Selecting a Gear Motor for Zero-Pressure Conveyor Zones
Zone conveyors are sized by belt load, accumulation time and jam torque rather than by nameplate power. A practical checklist for specifying the drive unit.
A zero-pressure accumulation conveyor is not one machine but a chain of independently controlled zones. Each zone motor starts, stops and jams many thousands of times per shift, which changes what matters in the specification.
Start from the load, not the power
Calculate the torque required to move the loaded zone at line speed, then add the torque needed to accelerate the product mass within the target ramp time. The resulting operating point, not the motor nameplate, determines whether the drive will run cool.
- Belt or roller friction torque at steady speed
- Acceleration torque for the product mass in the zone
- Radial load on the output shaft from belt tension
- Jam torque the gearhead must survive without tooth damage
Choose the reduction for the jam case
Jam events define the mechanical limit of the drive. A gearhead selected only for steady-state torque will fail on the first pallet that wedges against a side guide. Specify the peak torque the stage must transmit, and verify the output bearing rating against the belt side load.
Put the intelligence in the drive
Decentralised controllers mounted on the motor allow current-based jam detection within milliseconds and remove the need for a cabinet per zone. Fieldbus addressing lets a single cable carry power and commands along the whole conveyor frame.
For a worked example based on your line speed, product weight and zone length, send the parameters to our application team and we will return a matched motor, gearhead and controller set.