The working principle of roller conveyor line illustrates the drive mode and material conveying process analysis

I. Core power system: illustration of the four major drive modes

Question: How does a roller line convert electrical energy into transported kinetic energy?
答案关键在于drive system的设计。根据工业场景需求，主要存在四种驱动方式：

Drum Motor Drive: Integrated motor and drum design, suitable for space-compact scenarios (e.g., food packaging lines), withLow noise, maintenance-freeAdvantage.
chain drive: connection of several sets of rollers by means of sprockets (common in automotive assembly lines).Load capacity up to 2000kgbut need to be lubricated regularly.
belt friction drive: Roller driven by friction using rubber belts (suitable for conveying electronic components).Avoid scratches on the material surfaceBut it tends to slip at high speeds.
bevel gear: Designed for cornering steering, the gears mesh to enable90-degree steering without stickingfor logistics sorting centres.

Comparison table of drive modes:

typology	Applicable Scenarios	Maximum load	Maintenance requirements
drum motor	Lightweight precision conveying	300kg	Low (lubrication-free)
chain drive	Heavy Industrial Conveying	2000kg	High (requires regular lubrication)
a leather drive belt	Surface sensitive materials	30kg	Medium (belt replacement)
pinion gear	cornering area	500kg	Medium (gear check)

Second, the analysis of the whole process of material handling (with the operation of the logic diagram)

Question: How does the material move accurately on the drum line?
The process is divided into five steps that work in tandem:

mechanical transmission→ 2.friction drive→ 3.linear transport→ 4.Steering/Sorting→ 5.Positioning Uninstallation

Key Stage Details.

Stage 1: Power Start
The electric motor reduces the speed to 10-30 rpm via a speed reducer (to avoid inertial splashing of the material) and the torque is transmitted to the drive drum via a drive chain/belt.
Stage 3: Friction transport
Static friction is generated between the material and the contact surface of the rotating drum, pushing the material to move at a uniform speed.Adjustable conveying speed (0.5-5m/s)The food industry often uses rubber-coated rollers to increase the coefficient of friction.
Stage 4: Smart Steering
Tapered roller sets (3-5cm difference in diameter) are used in the 90-degree turn area.Outer ring drum speed increase 20%Compensates for path differences and ensures that the material trajectory is not offset.

Industry pain point breakthroughFor easy to dump cylindrical materials (e.g. oil drums), increase the V-type guide groove and photoelectric sensor linkage to dynamically adjust the speed difference of the drum.

III. Intelligent Optimisation and Industry Application Mapping

Question: How can Industry 4.0 upgrade traditional roller lines?
Directions for technology integration:

Internet of Things (IoT) monitoring: Temperature and vibration sensors monitor the bearing condition in real time.Failure warning response <10 seconds(e.g. anti-stop lines for automotive welding lines).
Dynamic speed control systems: automatically reduces the speed of the no-load section according to the spacing of the materials detected by infrared.Energy saving rate up to 35%.
Modular designQuickly change different roller diameters (Φ38mm-89mm) to suit multiple scenarios of box/pallet/bulk crate switching.

Industry Adaptation Programme.

E-commerce logistics: Accumulation roller line for buffer storage of parcels, sorting efficiency >8,000 pieces/hour
Lithium battery production: Stainless steel roller + anti-static coating, eliminating metal friction sparks
Heavy machinery assemblyDouble sprocket drive + hydraulic lifting module to carry 10 tonne engine block

roller conveyor的价值远不止于”物料搬运”——它是柔性生产线的血脉，更是智能工厂的底层逻辑。当锥齿轮在弯道处精准啮合时，物理摩擦的原始力量已悄然进化为数据驱动的工业艺术。未来十年，模块化与AI自适应的结合或将重新定义”输送”的本质：从线性运动到系统思考。