How Do Conveyor Belts Work

Discover how conveyor belts work, their integral role in warehouse automation, and how they enhance efficiency, speed, and accuracy in material handling!

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In the landscape of warehouse automation, conveyor belts stand out as fundamental components that facilitate the movement of goods from one point to another. They are the arteries of a warehouse, ensuring that items are transported efficiently and smoothly across different sections. This automated system is designed to handle a wide range of products, from small packages to large pallets, making it a versatile solution for various operational needs. In this article, we dive into how these conveyor belts actually work, including how they are in fact controlled.  

What is a conveyor belt?

A conveyor belt is a system that consists of a flexible belt looped over two or more pulleys that rotate, moving the belt and any material placed on it from one location to another. It's commonly used in various industries for transporting materials and goods across short or long distances within a site. The main functions of a conveyor belt include transportation, assembly processes, sorting, loading and unloading. Overall, conveyor belts are crucial for improving efficiency, speed, and accuracy in the handling and processing of materials and products.

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How conveyor belts work

So, at its core, a conveyor belt operates on a relatively simple principle: it consists of a belt that moves over a series of rollers or a flat surface. Simple, right? The belt is made from various materials like PVC, rubber, or mesh, depending on the application, and is powered by motors. These motors rotate the rollers, which in turn move the belt and the goods placed on it.

The operation of a conveyor belt involves several key components:

1. Motor drive

The heart of a conveyor belt system is the motor drive, which provides the necessary power to turn the drive pulley. This motor can vary in size and power depending on the load it needs to move and the speed at which the belt must operate. Motors are typically electric and can be equipped with speed controllers to adjust the conveyor belt's velocity according to the operational requirements.

2. Drive pulley

Attached to the motor drive is the drive pulley. This pulley is responsible for imparting the motion to the belt. As the motor rotates the pulley, the belt moves in the direction of the motor's rotation. The drive pulley is often coated or made of materials that increase its grip on the belt to prevent slippage.

3. Conveyor belt material

The belt itself is a critical component, made from various materials such as rubber, PVC, neoprene, urethane, or nylon, based on the application's specific needs. The choice of material affects the belt's durability, friction, and capability to transport different types of goods. For instance, a belt designed to carry sharp objects might be made from tougher materials to resist cuts and wear.

4. Idler rollers

Positioned along the conveyor frame, idler rollers support the belt and the goods being transported. These rollers help maintain the belt's tension and ensure it remains aligned and flat. They also reduce the friction and wear on the belt, extending its lifespan. In some systems, idler rollers can be adjusted to change the belt's path or tension.

5. Conveyor frame

The frame serves as the backbone of the conveyor belt system, providing support for the rollers, motor, and belt. It is typically constructed from steel or aluminum for durability and can be designed to accommodate various conveyor lengths and widths.

6. Control system

Modern conveyor belts are often part of an automated system controlled by a central computer. This control system can dictate the belt's speed, direction, and even integrate with sensors to start or stop the belt automatically based on the workflow. For example, in a warehouse, the system might pause the belt to allow for the automated sorting or scanning of packages.

Let&#;s take a closer look at how the conveyor belt is controlled.  

A conveyor belt is a system that consists of a flexible belt looped over two or more pulleys that rotate, moving the belt and any material placed on it from one location to another.

How a conveyor belt is controlled

The control of a conveyor belt is a critical aspect of its operation, ensuring that the system can efficiently and safely transport materials according to the specific needs of a facility. Modern conveyor systems are equipped with sophisticated control mechanisms that allow for precise management of the belt's movement, speed, and direction. Here's more specifically how these systems are controlled.  

Control systems and automation

Most conveyor belts are part of an automated system controlled by a central computer or programmable logic controller (PLC). These control systems are programmed to manage the conveyor's operation, including starting and stopping the belt, controlling the speed, and directing the belt's movement. The automation allows for seamless integration with other systems within a facility, enabling synchronized operations that enhance overall efficiency.

Speed control

The speed of a conveyor belt can be adjusted to match the operational requirements of a task. Variable speed drives (VSDs) or variable frequency drives (VFDs) are commonly used to control the motor's speed, allowing the conveyor to operate at different speeds as needed. This is particularly useful in assembly lines or when handling materials that require careful handling.

Direction control

Some conveyor belts are designed to move in both directions. This capability is controlled by reversing the motor's direction, allowing the conveyor to transport materials to and from different locations within a facility. Direction control enhances the flexibility and utility of the conveyor system.

Sensors and feedback loops

Conveyor systems often incorporate sensors and feedback mechanisms to monitor and control the belt's operation. These can include photoelectric sensors, proximity sensors, and weight sensors. They provide real-time data on the conveyor's status, such as the presence of items on the belt, the belt's alignment, and the load. This information is used to make automatic adjustments to the conveyor's operation, improving efficiency and preventing issues like overloads or jams.

Safety controls

Safety is a paramount concern in the control of conveyor belts. Emergency stop buttons, safety switches, and guards are integrated into the control system to ensure safe operation. These features allow for the immediate stopping of the conveyor in case of an emergency, protecting both the workers and the materials being transported.

Integration with Warehouse Management Systems (WMS)

In advanced logistics operations, conveyor belts are often integrated with Warehouse Management Systems (WMS) and other automation technologies. This integration allows for the coordinated movement of goods, optimizing the flow of materials through processes like sorting, packaging, and shipping. The WMS can dictate the operation of the conveyor belt based on real-time inventory needs, enhancing the precision and timing of material handling.

Modern conveyor systems are equipped with sophisticated control mechanisms that allow for precise management of the belt's movement, speed, and direction.

Evolution of conveyor belts: Advanced features

As conveyor belt systems have evolved, so have their capabilities, integrating advanced features that enhance functionality, efficiency, and adaptability in dynamic warehouse environments. These advancements are not just about moving goods from point A to point B; they are about optimizing the entire logistics chain within the warehouse, from sorting and tracking to load management and operational flexibility. The integration of technology into conveyor systems allows warehouses to handle a more significant volume of goods, improve accuracy in processing and shipping, and adapt to changing demands with greater agility.

Advanced conveyor systems may include features such as:

• Variable speed controls: Allows the conveyor to speed up or slow down based on the operational needs, optimizing workflow.
• Reversible direction: Some conveyor belts can move in both directions, offering greater flexibility in how goods are moved within a facility.
• Automated sorting systems: Integrated with sensors and actuators, these systems can identify items on the belt and direct them to specific locations.
• Load sensors: Detect the presence of items on the belt, allowing the system to automatically adjust its operation to prevent overloading or jams.

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How conveyor belts integrate with the AutoStore System

The integration of the AutoStore system with conveyor belts represents a significant advancement in warehouse automation, merging the high-density storage capabilities of AutoStore with the efficient material transport provided by conveyors.

AutoStore systems, known for optimizing storage density and retrieval speed, work seamlessly with conveyor systems that excel in moving goods swiftly from one point to another. This integration minimizes manual handling and streamlines operations, making warehouses more efficient and reducing the time needed for order processing.

Many AutoStore Workstation designs, such as the FusionPort, incorporate space for conveyor installation, ensuring a smooth flow of goods from the storage Grid to the conveyor system.

Key integration points

1. Conveyors at AutoStore Ports: Conveyor belts are effectively integrated at AutoStore Workstations (Ports), where goods are picked and placed onto conveyors for immediate transport to areas like shipping or packing. This setup enhances order fulfillment speed and reduces manual labor.
2. Design compatibility: Many AutoStore Workstation designs, such as the FusionPort, incorporate space for conveyor installation, ensuring a smooth flow of goods from the storage Grid to the conveyor system. This design consideration facilitates a compact and efficient workspace.
3. Transfer cells: Beyond Workstations, AutoStore can also have Transfer Cells for direct Bin movement from the AutoStore Grid to conveyors. This feature is helpful for optimizing the flow of goods within the warehouse, allowing for a more flexible sorting and distribution process without manual intervention.

The transfer cell is used at Siemens and is crucial for optimizing the flow of goods within the warehouse, allowing for a more efficient sorting and distribution process without manual intervention.

All in all, the strategic integration of AutoStore with conveyor systems significantly boosts warehouse operation efficiency. By combining AutoStore storage optimization with the transport efficiency of conveyors, warehouses achieve a streamlined, productive environment that minimizes manual labor and maximizes operational speed and accuracy. This synergy showcases the future direction of warehouse automation, emphasizing efficiency, and lean operation.

Conclusion

Understanding how conveyor belts work unveils the sophistication behind these pivotal components of warehouse automation. From basic transportation to complex integrations with systems like AutoStore, conveyor belts have revolutionized how goods are moved within various industries. Their evolution incorporates advanced features that not only meet but anticipate the needs of modern logistics, making them indispensable for efficiency and productivity. As warehouses continue to seek solutions that minimize manual labor and maximize operational throughput, the role of conveyor belts becomes increasingly central, embodying the future of automated and efficient logistics operations.

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FAQ

What causes the conveyor belt to move?

The movement of a conveyor belt is primarily caused by a motor drive that powers a drive pulley. The rotation of this pulley exerts force on the belt, causing it to move. The belt's movement is guided by rollers or a flat surface that support it across the system.

What makes the conveyor belt run?

A conveyor belt runs due to the mechanical action of a motor that turns the drive pulley. This pulley, in contact with the conveyor belt, transfers its rotational motion to the belt, propelling it forward. The system's design, including the belt's tension and the alignment of rollers, ensures smooth and continuous operation.

What are the basics of a conveyor belt?

The basic components of a conveyor belt system include the conveyor belt itself, which is made from materials like rubber or PVC; the motor drive that provides the power; drive and idler pulleys (or rollers) that support and move the belt; and a control system that manages the belt's speed and direction. These elements work together to transport items efficiently from one location to another within a facility.

How does a belt system work?

A belt system works by converting the rotational motion of a motor into the linear motion of a conveyor belt. The motor rotates a drive pulley, which then moves the belt around the conveyor system. The belt travels over idler rollers or a flat surface that maintains its path and tension. Items placed on the belt are thus transported along the system's length. Control systems can adjust the belt's speed and direction, enhancing the system's flexibility and efficiency in material handling processes.

The belt conveyor compared to other conveyors

Among the different types of conveyors, the belt conveyor stands out for its versatility and efficiency. This conveyor can be used to transport goods of different sizes and weights, making it ideal for warehouse processes.

Roller conveyors are also a popular conveyor, especially for heavy and large loads. However, compared to roller conveyors, a belt conveyor has several advantages. For example, it is more flexible in use, especially due to the following features:

• greater flexibility in terms of dimensions and weight of goods (min/max);
• ability to transport at a wide angle;
• possibility of transporting goods without trays and containers;
• possibility of setting a higher conveying speed than with a roller conveyor.

The economic advantage of using belt conveyors compared to roller conveyors starts at an alternating conveying length of 10 metres.

Belt conveyors: the most frequently used areas

The belt conveyor is one of the most versatile conveyors used in a wide range of warehouse logistics industries. These include: the manufacturing industry, the automotive industry, the food industry, the pharmaceutical industry, courier services and DIY.

The conditions for using a belt conveyor can vary depending on the industry and the requirements for transporting goods. In industry, for example, belt conveyors are used to transport goods in production areas, to transport goods from one workstation to another and to transport goods on picking and shipping lines.

If necessary, it can be made resistant to various climatic conditions &#; low temperatures, high humidity, dust and dirt. For this purpose, materials that are easy to clean are used in the manufacture of the conveyor. This allows it to be used in the food and pharmaceutical industries, where hygiene and safety requirements are particularly strict.

The belt conveyor in warehouse logistics

The use of a belt conveyor in warehouse logistics optimises the transport and picking of goods in the warehouse. In our warehouse automation projects, the belt conveyor accounts for about 10% of the total conveyor technology.

The most important advantages of using a belt conveyor in warehouse logistics:

Increased warehouse productivity: The use of belt conveyors increases the efficiency of the warehouse and reduces the time and labour required to transport goods. It increases labour efficiency in the warehouse and reduces personnel costs.

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Handling of different types of boxes and small goods: The belt conveyor is suitable for different types of packaging such as poly bags, plastic trays and corrugated cardboard boxes. In addition, it enables the handling of very small goods that cannot be transported with a roller conveyor.

Efficient use of space: the conveyor can be positioned in any area of the warehouse, depending on the main tasks of the warehouse and the need to optimise certain processes. The latest development of the KAPELOU team, which has been successfully tested, is the new drive station of the belt conveyor. It allows for use in confined spaces, as the drive motor is placed underneath the conveyor. This solution requires significantly less floor space.

Reduced risk of damage to goods: The belt conveyor allows goods to be moved without the need for manual transfer, reducing the risk of damage.

Increased conveyor speed: The belt conveyor can be adjusted to the desired speed of goods movement. This has a positive effect on the speed of delivery to the customer.

Improved working conditions: The belt conveyor can reduce employee workload and improve working conditions by eliminating the risk of employee injury.

Modularity: The configuration of the belt conveyor can be changed according to the needs of the company. This allows a company to respond quickly to market changes and improve warehouse processes according to product demand.

Belt conveyor. Tasks in the warehouse

Goods transport: A belt conveyor transports large quantities of goods &#; from the goods receiving area to the warehouse, from the warehouse to the packaging and shipping area, etc. If food or medicines have to be stored under special conditions, e.g. under temperature control, these goods can be brought to the right areas of the warehouse with the help of belt conveyors.

Shipping goods from the warehouse, loading into the warehouse: A telescopic conveyor, a type of belt conveyor, can be used to optimise the process of loading goods from the warehouse directly into vehicles for delivery to customers, as well as loading from vehicles into the warehouse.

Product sortation: The belt conveyor can be used for sorting goods in the warehouse. It allows goods to be categorised and delivered to the correct areas of the warehouse. Large warehouses use the belt conveyor to pack goods into batches that can then be sent to customers in separate shipments.

Facilitating inventory and accounting in the warehouse: In conjunction with vision systems and WMS, the belt conveyor takes on the task of classifying goods fully automatically &#; it directs them to the right place, which makes the above processes much easier.

Order picking: The conveyor can be part of the automation system for picking orders, reducing the time needed to process them.

Which conveyor to choose: Roller conveyor or belt conveyor

The choice between roller conveyor and belt conveyor depends on the area of application as well as the requirements in the warehouse and the tasks.

The roller conveyor is suitable for transporting large and heavy goods such as pallets and crates. The rollers make it possible to reduce the resistance to movement, which facilitates the transport of large goods. Belt conveyors are suitable for transporting light and small goods such as boxes and polybags.

It is also important to consider the financial possibilities of the company. The roller conveyor with a drive zone is usually more expensive than the belt conveyor. In addition, the choice between roller conveyor and belt conveyor can be influenced by the technology used in the warehouse, as well as the size of the goods, the packaging material and the technical characteristics of the conveyor. We therefore recommend that the choice of conveyor is made carefully, taking into account all possible factors.

Belt conveyors. How to choose the optimal speed

The speed of the belt conveyor is set in the planning concept according to the throughput requirements of the entire automation system or a specific storage area. As a rule, the speed is set at 0.2 to 0.5 m/s in the employee area where the goods are loaded or unloaded from the conveyor. It reaches 0.7 m/s to 2.0 m/s on the conveyors for transporting boxes. If necessary, the speed can be reduced to 0.1 m/s.

Determining the optimum speed for a belt conveyor depends on several factors:

Distance between the products to be conveyed: A gap belt conveyor or gapper can be used to ensure the distance between the boxes and gradually increase the speed by 20%. The distance to be covered on the conveyor can also influence the choice of speed. For short distances, the speed is usually higher than for long distances.

Safety: The speed of the conveyor must be safe for the workers to avoid the risk of injury.

Need for product integrity: In some industries, the goods can be very delicate. In such cases, the conveyor speed should be slower to avoid damage to the goods.

Production volume: Larger volumes of goods require higher conveyor speeds.

Use of additional systems: The speed of the conveyor also depends on additional systems used. If goods are weighed on the conveyor or if goods are scanned on the conveyor, the speed will normally be reduced to 1.0 m/s.

Selecting the optimum conveyor speed requires careful analysis of the above factors and selection of the optimum value for efficient and safe operation of the conveyor. It is important to consider the performance requirements, which may vary depending on the industry and the specifics of the production process.

KAPELOU belt conveyor. Technical data

• Capacity &#; up to 3,600 containers/hour
• Payload &#; up to 50 kg
• Belt width &#; 450, 650, 800, 1,000 mm
• Conveyor speed &#; 0.1-2 m/s
• Belt type &#; double-layer Habasit belt
• Belt length &#; 1,600-15,000 mm
• Drive power &#; 0.3-3 kW
• Angle of conveyor incline &#; 0-16 degrees.

Belt conveyor for the warehouse. Essential characteristics

The belt is one of the most important components of a belt conveyor. It keeps the entire process running smoothly by moving goods in a continuous flow from one part of the warehouse to another without interrupting loading and unloading. A modern belt conveyor is capable of transporting large quantities of goods, including heavy and difficult-to-transport goods. The efficiency of the entire system depends on the choice of belt for the application.

A belt can be made of different materials &#; rubber, plastic, metal or fabric. Depending on the needs of the warehouse, the belt can also have different widths, thicknesses and lengths. For the production of our belts, we use a belt from the Swiss company Habasit, the world market leader among conveyor belt manufacturers. These belts have widths of 450 mm, 650 mm, 800 mm and 1,000 mm. The most important feature is reliability and strength, because it must be able to withstand the heavy weight of the goods.

For horizontal conveying, the belt is characterised by increased strength in the transverse direction &#; it bends slightly in the running direction and not in the transverse direction. This results in greater stability under lateral loads. With inclined loads, the belt has a higher coefficient of friction on the effective surface. The belt is selected according to the principle of better adhesion of the material being conveyed. The belt is secured against tipping by end rollers.

Other key features of the belt conveyor

The KAPELOU belt conveyor is equipped with an intermediate piece, a rigid galvanised steel structure, end rollers, upper curve, lower curve, drive station and calipers. It allows quick installation and replacement of each element. The material from which the conveyor is made is characterised by high corrosion resistance and mechanical strength.

The inclined belt conveyor is equipped with an upper and lower deflection unit with adjustable rollers for a smooth transition between the inclined and horizontal sections of the conveyor. A smooth transition is necessary to reduce noise when transporting goods on the belt and to extend the life of the conveyor.

Placing the main drive elements in the drive station, which is equipped with a tensioning device, facilitates installation, maintenance and servicing of the conveyor. To adjust the height for each type of conveyor, stands are used on which the conveyor is mounted.

Depending on the requirements of a particular project, the belt conveyor can be equipped with a motor with an electric brake to prevent it from spinning in the event of a power failure.

The belt conveyor in KAPELOU&#;s projects

Express One: The belt conveyor was the most important automation element in a project for Hungary&#;s largest courier company, which belongs to the Austrian Post and delivers more than 60,000 parcels every day. The 40-metre-long belt conveyor transports up to 1,000 parcels of different shapes and weights per hour.

The belt conveyor is divided into four parts: The first part is at a standard height of 700 mm above the floor, the second part is a smooth ascent onto the platform, the third part is placed on the platform and the fourth part is a smooth descent from the platform to a height of 700 mm above the floor. This solution enables efficient use of the storage space and provides a clear passage for the storage equipment. The implemented system, the key element of which is the belt conveyor, enables sorting of standard, large and non-typical parcels.

Kalynivka Logistics Centre: In order to increase the productivity of one of the most modern warehouse complexes in Ukraine with an area of 72,000 m2, we implemented an extensive automated storage system, in which the belt conveyor played an important role. The belt conveyor transports the totes in the storage area at a 16-degree angle and is shaped like a shaft &#; allowing workers to move freely between the right and left storage areas. Details of the case at the link.

Watsons: For the largest international retail chain of health and beauty products in Ukraine, we equipped the picking area with more than 420 metres of belt and roller conveyors from our own production. They enable the safe transport of 13,000 items &#; cosmetics, perfumes, hygiene products, household goods and pharmaceuticals.

Conclusion

In KAPELOU projects, the belt conveyor is part of the automation concept in almost every project. For example, when goods need to be transported at an angle or in the area of high-speed barcode scanning or to reduce manual labour. The belt conveyor can reduce the time for goods transport in the warehouse and the workload of the employees by 40 %. Our experts will be happy to advise you and help you implement an effective solution based on belt conveyors of any kind &#; exactly what your warehouse needs.

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