Adrian POPESCU, Marius PARASCHIV, Nicoleta PASCU

VIRTUAL MODEL OF A ROLLER CONVEYOR INTEGRATED INTO

A LOGISTIC FLOW
Abstract: In this article is presented, with the help of graphics, a logistic flow for palletizing and wrapping
operations. The loaded pallets are transported by means of a roller conveyor. Creating the virtual model
for the conveyer allows us to emphasize the compatibility elements between on the one hand the
mechanical assemblies of the flow components and on the other hand the subassemblies of the conveyer
structure. The paper has focused on the presentation of the conveyor specific assembly and how are placed
the sensors on the mechanical structure of the conveyor. Finally, the main working phases are graphically
presented within the flow, highlighting the loaded pallet positions in the flow.
Key words: conveyor, rollers, logistic flow, sensors, pallet.
INTRODUCTION
The conveyors are used within the logistic flows to
transport the goods from a point to another on a rigid
path. Flow detection and identification of the goods
transported on conveyors is automatically made by using
various types of sensors and identification systems of the
same type as the bar codes readers and RFID systems [1],
[2].
Several types of conveyors are used for the
application proposed, depending on the activities to be
fulfilled. Thus the pallets are transported to the
palletizing system zone by means of a chain conveyor;
the loaded pallets are transported to the wrapping system
zone by means of a roller conveyor.
The virtual modeling of the equipment used in the
logistic flows introduces a series of advantages, one of
the most important being represented by the fact that it
can be used in dedicated software applications for
material flows simulation and optimization [7], [8]. The
virtual model 3D has been achieved in CATIA
application [3], [4].
2. LOGISTIC FLOW

Fig. 2 Conveyor used in the flow - virtual model

2.2 Logistic flow in which the conveyor is integrated

Logistic flows for palletizing and wrapping
operations
are
formed
of
mechanical
and
electromechanical components that allow, depending on
the size and complexity of the flows, their automatic
performance, without the intervention of human
operators during the process. Figure 3 presents a logistic
flow for the palletizing operation, used as reference
model for the designed flow. In this flow we highlighted
the main components, the movements made by the good
to be palletized and the movements made by the pallet as
well.

2.1 Overview of the conveyor

The conveyor used in the flow is meant to transport
loaded pallets. It is manufactured by Hytrol Company
and has the features listed below [9]:
centrally located motor;
motor power 1.49kW or 2.23kW;
chain-driven rollers.
The reference model of the conveyor used in the flow
is shown in figure 1, while in figure 2 is shown the
virtual model of this one.

Fig. 3 Example of logistic flow for palletizing operation [10]

The components of the flow are listed below:

1 Veering system;
2 Palletizing system;
3 Conveyor for palletized stack discharge;
Fig. 1 Conveyor used in the flow - reference model [9]
4 Feed conveyor;
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Virtual model of a roller conveyor integrated into a logistic flow

5 Pallets storage system;
6 Feed conveyor;
7 Feed conveyor with pallets.
In this paper, the designed logistic flow, besides the
palletizing system it also includes a wrapping system of
the loaded pallets. This conveyor is used in the flow in
the wrapping area for transport of the pallets loaded with
goods to the wrapping system. Its components are
highlighted in figure 4 top view and in figure 5
isometric view, respectively.

Fig. 6 Kinematic diagram of conveyor

Fig. 4 Components of the palletizing and wrapping

logistic flow top view

Infrastructure elements are shown in figure 7. The

rollers of the conveyor are supported on bearings on the
support frame - 11. The elements - 12 ensure the stiffness
of conveyor; the motor is clamped on the rigid support 13. Conveyor rests on the supports - 14.

Fig.7 Infrastructure elements of conveyor

Fig. 5 Components of the palletizing and wrapping

logistic flow isometric view

3.2 Components of roller conveyor

In terms of kinematics, the main components of the
conveyor were presented in the previous section. Next
there are highlighted the components related to conveyor
rollers drive, the detailed structure of a roller and also the
elements of infrastructure.

The components of the flow are listed below:

1 - Feed system (inlet conveyor);
2 - Pallets automated storage system;
3 - Pallets transport system (chain conveyor);
4 - Palletizing automated system;
5 - Conveyor for palletized stacks transport;
6 - Wrapping system;
7 - Final conveyor for wrapped stack transport to
final working area.
3. ROLLER CONVEYOR 36-CRRH
3.1 Kinematic diagram of roller conveyor
To highlight the operation of the conveyor designed,
we have made its kinematic diagram. Thus in figure 6 it
is shown the kinematic diagram of the roller conveyor
36-CRRH. The flange motor-10 drives the worm reducer
-9. This one transmits the movement to the sprocket-8
that operates by means of chain-7 wheel-6. Sprocket - 5
is fixed by means of a wedge on roller shaft - 4. On roller
-4, supported on bearings-2, are welded the sprockets - 5.
Sprockets-5 drive the chain - 3 through which are driven
rollers - 1.
20 VOLUME 10 ISSUE 2 NOVEMBER 2015

Fig. 8 Guiding roller drive (detail)

1 three-phase electric motor; 2 worm reducer (60:1);
3 driving shaft; 4 sprocket (13 teeth);
5 chain; 6 sprocket (15 teeth); 7 guiding roller;
8 roller bearing.

The guiding roller (figure 8) is actuated by means of

the three-phase electric motor and the work reducer. The
movement is transmitted to the guiding roller through the
sprockets - 4, 6 and the chain - 3. The sprocket - 6 is

Virtual model of a roller conveyor integrated into a logistic flow

fixed by means of a wedge on the guiding roller - 7,
which is supported on bearings at both ends.

Fig. 9 Components of roller

1 roller body; 2 sprockets; 3 roller shaft; 4 clamping
ring; 5 radial ball bearing; 6 sealing elements;
7 bearing housing; 8 clamping bushing;
9 protection cover.

Two sprockets are welded on roller body (figure 9),

making possible movement transmission from one roller
to another. Some components are assembled in the
following order inside the roller, on its shaft: clamping
ring, sealing elements, radial bearing, housing of the
bearing, clamping bushing and protection cover.

Fig. 11 Positioning of sensors in this application

Positioning and fixing of sensors on conveyor

structure is achieved through the agency of position
adjustment elements in all 3 directions (figure 12).

Fig. 12 Details of sensors positioning E3F2 and E3Z [5]

1 sensor E3F2; 2 horizontal adjustment elements;
3 vertical adjustment elements; 4 adjusting elements along
the length of the conveyor
Fig. 10 Conveyor infrastructure elements
1, 2 Roller support elements; 3 lower housing; 4 upper
housing; 5 support of motor; 6 housing of chain
transmission; 7 supporting beam.

The mechanical elements of the conveyor are shown

in figure 10. Conveyor rollers are secured by a hexagonal
end in the support elements - 1, 2. Motor is fixed on
support - 5 that is stiffened by support elements. The
supporting beams are used for stiffening - 7. Chain
transmissions are protected by means of housings - 3, 4,
6.
3.3 Sensors positioning on conveyor structure
To detect the presence of the pallet in different areas
of the conveyor there were used the photoelectric sensors
E3F2 and E3Z respectively [11].
In figure 11 is shown the location of sensors on the
conveyor structure [6]. There are 2 sensors E3F2 type
placed as follows: the first one at entrance onto
conveyor, which detects the loaded pallet, when the
transfer from the chain conveyor to the roller conveyor is
made, and the second one is located at the end of
conveyor. The sensor E3Z is positioned next to the
wrapping system, in the middle of the roller conveyor
approximately.

4. WORKING PHASES IN THE LOGISTIC FLOW

In the following lines are shown the main work
phases within the logistic flow, shown in terms of
graphics, highlighting the successive positions of the
loaded pallet.
The first major work phase in the flow is the pallet
transfer.

Fig. 13 Transfer of palletized stack from the chain conveyor to

the roller conveyor

The palletized stack is transported and transferred to

the roller conveyor by means of the chain conveyor.

JOURNAL OF INDUSTRIAL DESIGN AND ENGINEERING GRAPHICS 21

Virtual model of a roller conveyor integrated into a logistic flow

When the sensor E3F2 detects the stack, it sends a
signal to the control system and thus the electric motor is
engaged and drives the conveyor rollers. In this way is
made the transfer from the chain conveyor to the roller
conveyor (figure 13).
The second major phase is the positioning of the
loaded pallet next to the wrapping system and the
wrapping itself thereof.

Fig. 14 Stack wrapping

The loaded pallet is positioned by means of E3Z

sensor when this one detects. At this point, the rollers of
conveyor stop for 60 seconds during which time the
wrapping operation takes place (figure 14).
Last phase is the moment when the sensor E3F2
detects the palletized and wrapped stack and the
conveyor stops by means of the control system. The
palletized stack can be taken over by another transporttransfer system (figure 15).

Fig. 15 Evacuation of wrapped stack

5. CONCLUSIONS
In this paper we have presented both the building
elements of the conveyers partial assemblies and the
main work phases for the whole flow, successively
highlighting the transported assets position on the
conveyers, reported to the sensors position. In this way
we have revealed the manner in which the sensors can be
positioned and fixed on the conveyers structure so that
the flows work phases be continuous and every
operation be achieved with no intervention of the human
factor.
REFERENCES
[1] Enciu, G., Nicolescu, A. (2007). Modern logistics in
industrial manufacturing, Scientific Bulletin Series
C, Volume XXI: Fascicle Mechanics, Tribology,
Machine Manufacturing Technology, pp. 221-228,
ISSN-1224-3264, May 17-18, 2007, Baia Mare.
22 VOLUME 10 ISSUE 2 NOVEMBER 2015

[2] Enciu, G. (2006). Electromagnetic fields of RFID

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[9] Installation and Maintenance Manual, available at:
www.hytrol.com, Accessed: 2015-08-15.
[10] Multi-line palletizing systems, available at:
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[11] Industrial photoelectric sensors, available at:
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Authors:
Assistant professor PhD Eng. Adrian POPESCU,
University POLITEHNICA of Bucharest, Machine and
Manufacturing
Systems
Department,
E-mail:
popescuadrian_c@yahoo.com, tel.40722604606.
Lecturer PhD Eng. Marius PARASCHIV, University
POLITEHNICA
of
Bucharest,
Machine
and
Manufacturing
Systems
Department,
E-mail:
marius.d.paraschiv@gmail.com, tel.40745036876.
Lecturer PhD Eng. Nicoleta-Elisabeta PASCU,
University POLITEHNICA of Bucharest, Engineering
Graphics
and
Design
Department,
E-mail:
nicoletaelisabeta_pascu@yahoo.ro, tel.4073635120.