Belt Conveyor System

Engineering Design Department
Belt Conveyor System

Design Manual

P age |1
Design Manual
Version 1.0
2011 February 23
Importance of the manual

The purpose of this document is to explain the function of the components and the
manner in which they should be applied and selected.
Foreword
Whilst the utmost care is taken to ensure the accuracy of the data and design
details contained herein, they are provided on the understanding that the company
shall under no circumstances be liable for any injuries, expenses or other losses
which may in any way be attributable to the use, or adoption, of such data and/or
design details.
AE Conveyors reserves the right to alter or amend, without prior notices, data and
design details specified herein.
Any comments regarding this document or requests for further copies should be
addressed to AE Conveyors.
UPDATE
Version
Status
Version
date
Sections
affected
1.0
First
release
23.02.2011
All

P age |2
Comments
Initial version
Changed by
Azuwan
Design Manual
Version 1.0
2011 February 23
Contents
Section
Product Introduction......................................................................... 1
Technical Descriptions..................................................................... 2
Accessories...................................................................................... 3
Product Application ........................................................................ 4
References....................................................................................... 5

P age |3
Design Manual
Version 1.0
2011 February 23
THIS PAGE IS INTENTIONALLY LEFT BLANK

P age |4
Design Manual
Version 1.0
2011 February 23
Section 1 Product Introduction

Contents
Heading
Page
Warnings, Cautions & Notes ................................................ 6
Product Improvements .......................................................... 6
Trademarks............................................................................ 6
Technical Queries.................................................................. 6
Abbreviations......................................................................... 7
Principles of Powered Roller Conveyor................................. 8
Selling Features..................................................................... 8
Module Overview................................................................... 8
Range of Modules ................................................................. 9
9.1
Level Belt............................................................................ 9
9.2
Live Roller & Accumaflow................................................... 9
9.3
Incline................................................................................. 10
9.4
Metering Belt ...................................................................... 10
9.5
Booster............................................................................... 11
9.6
Blade Stops........................................................................ 11
9.7
Roller Stops........................................................................ 11

P age |5
Design Manual
Version 1.0
2011 February 23
1 Warnings, Cautions & Notes

Warnings, Cautions and Notes are used in the
main body of text and are used to emphasise
important points. The instructions contained within
these highlighted areas must be adhered to.
WARNING
WARNINGS CALL ATTENTION TO
INSTRUCTIONS, WHICH MUST BE
FOLLOWED PRECISELY TO AVOID
INCREASING THE RISK OF INJURY
OR DEATH. BE SURE TO ACT
UPON EVERY ITEM LABELLED IN
THIS WAY
CAUTION
CAUTIONS CALL ATTENTION TO
INSTRUCTIONS WHICH MUST BE
FOLLOWED PRECISELY IN ORDER
TO AVOID DAMAGE TO THE
PRODUCT, THE PROCESS, OR IT'S
ENVIRONMENT.
Product Improvements
It is the policy of AE Conveyors, to be ever mindful

of improvements in product design, materials and
construction.
Consequently, this document is
issued on an unrestricted basis with the
understanding that the information presented may
be subject to amendment or change.
3 Trademarks
Throughout this manual trademark names are used.
TM
Rather than put a trademark symbol ( ) in every

occurrence of a trademark name, the author states
that the names are used only in an editorial fashion,
and to the benefit of the trademark owner with no
intention of infringement of the trademark.

P age |6
Design Manual
Version 1.0
2011 February 23
5 Abbreviations
AC
APR
BB
BDMS
BS
BZP
CE
cSt
DC
DTGP
ECA
ERW
FIFO
FILO
FLT
F/min
FWR
Hp
HPT
id
ISO
kg
kW
LH
M/min
mm
Nm
od
PBR
PEC
PLC
psi
PS
RH
RHS
RSA
RSC
RTV
SAE
SEMA
SUS
SWG
SWL
T/L
TOR
TOC
TTR
VG
WW
Alternating Current
Adjustable Pallet Racking
Back to Back dimensions (measured
between inside faces of side channels)
Bright Drawn MiId Steel.
British Standard
Bright Zinc Plated
Communaute Europeene
Centistrokes
Direct Current
Dust Tight Grease Packet (Bearing)
Electronics Corporation of America
Electrically Resistance Welded
First-In, First-Out
First-In, Last-Out
Fork Lift Truck
Feet per minute
Full Width Roller
Horsepower
Hand Pallet Truck
Inside diameter
International Standards Organisation
Kilogram
Kilowatt
Left Hand
Metres per minute
Millimetre
Newton metre
Outside diameter
Push Back Rack
Photo-Electric Cell
Programmable Logic Controller
Pounds per square inch
Proximity Sensor
Right Hand
Rolled Hollow Section
Rolled Steel Angle
Rolled Steel Channel
Retractable Trip Valve
Society of Automotive Engineers
Storage Equipment Manufacturers Association
Saybolt Universal Seconds (Lubrication)
Standard Wire Gauge
Safe Working Load
Taper Lock
Top of Roller (Height)
Top of Chain (Height)
Twin Track Roller
Viscosity Grade (ISO Lubricant Reference)
Working Width (Dimension)

P age |7
Design Manual
Version 1.0
2011 February 23
Principles of Powered Roller

Conveyor
Belt conveyor is a package handling conveyor

system for use with a wide range of load weights
or sizes up to 60kg per metre of belt. They are
particularly useful when a conveyor is required to
carry fragile loads.
Selling Features
The main selling features (those that distinguish

it from other package conveyors) are:
Accumulating goods at a loading bay.
Move goods whilst picking.
The system consists of a number of standard

modules, level belt, Incline/decline belt, live roller,
Accumaflow, booster and metering belt.
Low maintenance costs and high reliability.
The conveyor operates on a principle of driving

an endless belt through a series of rollers and
drive unit.
Low noise operation
Level, incline, decline, metering and booster belts

all use a BB - 50mm wide belt.
Live roller and Accumaflow use a 150mm wide
belt, which drives a number of rollers within the
bed section.
The belt conveyor system has the capability of a
single drive unit powering up to 30 metres of
conveyor.

P age |8
Wide range of load weights or sizes.
Designed for application where improved load

control and speed of operation are important
factors.
Module Overview
Level Belt
Live Roller & Accumaflow
Incline
Metering Belt
Booster
Blade Stops
Roller Stops
Error! Reference source not found.
Design Manual
Version 1.0
2011 February 23
9 Range of Modules
9.1 Level Belt
9.2 Live Roller & Accumaflow

P age |9
Design Manual
Version 1.0
2011 February 23
9.3 Incline
9.4 Metering Belt

P a g e | 10
Design Manual
Version 1.0
2011 February 23
9.5 Booster
9.6 Blade Stops
9.7 Roller Stops

P a g e | 11
Design Manual
Version 1.0
2011 February 23

P a g e | 12
Design Manual
Version 1.0
2011 February 23
Section 2 Technical Descriptions

Contents
Heading
Page
Intended Use..................................................................................... 18
Incorrect Use..................................................................................... 18
Level Belt - Centre Drive................................................................... 20
3.1
Fixed Speeds............................................................................... 20
3.2
Available Lengths......................................................................... 20
3.3
Roller Pitch (Roller Bed Only).......................................................20
3.4
Belt............................................................................................... 20
Level Belt End Drum Drive............................................................. 21
4.1
Belt............................................................................................... 21
4.2
Fixed Speeds................................................................................21
4.3
4.4
Roller Pitch (Roller Bed Only)...................................................... 21
Incline Belt......................................................................................... 22
5.1
Angle of Incline............................................................................. 22
5.2
Height (Lift)................................................................................... 22
5.3
Fixed Speeds............................................................................... 22
5.4
5.5
Incline Sections............................................................................ 22
Feeder Bed Assembly................................................................ 23
6.1
Description .................................................................................. 23
6.2
Feeder Lengths............................................................................ 23
6.3
Belt............................................................................................... 23
6.4
Assembly...................................................................................... 24
6.5
End Terminals.............................................................................. 24
6.6
Feeder Unit .................................................................................. 24
Incline Section............................................................................... 25
7.1

P a g e | 13
Description .................................................................................. 25
Design Manual
Version 1.0
2011 February 23
Heading
Page
7.2
Centre Drive Unit.......................................................................... 25
7.3
Braked Motors.............................................................................. 25
7.4
Belt .............................................................................................. 25
Top Curve Bed Assembly ................................................................ 26
8.1
Description .................................................................................. 26
8.2
Bed Section.................................................................................. 26
8.3
End Terminals.............................................................................. 27
Booster Conveyor ............................................................................ 28
9.1
Description .................................................................................. 28
9.2
End Drum Drive........................................................................... 28
9.3
Angle of Incline............................................................................. 28
9.4
Fixed Speeds ...............................................................................29
9.5
9.6
9.7
Belt .............................................................................................. 29
10
Live Roller Centre Drive................................................................. 30
10.1
Fixed Speeds .............................................................................. 30
10.2
10.3
Roller Pitch................................................................................... 30
10.4
Belt .............................................................................................. 30
11
Live Roller End Drum Drive............................................................ 31
11.1
Fixed Speeds ...............................................................................31
11.2
11.3
Roller Pitch................................................................................... 31
11.4
Belt .............................................................................................. 31
12
Accumaflow Centre Drive.............................................................. 32
12.1
Fixed Speeds ...............................................................................32
12.2
12.3
Roller Pitch................................................................................... 32
12.4
Belt .............................................................................................. 32
13
Accumaflow End Drum Drive......................................................... 33

P a g e | 14
Design Manual
Version 1.0
2011 February 23
Heading
Page
13.1
Fixed Speeds ...............................................................................33
13.2
13.3
Roller Pitch................................................................................... 33
13.4
Belt .............................................................................................. 33
14
Metering Belt .................................................................................... 34
14.1
Fast Belt....................................................................................... 34
14.2
Brake Belt..................................................................................... 34
14.3
Speeds ........................................................................................ 34
15
End Terminal Unit..............................................................................35
15.1
Available Widths........................................................................... 35
16
End Terminal Unit (Square Nose)..................................................... 36
17
Live Roller/Accumaflow End Terminal Unit....................................... 37
18
End Terminal Unit (Round Nose)...................................................... 38
19
Centre Drive Unit............................................................................... 40
19.1
Description ...................................................................................40
19.2
Motors...........................................................................................40
19.3
Fixed Speeds ...............................................................................40
19.4
Chain Drive .................................................................................. 40
19.5
19.6
Snubs and Tension Rollers.......................................................... 41
19.7
Drive Pulley.................................................................................. 41
19.8
Guarding ...................................................................................... 41
20
High Speed Centre Drive Unit........................................................... 43
20.1
Description ...................................................................................43
20.2
Motors...........................................................................................43
20.3
Fixed Speeds ...............................................................................43
20.4
Pulley Drive.................................................................................. 43
20.5
21
End Drum Drive................................................................................. 46
21.1

P a g e | 15
Description ...................................................................................46
Design Manual
Version 1.0
2011 February 23
Heading
Page
21.2
Motor Unit..................................................................................... 46
21.3
Fixed Speeds ...............................................................................46
21.4
Snub Roller .................................................................................. 46
22
Metering Belt Drive Unit ................................................................... 48
22.1
Dive Unit....................................................................................... 48
22.2
Pulleys.......................................................................................... 48
22.3
Speeds ........................................................................................ 48
22.4
Chain Drive .................................................................................. 48
22.5
Available Widths.......................................................................... 48
23
Feeder Unit ...................................................................................... 50
23.1
Feeder Unit .................................................................................. 50
23.2
Snub Roller .................................................................................. 50
23.3
24
Top Curve Unit ................................................................................. 52
24.1
Description .................................................................................. 52
24.2
24.3
Angle of Incline............................................................................. 52
24.4
Snub Roller .................................................................................. 52
25
Tensioners......................................................................................... 54
25.1
Underslung Tensioner.................................................................. 54
25.2
Integral Tensioner ....................................................................... 54
25.3
Lengths ........................................................................................ 54
25.4
25.5
Facia ............................................................................................ 54
26
Bed Sections .................................................................................... 57
26.1
Mono Bed..................................................................................... 57
26.2
26.3
26.4
Rollers ......................................................................................... 57
26.5
Roller Bed .................................................................................... 58
26.6

P a g e | 16
Design Manual
Version 1.0
2011 February 23
Heading
Page
26.7
26.8
Rollers ......................................................................................... 58
26.9
Live Roller ....................................................................................59
26.10
26.11
26.12
Rollers ......................................................................................... 59
26.13
Accumaflow.................................................................................. 60
26.14
26.15
26.16
Rollers ......................................................................................... 60
26.17
Line Pressure............................................................................... 60

P a g e | 17
Design Manual
Version 1.0
2011 February 23
1 Intended Use
2 Incorrect Use
Belt conveyor is a package handling conveyor

system for use with dry cardboard packages /
boxes, plastic based products or tote bins up to a
maximum weight of 60kg per metre. Ideal for
handling fragile loads or a wide range of load
weight or sizes and is designed for applications
where improved load control and speed of
operation are important factors.
The belt ranges of conveyors are not suitable for

handling products or chemicals of an aggressive
nature (e.g. acids).
WARNING
THE BELT RANGE OF POWER
CONVEYORS IS DESIGNED FOR
PACKAGE HANDLING, (I.E. TO BE
LOADED BY HAND) AND SHOULD
NOT
UNDER
NORMAL
CONDITIONS BE LOADED BY
HAND BEYOND 25KG PER LOAD
WARNING
BELT
CONVEYORS
ARE
NOT
SUITABLE TO BE WALKED UPON.
DOING SO MAY RESULT IN SEVERE
PERSONAL INJURY. PERSONNEL
GATES OR STEP OVER GANTRYS
SHOULD
BE
USED
WHEN
CROSSING A CONVEYOR
The conveyor operates on the principle of being

able to drive a belt from a single motor drive unit
up to a variable length depending upon load (drive
unit can power up to 333 kg maximum).
Choose from a range of level belt, incline belt, or
belt driven roller conveyors to suit your
application. Level belt conveyors and belt driven
roller conveyors are for the horizontal
transportation of items and assembly line
operations. Incline belt conveyors are used to
deliver packages or boxes from one floor to
another and when fitted with a reversing control
can operate in either direction.
Belt speeds available are 9, 14, 18, 24, 30, 42, 52,
58, 72 and 85 metres per minute.

P a g e | 18
Design Manual
Version 1.0
2011 February 23

P a g e | 19
Design Manual
Version 1.0
2011 February 23
Level Belt - Centre Drive
Fig. DM2.1 Level Belt Centre Drive

As can be seen from the illustration the conveyor
consists of 3 basic units:
Centre Drive Unit
End Terminal Unit
Bed Sections (Mono Bed & Roller Bed)
Refer to the dedicated sections for detailed

technical information on the above units.
The drive and tension unit can be mounted
beneath any 1.0 (Mono Bed), 1.5, 2.0, 2.5 or 3.0
metre bed section. The shortest standard overall
conveyor length including the two end terminal
units, (each 250mm long) is 1.5 metres (Mono
Bed) or 2.0 metres (Roller Bed). Standard
intermediate bed sections of 1.0 (Mono Bed only),
1.5, 2.0, 2.5 and 3.0 metre are available.
3.1
Fixed Speeds
9, 14, 18, 24, 30, 42, 52, 58, 72 and 85

metres/minute
3.2 Available Lengths
Overall conveyor lengths of 2.0, 2.5, 3.0, 3.5, 4.0,
4.5, 5.0 metre etc., in 0.5 metre increments to 30
metres
3.3 Roller Pitch (Roller Bed Only)
250mm Pitch
3.4 Belt
The standard transmission belt is a 2-ply
polyester backed, PVC top coated belt 3mm thick
Belt width is BB - 50mm

P a g e | 20
Design Manual
Version 1.0
2011 February 23
Level Belt End Drum Drive
Fig. DM2.2 - Level Belt (End Drum Drive)
End Terminal Unit
Underslung Tensioner

The end drum drive is mounted at one end of the
conveyor and an end terminal at the other. An
underslung tensioner is mounted beneath the
conveyor bed to accommodate belt tensioning.
The shortest standard overall conveyor length
including the end terminal and end drive unit,
(each 250mm long) is 1.5 metres (Mono Bed) or
2.0 metres (Roller Bed). Standard intermediate
bed sections of 1.0 (Mono Bed only), 1.5, 2.0, 2.5
and 3.0 metre are available
4.2
Fixed Speeds
15, 18 and 21 metres/minute

4.3
Available Lengths

metre etc., in 0.5 metre increments to a maximum
of 10 metres.
4.4
Roller Pitch (Roller Bed Only)
250mm Pitch
4.1
Belt

polyester
uncoated
transparent
low-noise
underside, hard black PVC top coated belt 2.2
0.20mm thick
Belt width is BB - 50mm.

P a g e | 21
Design Manual
Version 1.0
2011 February 23
Incline Belt
Fig. DM2.3 - Incline Belt

Centre Drive Unit (Braked)
End Terminal Units
Top Curve Bed Assembly
Feeder Bed Assembly

Inclined belt conveyors are used to deliver
packages or boxes from one floor to another and
when fitted with a reversing control can operate in
either direction. They can be used as standalone units or as integrated elements of a
conveyor system.
5.1
Angle of Incline
o
Angles available: fully adjustable between 0 up to

o
30 .
5.2
Height (Lift)
The difference in height between the feeder and

top curve sections is referred to as the lift. Inclined
belt conveyors come in 1.5m to 6m lifts, in 0.25m
increments. The dimension between the floor and
the top of the feeder section belt is termed as the
infeed height, whereas the dimension to the top
curve belt is termed outfeed height.
5.3
Fixed Speeds
9, 14, 18, 24, 30, 42, 52, 58, 72 and 85

metres/minute
5.4
250mm Pitch
5.5
Incline Sections
A complete incline belt conveyor is made up from

three separate sections: Feeder, Inclined Belt and
Top Curve. The following pages outline the
characteristics of each section.

P a g e | 22
Design Manual
Version 1.0
2011 February 23
Feeder Bed Assembly
Fig. DM2.4 - Feeder Bed Assembly

6.1
Description
A short, level length of belt conveyor that prevents

the trailing edge of loads from bumping across
rollers as the leading edge climbs the inclined belt.
It comprises of an end terminal unit, a tension unit
and a feeder unit. This unit is split into two halves,
one half connected to the level portion, the next
(which is adjustable in angle) connects to the
Inclined Belt. A normal smooth top belt travels
along the length of the feeder section, returning
back underneath.
The feeder unit can be adjusted for any angle up
to 30, there is no handing of the feeder therefore
the chain guard can be positioned on the side
most convenient on site.
An integral or underslung tension unit is fitted to

the feeder section to allow belt tensioning.
6.2
Feeder Lengths
1000mm (300 500BB), 1500mm and 2000mm

6.3
Belt

polyester
uncoated
transparent
low-noise
0.20mm thick
Belt width is BB - 50mm.

P a g e | 23
Design Manual
Version 1.0
2011 February 23
Fig. DM2.5 Feeder Bed Assembly Lengths

6.4
Assembly
The feeder bed assembly is assembled with a

tensioned vulcanised belt and only requires
bolting to the bed section of the incline.
Sprockets/pulleys are installed on the side of the
feeder unit as shown in the above figure. If you
require the sprockets/pulleys to be installed on the
opposite side (access for maintenance due to
obstructions) please state when ordering the
assembly.
6.5
End Terminals
Two types of end terminals are available and can

be ordered for each length of assembly.
1.
Round Nose:
2.
Square Nose:
6.6
Feeder Unit
Two types of feeder unit are available and can be

ordered for each length of assembly.
1.
Feeder unit with sprocket and chains
2.
Feeder unit with pulleys and timing belt

P a g e | 24
Design Manual
Version 1.0
2011 February 23
Incline Section
Fig. DM2.6 Incline Section

7.1
Description
The actual part of the conveyor that allows the

load to gain height, travelling on a high grip belt.
This section is made up of a number of bed
sections (available in standard sizes), connected
to the feeder section via the second half of the
actual feeder unit, and to the top curve section
via the first half of the top curve unit. The bed
sections are joined together using splice plates.
7.2
Centre Drive Unit
A centre drive is attached beneath the bed

sections, through which the returning loadcarrying belt is threaded, providing motive power
for the conveyor. This drive is transferred to the
separate belt on the feeder section by use of a
transmission chain looped across the two halves
7.3
Braked Motors
The centre drive unit must be fitted with an

electromagnetic braked motor. These are fitted
to prevent overrun on a declined belt or run back
on an inclined belt when the electrical power is
removed. The brakes are made with a friction
disc on the extended motor shaft. When the
current is off, it is held stationary by a pressure
plate under heavy coil spring tension. When the
current is on, electro magnets retract the
pressure plate and compress the springs so that
the disc can turn freely without a drag on the
motor. Adjustment for tension and wear is made
via an external lever.
7.4
Belt
The incline section uses a high grip 2-ply

polyester belt, which has a black longitudinal
groove profile top surface, and a transparent
fabric finish underside belt 3.1 0.20mm thick.
The belt must be installed with the fabric surface
facing downwards.
The belt joint may be
vulcanised or fitted with the standard hook
fasteners (as Level Belt Conveyors).
Belt width is BB - 50mm

P a g e | 25
Design Manual
Version 1.0
2011 February 23
Top Curve Bed Assembly
Fig. DM2.7 - Top Curve Assembly

8.1
Description
Top Curve Section is used to bring the load back

to a level attitude after completing the transition
from an inclined position. The top curve section
comprises of a top curve unit connected to an end
terminal unit identical to that found at the feeder
section. The top curve unit itself is adjustable in
angle between 0 and 30 and comprises of two
halves similar to the feeder unit. However, unlike
the feeder section, this does not have a separate
load-carrying belt. In this instance, the belt
travelling up the inclined section is extended
around the top curve bed assembly, returning
down to the drive unit.
8.2
Bed Section
A bed section is fitted in between the Top Curve

and the End Terminal when using a top curve
length of 990mm or above. The bed section can
be either roller bed or mono bed.

P a g e | 26
Design Manual
Version 1.0
2011 February 23
Fig. DM2.8 Top Curve Bed Assembly

Lengths
8.3
End Terminals
Two types of end terminals are available and can

be ordered for each length of assembly.
1. Round Nose:
2. Square Nose:

P a g e | 27
Design Manual
Version 1.0
2011 February 23
Booster Conveyor
Fig. DM2.9 - Booster Conveyor

Centre Drive Unit or End Drum Drive
End Terminal Unit

9.1
Description
The booster conveyor is a level belt inclined at an

angle of 15 with the addition of a bottom and top
coupling unit.
These units assist the transfer of packages onto

and off the booster conveyor with the aid of a 35
dia. pop out roller. Primarily booster conveyors
are used to regain height lost in a gravity run,
they can only be used as inclines.
Boosters may be driven using a centre drive unit,
positioned below the conveyor (see illustration),
or an end drum drive.
9.2
End Drum Drive
The end drum drive is mounted at the top end of

the conveyor and an end terminal at the other
when using an end drum drive. An underslung
tensioner is mounted beneath the conveyor bed
to accommodate belt tensioning.
9.3
Angle of Incline
15 Degrees

P a g e | 28
Design Manual
Version 1.0
2011 February 23
9.4
Fixed Speeds
Centre Drive 9, 14, 18, 24, 30, 42, 52, 58, 72 and
85 metres/minute
End Drum Drive 15, 18 and 21 metres/minute
9.5
Available Lengths
Overall conveyor lengths of up to a maximum of

6.0 metres at 0.5m increments. (refer to table
opposite for available lengths)
9.6
250mm Pitch
9.7
Belt

polyester
uncoated
transparent
low-noise
0.20mm thick
Fig. DM2.10 - Booster Conveyor (key

Dimensions)

P a g e | 29
Design Manual
Version 1.0
2011 February 23
10 Live Roller Centre Drive
Fig. DM2.11 - Live Roller (Centre Drive)

Live roller conveyors consist of a roller bed driven
by a belt operating on the underside of the rollers.
Therefore, the belt will always travel in the
opposite direction to the required package flow.
The live roller conveyor consists mainly of three
basic modules: Centre Drive Unit
10.1 Fixed Speeds
End Terminal Unit
9, 14, 18, 24, 30, 42, 52, 58, 72 and 85

metres/minute
Bed Sections
beneath any 1.5, 2.0, 2.5 or 3.0 metre bed
section. The shortest standard overall conveyor
length including the two end terminal units, (each
250mm long) is 2.0 metres. Standard
intermediate bed

metres
10.3 Roller Pitch
83, 125 and 250mm Pitch
10.4 Belt
polyester
uncoated
transparent
low-noise
0.20mm thick
Belt width is 150mm

P a g e | 30
Design Manual
Version 1.0
2011 February 23
11 Live Roller End Drum Drive
Fig. DM2.12 - Live Roller (End Drum Drive)

Live roller conveyors consist of a roller bed driven
by a belt operating on the underside of the rollers.
Therefore, the belt will always travel in the
opposite direction to the required package flow.
The live roller conveyor consists mainly of four
basic modules: End Drum Drive
End Terminal Unit
11.1 Fixed Speeds
Bed Sections


of 10 metres.
The end drum drive is mounted at the back of the

conveyor and an end terminal at the front in
relation to the direction of travel (refer to above
figure). An underslung tensioner is mounted
beneath the conveyor bed to accommodate belt
tensioning. The shortest standard overall
conveyor length including the end terminal and
end drive unit, (each 250mm long) is 2.0 metres.
Standard intermediate bed sections of 1.5, 2.0,
2.5 and 3.0 metre are available.
11.3 Roller Pitch

83, 125 and 250mm Pitch
11.4 Belt
polyester
uncoated
transparent
low-noise
0.20mm thick
Belt width is 150mm

P a g e | 31
Design Manual
Version 1.0
2011 February 23
12 Accumaflow Centre Drive
Fig. DM2.13 - Accumaflow (Centre Drive)

In all aspects, the Accumaflow Conveyor is
identical to Live Roller except for the bed section.
Refer to bed section details for principle of
operation. The end terminal unit is a live roller unit
and does not have any accumulation feature. The
Accumaflow conveyor consists mainly of three
basic modules: Centre Drive Unit
End Drum Drive
Bed Sections
beneath any 1.5, 2.0, 2.5 or 3.0 metre bed section.
The shortest standard overall conveyor length
including the two end terminal units, (each
250mm long) is 2.0 metres. Standard
intermediate bed sections of 1.5, 2.0, 2.5 and 3.0
metre are available.
12.1 Fixed Speeds
9, 14, 18, 24, 30, 42, 52, 58, 72 and 85
metres/minute

P a g e | 32

metres
12.3 Roller Pitch
83 and 167mm Pitch
12.4 Belt
polyester
uncoated
transparent
low-noise
0.20mm thick
Belt width is 150mm
Design Manual
Version 1.0
2011 February 23
13 Accumaflow End Drum Drive
Fig. DM2.14 - Accumaflow (End Drum Drive)

In all aspects, the Accumaflow Conveyor is
identical to Live Roller except for the bed section.
Refer to bed section details for principle of
operation (refer to above figure).
The end
terminal unit is a live roller unit and does not have
any accumulation feature.
The Accumaflow
conveyor consists mainly of four basic modules: End Drum Drive
End Terminal Unit
Bed Sections
The end drum drive is mounted at the back of the
conveyor and an end terminal at the front in
relation to the direction of travel. An underslung
tensioner is mounted beneath the conveyor bed to
accommodate belt tensioning.
The shortest
standard overall conveyor length including the end
terminal and end drive unit, (each 250mm long) is
2.0 metres. Standard intermediate bed sections
of 1.5, 2.0, 2.5 and 3.0 metre are available
13.1 Fixed Speeds

9, 14, 18, 24, 30, 42, 52, 58, 72 and 85
metres/minute
of 10 metres.
13.3 Roller Pitch
83 and 167mm Pitch
13.4 Belt
polyester
uncoated
transparent
low-noise
0.20mm thick
Belt width is 150mm

P a g e | 33
Design Manual
Version 1.0
2011 February 23
14 Metering Belt
Fig. DM2.15 - Metering Belt

consists of 4 basic units:Metering Belt Drive Unit
End Terminal Unit
Tensioners
Bed Sections (Mono bed only)
14.1 Fast Belt

The fast belt is 1.0m (300BB to 500BB) or 1.5m
(600BB & 800BB) in length, achieved by
connecting a Tension Unit (500mm or 1000mm)
between the End Terminal Unit (250mm) and one
half of the Drive Unit (500mm / 2). It is fitted with
a standard transmission belt 2-ply polyester
uncoated transparent low-noise underside, hard
black PVC top coated belt 2.2 0.20mm thick
14.2 Brake Belt
A complete metering belt conveyor is made up

from two separate sections: Brake Belt and Fast
Belt. As these names suggest, there are two
speeds to this conveyor, which are achieved
using a single drive unit. This drive unit provides
motive power to the end of each section via a
chain and sprockets of different sizes, resulting in
a speed increase. This feature has the effect of
separating loads that are travelling nose to tail
across the conveyor. This is enhanced by the use
of two different belt types, one with higher grip
characteristics than the other.
There are various overall lengths of metering belts
available, giving different fast and slow belt length
combinations. Each combination is constructed of
a number of standard units: End Terminal units at
each end a Drive Unit in the centre, Tension
Unit(s) and Bed sections. Standard bed sections
of 1.0, 1.5, 2.0, 2.5 and 3.0 metres are available.
The brake can be a minimum length of 1.0m

(300BB to 500BB) or 1.5m (600BB & 800BB),
constructed identically to the fast belt. Other
lengths, in 0.5m increments up to 4.5m, are
achieved by connecting a bed section(s) between
the End Terminal Unit and the other half of the
Drive Unit. All length configurations above 1.5m
have an underslung Tension Unit designed to be
bolted below the bed section(s). It is fitted with a
The standard high grip profile belt is a 2-ply
polyester belt with a black longitudinal groove
profile top surface, and a transparent fabric finish
underside belt 3.1 0.20mm thick. The belt must
be installed with the fabric surface facing
downwards.
14.3 Speeds
Brake Belt -9,
metres/minute
14,
18.5,
24
and
27.5
Fast Belt - 14, 21, 27.5, 35 and 40metres/minute

P a g e | 34
Design Manual
Version 1.0
2011 February 23
15 End Terminal Unit
Fig. DM2.16 - End Terminal Unit

As can be seen from the illustration End Terminal
units come in three basic units:End Terminal Unit (Square Nose)
Refer to the following pages for detailed

dimensions for each type of end terminal shown
in the above illustration.
End Terminal Unit (Round Nose)

Live Roller/Accumaflow End Terminal Unit
In all cases, the end terminal unit consists of a
75mm diameter terminal pulley, which is the same
component as used on the centre drive/tension
unit and a 50mm diameter snubbing roller. This
snubbing roller has a wall thickness of. 3.2mm
and is fitted with a precision bearing.
The
snubbing roller provides a tracking facility via
adjusting brackets.
15.1 Available Widths
300, 400, 450, 500, 600 and 800BB

P a g e | 35
Design Manual
Version 1.0
2011 February 23
16 End Terminal Unit (Square Nose)

Bolted to each end of the conveyor length on the
following conveyors:Level Belt
Booster Belt
Metering Belt
Incline/Decline Belt
Fig. DM2.17 - End Terminal Unit (Square Nose)

- Key Dimensions

P a g e | 36
Design Manual
Version 1.0
2011 February 23
17 Live Roller/Accumaflow End

Terminal Unit
Bolted to each end of the conveyor length on the
following conveyors:
Live Roller
Accumaflow
Fig. DM2.18 - Live Roller/Accumaflow End

Terminal Unit - Key Dimensions

P a g e | 37
Design Manual
Version 1.0
2011 February 23
18 End Terminal Unit (Round Nose)

Bolted to the end of a belt conveyor system on the
following conveyors:
Level Belt
Incline / Decline Belt
Fig. DM2.19 - End Terminal Unit (Round Nose)

- Key Dimensions

P a g e | 38
Design Manual
Version 1.0
2011 February 23

P a g e | 39
Design Manual
Version 1.0
2011 February 23
19 Centre Drive Unit
Fig. DM2.20 - Centre Drive Unit

19.1 Description
19.3 Fixed Speeds
A centre drive is attached beneath the bed

sections, through which the returning loadcarrying belt is threaded, providing motive power
for the conveyor. Either a 0.75 kW, 1.5 kW or
1.5kW high speed motor is used with in line
helical spur gear box. The geared motor unit
gives an output speed of 43rpm and is coupled to
the drive pulley via a precision chain drive. Incline
Belt Conveyors: in addition, are fitted with an
electromagnetic braked motor. These are fitted to
prevent overrun on a declined belt or run back on
an inclined belt.
The following speeds are available for both

0.75kW and 1.5kW.
19.2 Motors
19.4 Chain Drive
The motors used are suitable for an electrical

supply of 415 volts, 3 phase, 50 Hertz. It is very
important to obtain full details of the customers
supply especially overseas where not only is the
voltage different but it can also be 60 Hertz. In
addition, the working conditions are also important.
Refer to application section.
This is a 1/2" pitch duplex transmission chain.
9, 14, 18, 24 and 30 metres/minute

These speeds are achieved by changing the
sprockets on the geared motor and headshaft.
For speeds outside this range, it is necessary to
change the geared motor. If this is the case, the
Design Department at Gainsborough should be
consulted. For sprocket combinations refer to
Table. DM2.1

300, 400, 450, 500, 600 and 800BB

P a g e | 40
Design Manual
Version 1.0
2011 February 23
19.6 Snubs and Tension Rollers
19.8 Guarding
The 75mm diameter rollers have precision

bearings pressed in to each end for a 30mm
diameter fixed shaft to pass through. The tension
pulley is adjustable in its position and has 360mm
of adjustment.
Chain Guard -This is a one-piece guard, which fits

over the driving chain totally enclosing all the
working, parts.
Bearing Guard -Fitted on the opposite side to the
chain guard giving protection from rotating shafts.
19.7 Drive Pulley

The 230mm effective diameter (723mm
circumference) pulley has a crowned outer
surface to assist belt tracking and is lagged to
ensure maximum transmission of power to the
belt. The pulley together with an integral 35mm
diameter shaft revolves in precision bearings
fixed to the drive side plates.
For dimensions for removal of guards refer to Fig.

DM2.21 - Centre Drive Unit - Key Dimensions
Table. DM2.1

P a g e | 41
Design Manual
Version 1.0
2011 February 23
Fig. DM2.21 - Centre Drive Unit - Key

Dimensions

P a g e | 42
Design Manual
Version 1.0
2011 February 23
20 High Speed Centre Drive Unit
Fig. DM2.22 High Speed Centre Drive Unit

20.1 Description
20.3 Fixed Speeds
High speed drive units use a timing belt drive

system rather than a sprocket and chain. Other
than the drive system the centre drive is Identical
to the standard drive unit with only a 1.5kW
geared motor option. The geared motor unit gives
an output speed of 124 rpm and is coupled to the
drive pulley via a timing belt drive.
The following speeds are available for 1.5kW.
20.2 Motors
The motors used are suitable for an electrical
supply of 415 volts, 3 phase, 50 Hertz. It is very
important to obtain full details of the customers
supply especially overseas where not only is the
voltage different but it can also be 60 Hertz. In
addition, the working conditions are also important.
Refer to application section.
42, 52, 58, 72 and 85 metres/minute

These speeds are achieved by changing the
pulleys on the geared motor and headshaft. For
speeds outside this range, it is necessary to
change the geared motor. If this is the case, the
Design Department at Gainsborough should be
consulted. For pulley combinations refer to Table.
DM2.2
20.4 Pulley Drive
14mm pitch x 20mm wide Polychain sprockets.
300, 400, 450, 500, 600 and 800BB

P a g e | 43
Design Manual
Version 1.0
2011 February 23
Table. DM2.2

P a g e | 44
Design Manual
Version 1.0
2011 February 23
Fig. DM2.23 High Speed Centre Drive Unit Key Dimensions

P a g e | 45
Design Manual
Version 1.0
2011 February 23
21 End Drum Drive
Fig. DM2.24 - End Drum Drive

21.1 Description
21.4 Snub Roller
The end drive is of a bolted construction

incorporating underguarding and finger guards.
Roller Tube: 50mm dia 3.2mm wall thickness,

mild steel tube zinc plated
21.2 Motor Unit
Bearing:
Precision
0.18 kW motorised drum, which is crowned to

assist with belt tracking.
Axle:
11mm A/F hexagonal steel bar.

Axle is sprung loaded both ends.
21.3 Fixed Speeds

The following speeds are available:

P a g e | 46
Design Manual
Version 1.0
2011 February 23
Fig. DM2.25 - End Drum Drive - Key

Dimensions
Fig. DM2.26 - End Drum Drive (Live Roller) Key Dimensions

P a g e | 47
Design Manual
Version 1.0
2011 February 23
22 Metering Belt Drive Unit
Fig. DM2.27 - Metering Belt Drive Unit

22.1 Dive Unit
22.3 Speeds
A 0.75kW geared motor drives both brake belt

and fast belt. For applications with up to 20
stop/starts per min, a brake motor is fitted. For
applications above 20 stop/starts per min, please
consult engineering department
Belt speeds given are based on the use of 17T

and 25T sprockets on pulleys (refer to Fig.
Metering Belt Drive Unit - Key Dimensions). This
ratio will generate a small (50% of load length)
gap between loads, which may be detected by
photoelectric cell arranged at the delivery end.
22.2 Pulleys
The drive unit is fitted with two 75mm diameter
lagged drive pulleys
There is a single motor rating available: 0.75kW,

with five speeds: See table below
22.4 Chain Drive
This is a 1/2" pitch duplex transmission chain.

300, 400, 450, 500, 600 and 800BB

P a g e | 48
Design Manual
Version 1.0
2011 February 23
Fig. DM2.28 - Metering Belt Drive Unit - Key

Dimensions

P a g e | 49
Design Manual
Version 1.0
2011 February 23
23 Feeder Unit
Fig. DM2.29 - Feeder Unit

23.1 Feeder Unit
23.1.3 Angle
23.1.1 Chain and Sprockets
The feeder unit can be adjusted for any angle up

to 30, there is no handing of the feeder therefore
the chain guard can be positioned on the side
most convenient on site.
The unit consists of two 75mm diameter drive

pulleys whose shafts run in bearings mounted on
the feeder side plates.
A 17 Tooth duplex
sprocket is fitted to each shaft and a duplex chain
drive transmits the power from the belt driving the
pulley on the inclined section to the feeder pulley,
giving drive to the feeder belt.
23.2 Snub Roller

50 diameter snub roller with a 3.2mm wall
thickness and is fitted with precision bearings.
300, 400, 450, 500, 600 and 800BB
23.1.2 Timing Belt and Pulley

The unit consists of two 75mm diameter drive
pulleys whose shafts run in bearings mounted on
the feeder side plates. A 32 Teeth timing belt
pulley is fitted to each shaft and an 8M timing belt
drive transmits the power from the belt driving the
pulley on the inclined section to the feeder pulley,
giving drive to the feeder belt.

P a g e | 50
Design Manual
Version 1.0
2011 February 23
Fig. DM2.30 - Feeder Unit - Key Dimensions

P a g e | 51
Design Manual
Version 1.0
2011 February 23
24 Top Curve Unit
Fig. DM2.31 - Top Curve Unit

24.1 Description
24.4 Snub Roller
Having conveyed packages from a horizontal

plane and up an incline, it is desirable to bring the
conveyor back to the horizontal plane again and
for this reason, a top curve is used. The unit,
which is bolted to the last bed section, is made
from two pairs of side plates, which in turn locates
4 bed and 2 return rollers. The side plates are
hinged in the middle to allow for angular
adjustment up to 30. On one side, the rollers are
mounted in adjustable brackets to allow for
tracking. The top curve is bolted directly to an end
terminal unit (490mm only) or a bed section of
varying length (500, 1000, 1500mm).
6 off 50 diameter snub roller with a 3.2mm wall

thickness and are fitted with precision bearings.
Roller Dimensions
4 top snub rollers are BB - 112mm
2 bottom snub roller are BB - 3mm

300, 400, 450, 500, 600 and 800BB
24.3 Angle of Incline
o
Angles available: up to 30 .

P a g e | 52
Design Manual
Version 1.0
2011 February 23
Fig. DM2.32 - Top Curve Unit - Key Dimensions

P a g e | 53
Design Manual
Version 1.0
2011 February 23
25 Tensioners
Fig. DM2.33 - Tension Units

25.1 Underslung Tensioner
This unit is 500mm long and available in standard
Back to Back. It comprises of two 90mm deep
channels with four 80mm diameter tension rollers,
2 fixed and 2 adjustable giving a maximum belt
tensioning of 208mm. The unit is fixed
underneath the conveyor bed section to the
bottom flange of the channel with 8 off M8 x
20mm Hex Head Setscrews.
25.2 Integral Tensioner
The horizontal feeder of an incline conveyor has
an integral tension unit 500mm long on 300, 400,
450 and 500mm wide conveyors. The unit
comprises of two 180mm deep channels with four
80mm diameter tension rollers 2 fixed and 2
adjustable giving a maximum belt tensioning of
208mm. The tensioner is bolted between the
power feeder and an end terminal unit refer to Fig.
DM2.35 - Integral Tension Unit - Key Dimensions
25.3 Lengths
500mm long (Integral unit for 300 to 500BB feeder
sections)
500mm long (Underslung unit for 300 to 800BB)
300, 400, 450, 500, 600 and 800BB
25.5 Facia
The underslung tensioner accepts standard 90mm
deep facia. The integral tensioner is finished off
with standard 140mm deep facia.
600BB & 800BB feeder sections use the

underslung tensioners mounted beneath a
1000mm frame.

P a g e | 54
Design Manual
Version 1.0
2011 February 23
Fig. DM2.34 - Underslung Tension Unit - Key

Dimension

P a g e | 55
Design Manual
Version 1.0
2011 February 23
Fig. DM2.35 - Integral Tension Unit - Key

Dimensions

P a g e | 56
Design Manual
Version 1.0
2011 February 23
26 Bed Sections
Fig. DM2.36 - Monobed Panel - Bed Section

26.1 Mono Bed
26.4
Rollers
Conveyor frames are made from cold formed

90mm x 35mm x 2.5mm thick painted steel
channels. Monobed panels are 500mm long and
are made from 1.6mm thick zinc plated steel, and
are fitted within the frames. Return rollers are
35mm diameter x 1.2mm wall thickness with
precision bearings.
They are placed in the
conveyor every 1000mm.
Return Rollers
Roller Tube:
35mm dia 1.2mm wall thickness,

Bearing:
Precision
Axle:


Standard bed lengths of 1.0, 1.5, 2.0, 2.5 and 3.0
metres.
300, 400, 450, 500, 600 and 800BB

P a g e | 57
Design Manual
Version 1.0
2011 February 23
Fig. DM2.37 - Rollerbed - Bed Section

26.5 Roller Bed
26.8 Rollers
Conveyor frames are made from cold-formed

channels. The load bearing rollers are 50mm
diameter x 1.5mm wall thickness. These are fitted
with precision bearings and are rated at
100kg/roller. They are placed in the conveyor
every 250mm pitch as standard. Return rollers
are 35mm diameter x 1.2mm wall thickness with
precision bearings.
They are placed in the
conveyor every 1000mm.
Bed Rollers
Roller Tube:

Bearing:
Precision
Axle:

Return Rollers
Standard bed lengths of 1.5, 2.0, 2.5 and 3.0
metres.
300, 400, 450, 500, 600 and 800BB

P a g e | 58
Roller Tube:

Bearing:
Precision
Axle:

Design Manual
Version 1.0
2011 February 23
Fig. DM2.38 - Live Roller - Bed Section

26.9 Live Roller
26.12
Rollers
Conveyor frames are made from cold-formed

channel sections with "pop out" slots punched at
41.46mm pitch in the web and top flanges. The
bed rollers are 50mm diameter x 1.5mm wall
thickness.
These are fitted with precision
bearings and are rated at 100kg/roller. They are
placed in special pop out slots in the conveyor at
83, 125 or 167mm pitch as standard.
Bed Rollers
The top strand of the belt rests on pressure rollers,

which are 35mm diameter x 1.2mm thickness with
precision bearings and are rated at 35kg/roller.
Punched in the web of this section at 83mm pitch
are holes for the pressure rollers. The pressure
roller holes are positioned at varying pitches refer
to Fig. DM2.38 - Live Roller - Bed Section
Roller Tube:

Bearing:
Precision
Axle:

Roller Tube:

Bearing:
Precision
Axle:

Pressure & Return Rollers
Return rollers, which are the same specification

as pressure rollers are fitted at 1000mm pitch.
metres.
300, 400, 450, 500, 600 and 800BB

P a g e | 59
Design Manual
Version 1.0
2011 February 23
Fig. DM2.39 - Accumaflow - Bed Section

26.13
Accumaflow
Conveyor frames are made from cold formed

channel sections with "sloped slots" cut out at
83mm pitch in the web and top flanges. The bed
rollers are 50mm diameter x 1.5mm wall
thickness and fitted with precision bearings and
are rated at 100kg/roller. The roller axles are set
in nylon collars, which ride on sloped steel slots in
the conveyor frame. When the forward motion of
a package is interrupted, the backward force of
the belt causes the conveying rollers to travel up
the sloped slots. As the rollers move up these
slots a floating effect is created with the roller only
lightly touching the belt and producing a state of
equilibrium with pressure reduced to a minimum.
The carrying rollers automatically resume their
normal positive action position when the package
is allowed to flow forward.
Return rollers, which are the same specification

as pressure rollers are fitted at 1000mm pitch
26.14
Available Lengths

metres.
26.15
Available Widths
300, 400, 450, 500, 600 and 800BB

26.16
Rollers
Bed Rollers
Roller Tube:

Bearing:
Precision
Axle:

Pressure & Return Rollers

The top strand of the belt rests on pressure rollers,
which are 35mm diameter x 1.2mm thickness with
precision bearings which are rated at 35kg/roller.
Punched in the web of this section at 167mm
pitch are slotted holes for the pressure rollers.
The pressure rollers can be adjusted to vary the
amount of drive by using the cam adjusters refer
to Fig. DM2.39 - Accumaflow - Bed Section
Roller Tube:

Bearing:
Precision
Axle:
26.17
Line Pressure
The line pressure of an accumulated package is

in the range of 4% - 7% of its total.

P a g e | 60
Design Manual
Version 1.0
2011 February 23
Section 3 Accessories
Contents
Heading
1
Page
Roller Stop.........................................................................................62
1.1
Roller Stop Operation.................................................................... 62
1.2
Roller Stop (pneumatic)................................................................. 62
1.3
Air Consumption.............................................................................62
1.4
Available Widths.............................................................................62
Blade Stop......................................................................................... 64
2.1
Blade Stop Operation..................................................................... 64
2.2
Blade Stop (pneumatic)................................................................. 64
2.3
Air Consumption.............................................................................64
2.4
Available Widths.............................................................................64
Splice Angles and Floor Fixing ......................................................... 66
Side Guides....................................................................................... 67
Facia..................................................................................................68
Photo Cell and Reflector Brackets.................................................... 69
6.1
Metal Shielded Type...................................................................... 69
6.2
Plastic Type....................................................................................70
6.3
PEC Angle Moulding...................................................................... 70
Encoder Kit........................................................................................ 72
Remote Emergency Stop................................................................. 73

P a g e | 61
Design Manual
Version 1.0
2011 February 23
Roller Stop
Fig. DM3.1 - Roller Stop

1.1
Roller Stop Operation
The roller stop is intended to hold back a queue of

boxes.
The stop assembly features a failsafe normally up
system of operation, by the use of an extended
spring located between the opposing link arm and
inner side channel.
1.3 Air Consumption

32 Bore x 50mm Stroke
300 BB to 800 BB = 0.52 litres of free air per
cycle.
300, 400, 450, 500, 600 and 800mm.
The roller stop is 50mm above roller height in the

up position and level with roller height in the down
position.
1.2
Roller Stop (pneumatic)
Each stop assembly consists of two side channels

spaced apart by bolted crossties, the distance
between the channels is variable to suit the
conveyor size, up to a maximum of 800mm back to
back. The overall width of the stop assembly is
60mm greater than the back to back dimension.
The roller is fastened between two side plates and
forms the lifting part of the stop. The pivot arm
mechanism comprises of a 20mm diameter bright
drawn mild steel shaft, together with link arms
30mm x 12mm thick, drilled and pinned to the pivot
shaft. This mechanism provides the link between
the lifting stop, the air, and an attachment point for
the extension spring.

P a g e | 62
Design Manual
Version 1.0
2011 February 23
Fig. DM3.2 - Roller Stop (pneumatic) - Key

Components
Fig. DM3.3 - Roller Stop (pneumatic) - Key

Dimensions

P a g e | 63
Design Manual
Version 1.0
2011 February 23
Blade Stop
Fig. DM3.4 - Blade Stop

2.1 Blade Stop Operation
2.4 Available Widths:
The blade stop is intended to hold back a queue

of boxes and accumulate them.
300, 400, 450, 500, 600 and 800mm.
The blade stop is 20mm above roller height in the

up position and 15mm below in the down position.
2.2 Blade Stop (pneumatic)
The blade itself is a 3mm thick steel plate. The
blade is guided in two nylon blocks and is lifted by
a double acting pneumatic cylinder.
2.3 Air Consumption
32mm Bore x 25mm Stroke
300 BB to 800 BB = 0.26 litres of free air per cycle.

P a g e | 64
Design Manual
Version 1.0
2011 February 23
Fig. DM3.5 - Blade Stop - Key Components
Fig. DM3.6 - Blade Stop (pneumatic) - Key

Dimensions

P a g e | 65
Design Manual
Version 1.0
2011 February 23
Splice Angles and Floor Fixing
On applications where it is not possible to

position a stand directly under a joint in the
conveyor frames, a splice angle connector must
be fitted. In any circumstances, the un-supported
span of conveyor frames must not exceed 3
metres.
Two splice angles will be required for each joint.
It is preferable to position a stand as near to the
splice angle as possible.
Fig. DM3.7 Splice Angle Location
Both Type 1 and Type 2 conveyor stands require

securing to the floor using an expandable FloorFixing Bolt.
Two M10 x 90 Floor Fixing Bolts are required for
each stand.
A hole that exceeds the length of the bolt by
15mm should be drilled into the floor to
accommodate the fixing see Fig. DM3.8 - Fixing
Stand to Floor.
Fig. DM3.8 - Fixing Stand to Floor

P a g e | 66
Design Manual
Version 1.0
2011 February 23
Side Guides
Each guide is 25.4mm x 25.4mm zinc plated

square tube supplied in lengths of 3 metres.
Support brackets are clamped to the conveyor
channels at approximately 1.5 metre spacing. The
guide tubes are located in the brackets and
secured by locking screws.
Guide support brackets are available as single or
double rail assemblies for 90 or 140 deep
channels. The single rail assembly positions the
underside of the guide tube 40mm above the
TOR or TOB.
The double rail assembly positions the underside
of the guide tubes 40mm and 190mm above the
TOR or TOB.
Fig. DM3.9 Single Side Guide Location
To further enhance the smooth lines of the guides

special plastic connectors and end caps are
available.
For coding to order see Reference section.
Fig. DM3.10 - Side Guide Fixing Details

P a g e | 67
Design Manual
Version 1.0
2011 February 23
Facia
This is an easily fitted accessory, made of

extruded PVC section, which may be added to the
conveyor side channels (90mm or 140mm) to give
a smooth and neat appearance.
The facia should be fitted after such items as
pneumatics or photocells, as their brackets will
dictate how lengths are cut.
For coding to order see Reference section.
Fig. DM3.11 Fitting the Facia

P a g e | 68
Design Manual
Version 1.0
2011 February 23
Photo Cell and Reflector Brackets
There are two types of PEC/Reflector mounting

available, metal shielded and plastic.
6.1
Metal Shielded Type
Designed to be used where personnel are

working or constantly passing the conveyor.
In order to protect the PEC, reflector and any
personnel from catching or obstructing the units, a
formed metal shroud is fitted to both the PEC and
reflector mounting brackets.
This shroud does limit the angular rotation (across
the conveyor) of the PEC and reflector to 45
degrees from the perpendicular.
Fig. DM3.12 - PEC Bracket Assembly
For codes to order see Reference section.
Fig. DM3.13 - Reflector Bracket Assembly

P a g e | 69
Design Manual
Version 1.0
2011 February 23
6.2
Plastic Type
The second type of PEC and Reflector mounting

is intended to be used in areas where there is
less personnel traffic or where large angular /
vertical adjustment is required.
They are not shrouded and therefore are more
vulnerable to damage or accidental misalignment.
However, they are capable of being rotated much
further from the perpendicular than the metal type.
The PEC/Reflector is mounted on a clamp fitted
around a plastic tube. This tube is itself clamped
in position by the lower plastic (nylon) moulding.
The tube is prevented from rotating in the lower
clamp by a plastic location pip and a self-tapping
screw.
Fig. DM3.15 - PEC Bracket Assembly
To detect very low height loads (down to 20mm

high) the PEC can be mounted upside down if
necessary.
6.3
PEC Angle Moulding
This accessory enable the plastic PEC bracket to

accept the photoelectric cell normally used on the
metal shielded PEC bracket assembly.
Fig. DM3.16 - Reflector Bracket Assembly
Fig. DM3.14 - Location of PEC Angle Moulding

P a g e | 70
Design Manual
Version 1.0
2011 February 23
Fig. DM3.17 PEC Angle Moulding - Detail
Fig. DM3.18 - PEC Guard Assembly

P a g e | 71
Design Manual
Version 1.0
2011 February 23
Encoder Kit
Fig. DM3.19 Encoder Kit Assembly

The encoder wheel is fitted with four metal strips,
which are located on one side. When rotating they
are detected via a 18mm diameter proximity
sensor mounted to a bracket. This then enables a
control system to calculate accurate tracking and
speed of packages through a length of conveyor.

P a g e | 72
Design Manual
Version 1.0
2011 February 23
Remote Emergency Stop
Fig. DM3.20 Remote Emergency Stop

As part of the safety circuit, running throughout
each system, emergency stop buttons can be
inserted into the string at appropriate positions.
Remote Emergency Stop: This is a push button
emergency stop requiring wiring on site to a motor
junction box nearby utilising the break-in facility.

P a g e | 73
Design Manual
Version 1.0
2011 February 23

P a g e | 74
Design Manual
Version 1.0
2011 February 23
Section 4 Product Application

Contents
Heading
1
Page
Belt Conveyor Application....................................................... 78
1.1
Below are some typical examples........................................ 78
1.2
Environment......................................................................... 78
Loads to be Conveyed............................................................ 79
Roller Pitch Selection.............................................................. 79
3.1
Live Roller/Accumaflow........................................................ 79
3.2
Level Belt and Booster Belt (roller bed only)........................ 79
3.3
Incline/Decline...................................................................... 79
3.4
Pitches Available.................................................................. 79
3.5
Minimum Load Sizes Live Roller/Accumaflow................... 80
3.6
Minimum Load Sizes Level Belt / Booster......................... 80
3.7
Conveyor Width Selection.................................................... 80
3.8
Conveyor Speed Selection................................................... 80
3.9
Centre Drive Unit.................................................................. 80
3.10
High Speed Centre Drive Unit.............................................. 80
Application of Level Belt Conveyor.......................................... 81
4.1
Level Belt Loadings.............................................................. 81
4.2
Spacing of Stands................................................................ 81
4.3
Mechanical Loading Level Belt - Centre Drive..................... 82
4.4
Mechanical Loading Level Belt - End Drum Drive................ 83
Application of Inclines/declines................................................ 84
5.1
Maximum Inclines and Declines........................................... 84
5.2
Load Stability........................................................................ 84
5.3
The following should be considered..................................... 84
5.4
Belt Considerations.............................................................. 86
Feeder and Top Curve Angle Positions................................... 87
Incline/Decline Loadings.......................................................... 89
7.1

P a g e | 75
Incline/Decline Structural Loadings...................................... 89
Design Manual
Version 1.0
2011 February 23
Heading
7.2
8
Page
Mechanical Loading............................................................. 89
Application of Accumaflow....................................................... 90
8.1
Loads.................................................................................... 90
8.2
Selection............................................................................... 90
Application of Live Roller......................................................... 90
9.1
Line Pressure ...................................................................... 90
9.2
Structural Loadings.............................................................. 91
9.3
Mechanical Loadings - Centre Drive.................................... 91
9.4
Mechanical Loadings - End Drum Drive............................... 92
10
Application of Metering Belts................................................... 93
10.1
Fast Belt Length .................................................................. 93
10.2
Brake Belt Length................................................................. 93
10.3
Stands ................................................................................. 93
10.4
Loadings............................................................................... 93
11
Horizontal Curve Tangents...................................................... 95
12
Special Loads.......................................................................... 95
12.1
Bag Handling........................................................................ 95
12.2
Tapered Containers.............................................................. 96
12.3
Runners................................................................................ 96
12.4
Partially Filled Containers..................................................... 96
12.5
Wire Baskets........................................................................ 96
12.6
Wooden Boxes..................................................................... 96
12.7
Loads with Uneven Weight Distribution................................96
12.8
Recessed Bottoms............................................................... 96
12.9
Bales or Bundles.................................................................. 96
13
Soft Starts and Inverters.......................................................... 97
13.1
Electronic Soft Start.............................................................. 97
13.2
`Motec` Frequency Inverter.................................................. 97
14
Incline Stand Selection............................................................ 98
14.1
Sideguides............................................................................ 100
14.2
Underguards......................................................................... 100

P a g e | 76
Design Manual
Version 1.0
2011 February 23
Heading
Page
14.3
Working Areas...................................................................... 100
14.4
Traffic Areas......................................................................... 100
14.5
Transport Areas.................................................................... 100
15
15.1
Accumulation .......................................................................... 101

Loads.................................................................................... 101
16
End Stops ............................................................................... 102
17
End Plates............................................................................... 102
18
System Design Considerations - Mechanical.......................... 103
18.1
Environment......................................................................... 103
18.2
Site Conditions .................................................................... 103
18.3
Product ................................................................................ 103
19
System Design Example ........................................................ 104
19.1
Application ........................................................................... 104
19.2
Deciding on Modules............................................................ 105
19.3
Deciding on Conveyor Width and Speed............................. 105
19.4
Accumaflow Section ............................................................ 106
19.5
Accumaflow Summary.......................................................... 106
19.6
Metering Belt Section........................................................... 106
19.7
Metering Belt Summary........................................................ 106
19.8
Incline Section ..................................................................... 106
19.9
Incline Summary................................................................... 107
19.10
Accessories.......................................................................... 108

P a g e | 77
Design Manual
Version 1.0
2011 February 23
Belt Conveyor Application
The type of conveyor to be used in a particular

installation is dictated by several factors. The type
of package, object or load to be conveyed; the
operation to be performed on the conveyor, if any;
and the physical conditions surrounding the
installation, all play a part in determining the kind
of conveyor to be used. It is, of course, impossible
to formulate a standard that would permit proper
choice of the type of conveyor best suited to a
particular problem, but the following generalities
will help.
Use belt conveyors for any load whose shape or
construction would not result in damage to the
belting.
1.1
Below are some typical examples.

Bottles
Christmas tree ornaments
Pieces of paper
Light bulbs
Fuses
Sticks of chewing gum
Individual packages of food products
Cartons of soap products
Paper products
Canned goods
Radio and television cabinets
The conveyors can negotiate inclines or declines

up to 30 with ease. Almost always, the centre of
gravity of the package governs the maximum
angle rather than the friction between the surface
of the belt and the package.
Decline belt conveyors are frequently used in
place of gravity roller or wheel spirals and in place
of spiral chutes when fragile loads are to be
lowered, or when it is necessary for any reason to
control the speed of descending loads.
1.2
Environment
It is very important to obtain full details of the

customers working conditions.
Examples
Volatile atmosphere - explosion proof motor.
Hot climate - tropical insulation, in this instance we
must know the temperature range, relative
humidity, if air-conditioned site, is salt present in
the atmosphere.
Please contact the engineering department for any
quires regarding special environments or working
conditions
Belt conveyors, in addition to conveying fragile

loads, will convey any load that would travel on
gravity conveyor when vertical drop or gradients
are not available.
Belt conveyors are ideally suited to assembly line
operations as they can be operated at almost any
speed with equal success. They can be used
where speed of travel and spacing of loads must
be controlled.
When vertical drop is desired for fragile loads, the
belt conveyor is usually the best solution as it can
negotiate steep declines with complete control
over the speed of the descending load.
The belt conveyor is the most commonly used
power conveyor because of its versatility.
Packages or objects of the smallest size and
weighing grams, as well as large sizes can be
conveyed with equal ease. Fragile loads can be
conveyed successfully.

P a g e | 78
Design Manual
Version 1.0
2011 February 23
Loads to be Conveyed
Roller Pitch Selection
It is important to find out as much about the load

to be conveyed as possible. This is the first step
in successful conveyor design.
3.1 Live Roller/Accumaflow
The details needed to be known are as follows:
There must be at least 3 rollers under the load

being conveyed at any one time. Take the
minimum load length and divide by 3 to give the
maximum pitch of rollers required.
Load Dimensions length, width and height.

Load Weight
(Fig DM4.1)
The condition of the load must not result in

damage to the belting.
3.2
Level Belt and Booster Belt (roller bed

only)
Position of the Centre of Gravity in relation to the

height of the load. Is the load likely to topple when
running on an incline or decline?
The rollers on these conveyors need to be

spaced only close enough to keep the belting
from sagging unduly between the idler or carrying
rollers. When conveying light loads weighing up
to a few kgs, it is only necessary to space the
rollers at 250mm apart. (Loads as usually
encountered in department stores and mail order
houses are examples of the types of loads that
will operate properly with rollers on 250mm pitch).
On heavy unit loads that are also short it is
advisable to always have at least two rollers
under a load on a booster or level belt conveyor.
Loads above 15kg that are less than 500mm long
require bed rollers spaced at equal or less than
half the load length.
3.3 Incline/Decline
On incline and decline conveyors, two rollers
under the loads are required to prevent "bobbing"
and slip back on inclines or slip ahead on
declines.
3.4 Pitches Available
Fig. DM4.1 Calculating Required Pitch

P a g e | 79
Design Manual
Version 1.0
2011 February 23
3.5 Minimum Load Sizes Live

Roller/Accumaflow
3.7
Conveyor Width Selection
Generally, the conveyor width should be selected

to be 50mm wider than the widest load being
handled. This gives adequate working clearance
between load and side guiding.
3.8
Conveyor Speed Selection
For general purposes, a speed of 18 metres per

minute is adequate for most needs. This speed
would be used where loads have to be placed on
or taken off the conveyor when in motion.
3.6 Minimum Load Sizes Level Belt /
Booster
When a certain number of loads have to be

transported in a given time, the minimum
conveyor speed can be calculated by using the
following formula.
(Length of longest load + gap required between
loads (both in metres)) x loads per minute.
Example:
Longest Load = 500mm
Gap = 100mm
Loads per minute = 20
(0.5m + 0.1m) x 20 = 0.6 x 20 = 12m/min
Looking at the tables below the next standard
speed above 12m/min is 14. This gives an
answer of 14 metres per minute and is the
minimum conveyor speed to be used.
3.9
Centre Drive Unit
3.10 High Speed Centre Drive Unit

P a g e | 80
Design Manual
Version 1.0
2011 February 23
4
4.1
Application of Level Belt Conveyor

Level Belt Loadings
4.1.1 Structural Loading Level Belt

The belt range of conveyors is designed for
package handling, (i.e. to be loaded by hand) and
should not under normal conditions be loaded
beyond 60kg per metre.
4.2
WARNING
Spacing of Stands
The spacing of stands is dependent on the

loading on the conveyor or location of them (i.e.
around a centre drive unit). Fig. DM4.2 - Stand
Spacing Chart shows the maximum span
between stands for various conveyor loadings.
THE BELT RANGE OF POWER

CONVEYORS IS DESIGNED FOR
PACKAGE HANDLING, (I.E. TO BE
LOADED BY HAND) AND SHOULD
NOT UNDER NORMAL CONDITIONS
BE LOADED BY HAND BEYOND
25KG PER LOAD.
Note
On level belt conveyors the centre
drive unit should be positioned at the
back of the conveyor run when looking
at the package direction of travel.
Fig. DM4.2 - Stand Spacing Chart

P a g e | 81
Design Manual
Version 1.0
2011 February 23
4.3 Mechanical Loading Level Belt Centre

Drive
The level belt range of conveyors is available with
either 0.75kW or 1.5kW motors and the load
capability of specific conveyors can be read from
the loading chart. The figures given on the chart
are for both roller bed and mono bed conveyors.
Fig. DM4.3 - Level Belt (centre drive) Loading

P a g e | 82
Design Manual
Version 1.0
2011 February 23
4.4 Mechanical Loading Level Belt - End Drum

Drive
The belt range of conveyors is available in three
speeds and the load capability of specific
conveyors can be read from the loading chart. The
figures given on the chart are for both roller bed
and mono bed conveyors.
Fig. DM4.4 - Level Belt (end drum drive)

Loading Chart

P a g e | 83
Design Manual
Version 1.0
2011 February 23
5 Application of Inclines/declines
5.1
Maximum Inclines and Declines
The maximum belt angle is a function of the

characteristics of the load.
The condition of the load itself is the most
important consideration. For example, a wooden
box with a flat, rough bottom might negotiate a
30 incline while a smooth oily tote box may slide
at 20 both on the same belting. While the weight
of the load has some effect on friction, the
flatness and roughness of the load bottom are
usually the determining factors.
5.2 Load Stability

In many cases the stability of the load is the
limiting factor. For uniformly packed loads the
centre of gravity is close to the geometric centre
of the load and can be located at the intersection
of diagonals drawn between opposite corners
(refer to Fig. DM4.5 Load Stability). For nonuniform loading (T.V. sets, bottles etc.) the centre
of gravity may have no relation to the shape of
the load. It can be located by "balancing" the load
on each of its four bottom edges and noting the
angle of stability in each direction.
Since it is impractical to determine the exact

degree of roughness and/or "bulge" for every load,
no precise engineering formula can be applied.
We must therefore, rely on experience "averages",
plus personal evaluation of the individual job
conditions.
The following recommendations should be
considered as high averages when using the
following types of loads.
Fig. DM4.5 Load Stability

It is well known that under static conditions a load
will be stable if a perpendicular from its centre of
gravity falls within its base. Unfortunately, belt
conveyors do not provide a static condition. They
must stop and start quickly and a load must be
able to absorb forces such as momentum and
acceleration without rocking beyond its stability
point resulting in tumbling or tipping.
5.3 The following should be considered.
A short, high load is vulnerable to tilting as
momentum is applied at the long lever arm from
its base to the centre of gravity.
High-speed will apply greater accelerating and
decelerating forces than a low speed unit. Also,
the use of brakes will accentuate decelerating
action.
Table. DM4.1 - Type of Load

P a g e | 84
The bottoms of most loads are not flat but slightly

bulging.
Some rocking can occur even on
horizontal conveyor beds.
Design Manual
Version 1.0
2011 February 23
The spacing of intermediate section rollers affects

the amount of "bobbing" or sway in transit. The
closer the rollers the smoother the action. Mono
bed section provides the smoothest action.
The contents of loosely packed tote boxes can
shift in transit, and change the calculated centre
of gravity.
No precise measurement of all forces is practical

and we must rely on a "rule of thumb" and modify
it by judgement based on the individual job
conditions. The rule states that for reasonable
stability under normal conditions, a perpendicular
from the centre of gravity shall fall within the
centre 1/3 of the base. Thus, for a square load the
theoretical maximum angle is 18. For a good
package this could be increased to 20, and for a
poor load, Should probably be reduced to 16.
Refer to Fig. DM4.6 - Load Stability Check for
Incline/Decline Conveyors
Fig. DM4.6 Load Stability Check for

Incline/Decline conveyors

P a g e | 85
Design Manual
Version 1.0
2011 February 23
5.4 Belt Considerations

On the incline section of the conveyor an
alternative grip face belt is used on inclines above
22. The alternative belt has a green polyurethane
top surface with longitudinal grooves which
ensures a higher grip surface.

P a g e | 86
Design Manual
Version 1.0
2011 February 23
Feeder and Top Curve Angle

Positions
Below shows the positioning of the feeder and top

curve unit for incline/decline conveyors. The
feeder positions are set to enable a smoother
transfer when loads convey from the incline to
horizontal plane or visa versa.
Fig. DM4.8 - Feeder Angle Dimensions

Fig. DM4.7 - Feeder Angle Positions
Fig. DM4.9 - Top Curve Angle Dimensions

P a g e | 87
Design Manual
Version 1.0
2011 February 23
Fig. DM4.10 - Incline Dimensions

P a g e | 88
Design Manual
Version 1.0
2011 February 23
7 Incline/Decline Loadings
7.1
Incline/Decline Structural Loadings
The structural loadings are the same as level belt

conveyors
7.2
Mechanical Loading
The Incline/decline belt range of conveyors is

available in five speeds and the load capability of
specific conveyors can be read from the loading
chart. The figures given on the chart are for both
roller bed and mono bed conveyors at 20, 25
and 30.
Fig. DM4.11 - Incline Belt Loading Chart

P a g e | 89
Design Manual
Version 1.0
2011 February 23
8
8.1
Application of Accumaflow
Loads
For any package weighing less than 1 kg, the

conveyor will tend to function as Live Roller
Conveyor, i.e. the bed rollers will always be
positively driven due to the package weight being
insufficient to move the rollers up the slots
Packages of varying sizes with sloping sides (e.g.
tote boxes) are liable to "jack knife" under the
effects of line pressure. If there is doubt regarding
a particular package then consult the engineering
department at Gainsborough.
The line pressure of an accumulated package is
in the range of 4% - 7% of its total weight,
depending on the nature of the package.
If varying types of boxes are being conveyed, e.g.
empty and full cardboard, then the line pressure
must be such that it does not have the ability to
"crush" an empty box, especially if a gap in the
package run is being closed up.
Fig. DM4.13 - Accumaflow Principle

8.2
Selection
For use when controlled minimum pressure

accumulation is required to match a varied input
with a fixed output, eliminating peaks and troughs,
i.e:Assembly Lines
An operator can only be expected to hold back

approximately
3kgs
line
pressure,
so
consideration must be given to stops.
Within operating positions, removable stops

would be fitted to stop or hold back a queue of
loads.
For individual loads in excess of 25kgs consult

the engineering department at Gainsborough
Prior to sealing/strapping machines or similar

At the discharge end of the accumaflow conveyor
a metering belt or removable stop would be fitted
operated on a cycle to suit the following machine.
9
9.1
Application of Live Roller

Line Pressure
As a comparison, the line pressure of an average

package on live roller conveyor is approximately
1/3 of the package load.
For individual loads in excess of 25kgs consult
the engineering department at Gainsborough
Fig. DM4.12 - Line Pressure

P a g e | 90
Design Manual
Version 1.0
2011 February 23
9.2
Structural Loadings
Refer to Structural Loading Level Belt Conveyors

9.3
Mechanical Loadings - Centre Drive
Fig. DM4.14 - Live Roller / Accumaflow

Loading Chart (Centre Drive)

P a g e | 91
Design Manual
Version 1.0
2011 February 23
9.4
Mechanical Loadings - End Drum Drive
Fig. DM4.15 - Live Roller / Accumaflow

Loading Chart (End Drum Drive)

P a g e | 92
Design Manual
Version 1.0
2011 February 23
10 Application of Metering Belts

10.1 Fast Belt Length
Minimum length of "fast" belt depends upon the
BB length, 1000mm overall length for 300 to
500BB and 1500mm overall length for 600 and
800BB. It is important to have the fast belt length
at least 1 times the width of the belt as it is
difficult to track short but wide belts.
10.2 Brake Belt Length
Length of "Brake" belt depends upon the line
pressure to be held back, whether the pressure is
created by the feed of cartons from gravity
conveyor or from accumaflow conveyor. Only the
friction from the cartons occupying the brake belt
is available to hold back the line pressure. As a
general guide the brake belt length should not be
less than 1/6 of the proceeding accumaflow
conveyor length. The maximum length of a brake
belt is 4.5 metres (refer to Fig. DM4.16 - Metering
Belt Details) as this is the limit of belt tensioning
facility. It hence follows that using a 4.5m long
brake belt means the maximum length of the
preceding accumaflow conveyor is
6 x 4.5m = 27 metres
10.3 Stands
Stands must be positioned generally as indicated
in Fig. DM4.16 - Metering Belt Details
10.4 Loadings
Structural
Refer to Level Belt Loadings Mechanical

Loading
Mechanical Loadings same as level belt

P a g e | 93
Design Manual
Version 1.0
2011 February 23
Fig. DM4.16 - Metering Belt Details

P a g e | 94
Design Manual
Version 1.0
2011 February 23
11 Horizontal Curve Tangents

When a package discharges from a belt on to a
roller curve, it is not free to turn until clear of the belt.
Thus, if a straight section of rollers (a "tangent
section" is not added, the load will be pushed into
the curve, without turning and hang-up or jam.
Theoretically, the tangent section should be equal
to the length of the longest load. However, because
the turning action at the start of the curve is small
and because "clear" distance is included between
the pulley frame rails the length of the tangent is
specified as -"not less than the length of the longest
load".
A similar condition exists when leaving a curve and
feeding onto a powered belt conveyor. Unless the
load is free to turn until it is clear of the curve, it will
not turn a full 90, and will discharge on to the
receiving belt conveyor in a cocked position.
For this reason Wherever possible the straight section of conveyor
feeding and taking away from a roller curve should
be roller conveyor.
12 Special Loads
There are many "special" loads, which require
special treatment if they are to be handled
successfully on a belt conveyor system.
12.1 Bag Handling
The handling of multi-wall paper, cloth or
polyurethane bags presents many problems of
conveyor design and application not normally
present in package conveyor work.
A complete knowledge of the contents of the bags
is vital. Bags are not as completely sealed as
cartons and it is inevitable that a certain amount of
"tramp" material will leak out and come in contact
with the equipment. In many cases, the material will
be corrosive and "rust" or "eat" the conveyor
components. This is especially noticeable on chutes
where galvanising, special alloys or special linings
may be required. Salt or fertilisers are examples of
this type of load.
In other cases the material may create a dust or
abrasive condition for which special treatment or
design features must be added. In some cases, the
"dust" condition will require the use of explosionproof equipment. Occasionally the dust may act as
a lubricant and permit shallow pitches

P a g e | 95
on chutes. Examples of dust conditions are bags

of cement, starch and flour.
Other types of material may be affected by
environmental changes and in turn affect the
equipment. Sugar, for example, will act as a
lubricant in dry weather but becomes tacky in
humid climates.
In most cases the customer is most familiar with
his particular product and must advise the
equipment supplier regarding correct and complete
information required to design around problems of
this type.
The contents of the bags also affect their shape
and hardness, which is an important consideration.
Powdered substances tend to create soft of floppy
bags. Granular materials tend to be more stable.
Some materials soft when filled, become more
solid after period of storage.
The use of bag flatteners (bag squeezing devices)
tends to provide more uniform loads. There are
several standard types currently available. Care
should be taken to feed bags into flatteners so that
the bottom of the bag (which absorbs most of the
contents in vertical filling) enters first.
This is also true of action at deflectors where
different motions may be expected with bags of
different consistency. At transfers, deflectors and
in chutes, bags must be closely contained and
guided. Any wide tolerances in the guides can
easily result in rotation and jams or broken bags.
A proper appreciation of the bags stability or
hardness is important. Bag transfers from
conveyor to conveyor are usually by chute or butt
transfer. In the latter case the action is not simple
and the hardness of the bag is an important factor.
Because of the wide variations in bag
characteristics noted previously, all bag jobs must
be handled in a special manner.
Field engineers should make special effort to see
the actual job conditions and make field tests on
transfers and deflectors when existing conveyors
are available. They should also check closely on
corrosive, abrasive, dust and tacky conditions
noted above.
Whenever practicable, a site survey should be
carried out to observe the actual conditions on a
pre-contract basis.
Design Manual
Version 1.0
2011 February 23

P a g e | 96
Design Manual
Version 1.0
2011 February 23
13 Soft Starts and Inverters
13.2 `Motec` Frequency Inverter
Belt conveyor centre drive units can be fitted with

an Electronic Soft Start or `Motec` frequency
inverter.
13.1 Electronic Soft Start
Fig. DM4.18 - Inverter
Fig. DM4.17 - Electronic Soft Start

Used to create a soft motor acceleration. Soft
Start creates less wear on the mechanical
equipment i.e chains, keys and sprockets. Fitted
with its own motor protection, contactor and
diagnostics. They do not control motor
deceleration.

P a g e | 97
Used to create controlled motor acceleration and

deceleration to an adjustable ramp profile. Fitted
with its own motor protection, contactor and
diagnostics.
Frequency inverters control the
frequency of the 3-phase supply to the motor,
which can be adjusted between 20 and 80Hz
nominally.
Design Manual
Version 1.0
2011 February 23
14 Incline Stand Selection

P a g e | 98
Design Manual
Version 1.0
2011 February 23
Fig. DM4.19 - Incline Stand Selection

P a g e | 99
Design Manual
Version 1.0
2011 February 23
14.1 Sideguides
14.5 Transport Areas
Sideguides are used to retain loads on the

conveyor.
These are areas that are occupied solely by the

conveyor, and it is assumed that maintenance
staff are the only people allowed to enter.
Single height sideguides are suitable for use in

most locations. However, where conveyors pass
over gangways or areas where people are working,
double height sideguides must be used. Where
there is felt to be a risk of long queues forming
resulting in an excessive line pressure build up,
special sideguides with an overhead restraining
guide must be fitted in addition.
Underguards are not necessary in these areas

as the risk is assessed as small.
Exception: Underguards are necessary, however,
if the conveyor passes over areas where people
are working or above gangways.
14.2 Underguards
Underguards
are
required
in
certain
circumstances by the safety legislation.
The
legislation refers to 3 main classification of areas:
14.3 Working Areas
These are areas where operatives spend most of
their working time at the conveyor. Likely
examples are picking and assembly operations. In
these locations, there is an increased risk of them
trapping fingers in the drive arrangement while
loads are on the conveyor. The presence of loads
on the conveyor increases the weight on the
rollers and thereby the trapping force between belt
and rollers.
In these areas, underguards must be fitted up
to a height of 2500mm.
Exception: Underguards need not be fitted when
the operatives are separated from the belt
Conveyor by horizontal gravity or work tables.
Underguards are not required in these cases as
the potential danger is considered too far away.
14.4 Traffic Areas
These are areas where conveyors run along
edges of gangways and the like and operatives
are not working on the conveyor.
Underguards are not necessary in these areas
because the risk is assessed as being small.
Exception: Underguards are necessary if the
conveyor passes over areas where people are
working or above gangways.

P a g e | 100
Design Manual
Version 1.0
2011 February 23
15 Accumulation
15.1 Loads
Accumaflow
For any package weighing less than 1 kg, the
conveyor will tend to function as Live Roller
Conveyor, i.e. the bed rollers will always be
positively driven due to the package weight being
insufficient to move the rollers up the slots.
Packages of varying sizes with sloping sides (e.g.
tote boxes) are liable to "jack knife" under the
effects of line pressure. If there is doubt regarding
a particular package then consult the Design
Office at Gainsborough.
The line pressure of an accumulated package on
accumaflow conveyor is in the range of 4% - 7% of
its total, depending on the nature of the package.
If varying types of boxes are being conveyed, e.g.
empty and full cardboard, then the line pressure
must be such that it does not have the ability to
"crush" an empty box, especially if a gap in the
package run is being closed up.
An average operator can only be expected to hold
back approximately 3kgs line pressure, so
consideration must be given to stops.
As a comparison, the line pressure of an average
package on Live Roller Conveyor is approximately
1/3 of the package load(s).
For loads in excess of 60kgs/m refer to AE
Conveyors.

P a g e | 101
Design Manual
Version 1.0
2011 February 23
16 End Stops
17 End Plates
Fig. DM4.20 End Stop
Fig. DM4.21 End Plate
End Stops must be fitted at all open ends of

Live/Accumaflow Roller conveyor systems where
the conveyors direction of travel is towards the
open end. This is an important safety feature and
must not be overlooked.
End Plates give a smooth closed appearance to

the end of a conveyor. They may be fitted as an
alternative to an end stop only where the conveyor
is powered to run in a direction away from the
open end.
End stops stand 64mm above top of roller height

and are made from 5mm thick mild steel.
End plates are 5mm thick mild steel. They align

with the side channels (6mm below top of roller
height).
They come complete with connectors and fixings.
They come complete with connectors and fixings.

P a g e | 102
Design Manual
Version 1.0
2011 February 23
18 System Design Considerations Mechanical

Conveyor systems vary greatly in mechanical and
control complexity. There are, however, basic
requirements that must be considered for any
installation.
18.1 Environment
Belt conveyors are designed to operate indoors in
ambient temperatures between -2C and 40C.
They must always be kept indoors and dry.
They are however available to operate in other
environments e.g. cold stores, outdoor etc. Please
contact AE Conveyors for details of any necessary
changes to the equipment specification.
WARNING
BELT CONVEYORS ARE NOT
SUITABLE FOR USE IN EXPLOSIVE
ENVIRONMENTS
OR
WHERE
INFLAMMABLE
VAPOURS
OR
GASSES ARE PRESENT.
18.2 Site Conditions
Civil work should be completed before beginning
to install belt conveyors. If performing any
concrete cutting near a conveyor, it must be fully
covered preferably in shrink wrap or cling film.
CAUTION
EXCESSIVE AMOUNTS OF DUST
(CONCRETE, SAND ETC) CAN LEAD
TO PREMATURE FAILURE OF KEY
COMPONENTS.
18.3 Product
The conveyors should not be used to handle
products or chemicals of an aggressive nature
(such as acids) or be subject to contact with such
substances.

P a g e | 103
Design Manual
Version 1.0
2011 February 23
19 System Design Example

19.1 Application
The conveyor is required to handle packed
cartons weighing a maximum of 15kg, maximum
size 500mm wide x 600mm long x 300mm high,
minimum size 300mm x 300mm x 150mm. They
are packed and loaded with books by hand and
will require sealing before offloading at despatch.
The planned route is the shortest distance
between two points. Upper floor (Despatch) is
situated 2.5 metres above the lower floor.
Requirements of Conveyor
The conveyor needs to feed a case sealer at

10 carton per minute.
The case sealer requires a gap between each
box.
The conveyor needs to transport loads from
the lower floor to despatch on the upper floor.
To accept varying load throughput from the
packing area.
Fig. DM4.22 - System Design Example

P a g e | 104
Design Manual
Version 1.0
2011 February 23
19.2 Deciding on Modules
Starting from the packing area accumaflow

conveyor has been selected to reduce the line
pressure build up from loads queuing up
before entering in to the case sealer.
The case sealer requires a gap between each
box for this reason a metering belt will be
installed prior to the case sealer to create load
separation. The metering belt conveyor will
also be able to hold back any accumulating
boxes that are despatched at varying rates
from the packing area.
A key feature is the upper floor; loads will be
required to convey to the upper floor and into
the despatch area. An incline belt is used to
transport loads between levels.
Finally a run of gravity conveyor is to be
installed after the incline belt. The gravity
conveyor is declined to allow loads to travel to
the end of the gravity conveyor run. Refer to
Gravity Design Manual for details.
19.3 Deciding on Conveyor Width and Speed

Width
Maximum package width is 500mm the minimum
recommended conveyor width is width + 50mm i.e.
550 minimum we should hence use 600BB
conveyor width.
Speed
To determine the speed we can see from the
Conveyor Speed Selection formula that;
Minimum Speed
=
(Length of longest load + gap

req'd) x
Loads per minute
(0.6m + say 0.1m) x 10
0.7 x 10
7m/min
From the technical descriptions, it can be seen

that the slowest speed is 9m/min and our required
minimum speed is 7m/min. Therefore 9m/min
will easily cope.
Roller Pitch
Calculate the roller pitch for the accumaflow
conveyor from the shortest load length of 300mm.
We can see from the Roller Pitch Selection
formula that;
Maximum Pitch
=L/3
= 300mm / 3
= 100mm
Therefore, we must use 83mm pitch not 125mm

pitch.
Fig. DM4.23 - System Design Example - Modules

P a g e | 105
Design Manual
Version 1.0
2011 February 23

P a g e | 106
Design Manual
Version 1.0
2011 February 23
Calculating Actual Load Per Metre (kgs/m)

Referring to the diagram below we can see that
the carton pitch is 1.4m. Therefore conveyor
loading (load per metre)
= 15kgs every 1.4 metres
= 15 divided by 1.4 = 10.7 kgs/m
10.7 x 3 = 32.1 (actual load) x 0.89 (600BB) x 0.3
(9 m/min) = 8.6kgs/metre effective load
We can see Fig. DM4.11 - Incline Belt Loading
Chart that 8.6kgs/metre effective load at 2.5m lift
can use either a 0.75kW or 1.5kW Drive Unit at
any angle of incline . We will use the most costeffective solution 0.75kW Drive Unit for our
application.
For our application we will use a 25 angle of

incline. We can now calculate the overall length of
our incline conveyor.
Feeder Length + Length 'L' + top curve length
1500 (600BB) + 5620 + 990 = 8110mm Overall
Length
Fig. DM4.24 - Detailed Application Example

19.8.4 Overall Length
19.9 Incline Summary
Finally we need to decide what the overall length

and angle will be for our incline conveyor. Referring
to Fig. DM4.10 - Incline Dimensions we can see
that in the table for a standard 2.5m lift up to 25
angle of incline shows two dimensions for Length 'L'.
The following
Conveyor is:
specification
2.5m Lift
25 degree Incline
At 20 angle of incline = 7230mm
Monobed
At 25 angle of incline = 5620mm
0.75kW Drive Unit
8110mm Overall Length

P a g e | 107
for
our
Incline
Design Manual
Version 1.0
2011 February 23

P a g e | 108
Design Manual
Version 1.0
2011 February 23
Stand E =
Stand E Height + Top of Belt Lift
=
2257mm + 700mm 2500mm)
457mm
Incline Stand Selection =

Stand A2
604mm
Stand A3
604mm
Stand B
752mm
Stand C1
1780mm
Stand E
457mm
Fig. DM4.25 - Top Curve Stand Selection

P a g e | 109
Design Manual
Version 1.0
2011 February 23
19.10.3
Metering Belt Stands
Referring to Fig. DM4.16 - Metering Belt Details

we can check which tensioner assembly will be
required. Both the brake belt and fast belt
sections require underslung tensioners therefore:
Height to underside
= 700mm 96mm
= 604mm
19.10.3.1 Side Guides

Side guides are only required for the incline
conveyor at this height unless the customer
specifies that side guides are to be fitted
throughout the entire system.
An end stop assembly will be required at Dispatch
to prevent loads falling onto the floor if the
conveyor is unattended.

P a g e | 110
Design Manual
Version 1.0
2011 February 23
Section 5 References
Contents
Heading
1
Page
Level Belt.................................................................................. 114
1.1
Conveyor Frame (Centre Drive)............................................. 114
1.2
Conveyor Frame (End Drive)................................................. 115
1.3
Side Guides........................................................................... 116
1.4
Level Belt Components.......................................................... 117
Booster Conveyor..................................................................... 118
2.1
Conveyor Frame and Roller Quantity and Belt Length.......... 118
2.2
Booster Belt Components ..................................................... 119
Incline Belt Conveyor................................................................ 120
3.1
Conveyor Frame and Roller Quantity and Belt Length.......... 120
3.2
Side Guides 20 .................................................................. 122
3.3
Side Guides 25 .................................................................. 123
3.4
Side Guides 30 .................................................................. 124
3.5
Incline Underguards 20 ........................................................125
3.6
Incline Underguards 25 .........................................................126
3.7
Incline Underguards 30 .........................................................127
3.8
Facia Quantities..................................................................... 128
3.9
Knee Brace Kit Quantities...................................................... 128
3.10
Incline Belt Components........................................................ 129
3.11
Incline Belt Components cont.............................................130
Live Roller................................................................................. 131
4.1
Conveyor Frame Quantity...................................................... 131
4.2
Belt Length ............................................................................ 132
4.3
Rollers Quantity..................................................................... 133
4.4
Side Guides........................................................................... 134
4.5
Live Roller Components......................................................... 135
Accumaflow .............................................................................. 136
5.1

P a g e | 111
Conveyor Frame Quantity and Belt Length............................136
Design Manual
Version 1.0
2011 February 23
Heading
Page
5.2
Conveyor Roller Quantity....................................................... 138
5.3
Side Guides........................................................................... 139
5.4
Stand Quantities.................................................................... 140
5.5
Accumaflow Components...................................................... 141
Metering Belt............................................................................. 142
6.1
Side Guides........................................................................... 142
6.2
Conveyor Belt Length............................................................ 142
6.3
Facia Quantities..................................................................... 143
6.4
Stand Quantity....................................................................... 143
Metering Belt Components........................................................ 144
Underguards............................................................................. 145
Accessories .............................................................................. 146
9.1
Blade Stops (Pneumatic)....................................................... 146
9.2
End Terminal Unit - End of Line............................................. 146
9.3
PEC / Reflector Bracket (Metal Shielded type)...................... 146
9.4
PEC / Reflector Bracket (Plastic Non-shielded type)............. 146
9.5
PEC Angle Moulding.............................................................. 146
9.6
PEC Guard Assembly ........................................................... 146
9.7
Photo Electric Cells................................................................ 146
9.8
Facia...................................................................................... 146
9.9
Splice Angle Kit...................................................................... 146
9.10
Butt End Connector Kit.......................................................... 147
9.11
Photo Electric Cell Reflectors................................................ 147
9.12
Sensor Leads......................................................................... 147
9.13
Encoder Wheel Kit................................................................. 147
9.14
End Stops.............................................................................. 147
9.15
End Plates.............................................................................. 147
9.16
Connectors............................................................................. 148
10
Electrical Components.............................................................. 150
10.1
11
Remote Emergency Stop....................................................... 150

Miscellaneous........................................................................... 150

P a g e | 112
Design Manual
Version 1.0
2011 February 23
Heading
Page
11.1
User Manual......................................................................... 150
11.2
CE Plate Kit.......................................................................... 150
12
Weights (kg)............................................................................ 151
12.1
Roller Bed Frame Excluding Rollers ................................ 151
12.2
Mono Bed Frame.................................................................. 151
12.3
Accumaflow Frame Excluding Rollers............................... 151
12.4
Live Roller Frame - 83 pitch Excluding Rollers................. 151
12.5
Live Roller Frame - 125 pitch Excluding Rollers............... 152
12.6
Live Roller Frame - 167 pitch Excluding Rollers............... 152
12.7
End Terminal........................................................................ 152
12.8
End Terminal (Live Roller / Accumaflow)............................. 152
12.9
Top Curve............................................................................. 152
12.10
Feeder Unit........................................................................... 152
12.11
Drive Unit.............................................................................. 153
12.12
Metering Belt Drive unit........................................................ 153

P a g e | 113
Design Manual
Version 1.0
2011 February 23
1
1.1
Level Belt
Conveyor Frame (Centre Drive)

P a g e | 114
Design Manual
Version 1.0
2011 February 23
1.2 Conveyor Frame (End Drive)

P a g e | 115
Design Manual
Version 1.0
2011 February 23
1.3
Side Guides

P a g e | 116
Design Manual
Version 1.0
2011 February 23
1.4
Level Belt Components

P a g e | 117
Design Manual
Version 1.0
2011 February 23
2
2.1
Booster Conveyor
Conveyor Frame and Roller Quantity and Belt Length
Side Guides

P a g e | 118
Design Manual
Version 1.0
2011 February 23
2.2
Booster Belt Components

P a g e | 119
Design Manual
Version 1.0
2011 February 23
3
3.1
Incline Belt Conveyor

Conveyor Frame and Roller Quantity and Belt Length

P a g e | 120
Design Manual
Version 1.0
2011 February 23

P a g e | 121
Design Manual
Version 1.0
2011 February 23
3.2
Side Guides 20

P a g e | 122
Design Manual
Version 1.0
2011 February 23
3.3
Side Guides 25

P a g e | 123
Design Manual
Version 1.0
2011 February 23
3.4
Side Guides 30

P a g e | 124
Design Manual
Version 1.0
2011 February 23
3.5
Incline Underguards 20
** Replace three dashes at end of code with back to back in mm. E.g. 600bb 1m plain guard:
18gu6866000600
For 600 & 800BB add 0.25m Notched Underguards (2 off) for feeder unit. Part No. 18gu7760000600

P a g e | 125
Design Manual
Version 1.0
2011 February 23
3.6
18gu6866000600

P a g e | 126
Design Manual
Version 1.0
2011 February 23
3.7
18gu6866000600

P a g e | 127
Design Manual
Version 1.0
2011 February 23
3.8
3.9
Facia Quantities
Knee Brace Kit Quantities

P a g e | 128
Design Manual
Version 1.0
2011 February 23
3.10 Incline Belt Components

P a g e | 129
Design Manual
Version 1.0
2011 February 23
3.11 Incline Belt Components cont

P a g e | 130
Design Manual
Version 1.0
2011 February 23
4
4.1
Live Roller
Conveyor Frame Quantity

P a g e | 131
Design Manual
Version 1.0
2011 February 23
4.2
Belt Length

P a g e | 132
Design Manual
Version 1.0
2011 February 23
4.3
Rollers Quantity

P a g e | 133
Design Manual
Version 1.0
2011 February 23
4.4
Side Guides

P a g e | 134
Design Manual
Version 1.0
2011 February 23
4.5
Live Roller Components

P a g e | 135
Design Manual
Version 1.0
2011 February 23
5
5.1
Accumaflow
Conveyor Frame Quantity and Belt Length

P a g e | 136
Design Manual
Version 1.0
2011 February 23

P a g e | 137
Design Manual
Version 1.0
2011 February 23
5.2
Conveyor Roller Quantity

P a g e | 138
Design Manual
Version 1.0
2011 February 23
5.3
Side Guides

P a g e | 139
Design Manual
Version 1.0
2011 February 23
5.4
Stand Quantities

P a g e | 140
Design Manual
Version 1.0
2011 February 23
5.5
Accumaflow Components

P a g e | 141
Design Manual
Version 1.0
2011 February 23
Metering Belt
6.1
Side Guides
6.2
Conveyor Belt Length

P a g e | 142
Design Manual
Version 1.0
2011 February 23
Replace three dashes at end of code with back to back in mm. E.g. 600bb 1m plain guard:
18gu6866000600
6.3
Facia Quantities
6.4 Stand Quantity

P a g e | 143
Design Manual
Version 1.0
2011 February 23
Metering Belt Components

P a g e | 144
Design Manual
Version 1.0
2011 February 23
Underguards
Note: All kits include fixings

P a g e | 145
Design Manual
Version 1.0
2011 February 23

P a g e | 146
Design Manual
Version 1.0
2011 February 23

P a g e | 147
Design Manual
Version 1.0
2011 February 23

P a g e | 148
Design Manual
Version 1.0
2011 February 23

P a g e | 149
Design Manual
Version 1.0
2011 February 23
10 Electrical Components
10.1 Remote Emergency Stop
11 Miscellaneous
11.1 User Manual
11.2 CE Plate Kit

P a g e | 150
Design Manual
Version 1.0
2011 February 23
12 Weights (kg)
12.1 Roller Bed Frame Excluding Rollers
12.2 Mono Bed Frame
12.3 Accumaflow Frame Excluding Rollers
12.4 Live Roller Frame - 83 pitch Excluding Rollers

P a g e | 151
Design Manual
Version 1.0
2011 February 23
12.7 End Terminal
12.8 End Terminal (Live Roller / Accumaflow)
12.9 Top Curve
12.10 Feeder Unit

P a g e | 152
Design Manual
Version 1.0
2011 February 23
12.11 Drive Unit
12.12 Metering Belt Drive unit
* Consult Engineering Department

P a g e | 153
Design Manual
Version 1.0
2011 February 23

P a g e | 154
Design Manual
Version 1.0
2011 February 23

Belt Conveyor System

Enviado por

Dados do documento

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Belt Conveyor System

Enviado por

Direitos autorais:

Formatos disponíveis

Engineering Design Department