, we can fully personalized everything. Collection of packages, synchronized methods, setting sections and many other things can be set with the help of the controls. Simple control using I/O. These can be controlled with the help of external power sources.
Operating modes, basic functions:
Tero pressure accumulation
The BP120 controllers provide fully independent Zero Pressure Accumulation (ZPA) mode of operation. This allows transportation of the goods without them touching each other. The conveyor system is divided to segments, each segment has its own sensor, an engine-driven E-cylinder and multiple driven rollers. As the controllers directly communicate with each other, they are aware of the status of each conveyor module.
Delay and time limitsThe controller has multiple delay function and time limit regulation that can easily be personalized. They include. for example dispatch launch, handover waiting and sensor delay. Personalization of these delays allows the smoothest possible operation of the system.
Train- permanently switched modeBy interconnecting multiple controllers it becomes possible to ensure identical behavior of all controllers and engines included in the system. This is particularly useful in case of long and simple conveyor systems. In this setting only one BP 120 controller has to be controlled, the others will simply follow its features.
Jam protection
If the engine revolution is blocked, the jam protection of the controller activates to protect the engine. The control attempts to start the jammed drive a couple of times. When the engine stops, the control displays an error on the screen, and sends an I/O error signal.
Surge protectionThe BP120 is supplied with protection against the induced surge of engine driven E-rollers, when it operates as a generator.
UTC
The universal transportation controller is an easy-to-use and flexible controller. Due to its flexibility it accelerates development, but is still capable of controlling complex systems. It is easy to use, less complex and more flexible, than PLC.
90° cross section divider
The NDW CSD can be used in many ways. The field of application includes sorting packages, combining or dividing processes. Thanks to its modular size, it can easily be implemented in any current or new system. They extend from rectangular transmission and sorting of the products to 180 degree turning of conveyor systems and other conceivable complexity.CSD is compact, modular component allowing integration to almost any kind of automated conveyor system.
The CSD consists of four brushless engine-driven E-cylinders. One motor for the conveyor rollers, two motors to drive flat straps and a single motor for lifting. When the lifting unit is lowered, packages can be forwarded with the roller unit. If a package must make a 90 degree turn, the CSD stops, the lifting unit elevates and the transfer straps are launched, making lateral displacement of the product possible. Naturally the inverse of this process is also possible.
- Power supply voltage: 230V AC
- Operating power consumption: 0,7A
- Performance: 150W
- Operating conditions: 0°C - 40°C dehumidifying environment
- Control: 4pcs BC50
- Driving motors: 4pcs E-roller Ø50mm
- Protection rollers: IP54
- Protection structure: IP20
- noise impact: 47-63dB
- Mass: 30kg
- Performance: 1000 shifts/hour
- Speed ranges, torques: 0,2-1,00 m/s propulsion drive
- 0,1-0,05 m/s transfer drive