Accumulation Roller Conveyor

An accumulation roller conveyor is a specialized type of roller conveyor designed to allow items to stop and accumulate at specific points along the system without causing pressure or damage to the goods. This is particularly useful in applications where products need to queue or buffer before moving to the next stage. Unlike standard roller conveyors that continuously move items, accumulation conveyors offer controlled pauses, making them a key component in automated and high-efficiency material handling systems.

Conveyor Rollers

• Typically made from steel, aluminum, or plastic, depending on load requirements. Steel rollers handle heavy items, while plastic suits lighter or delicate goods.
• Rollers may be powered or unpowered in specific zones, depending on the design.

Drive Mechanism

• Powered: Most accumulation conveyors are motorized, using belts, chains, or individual roller motors (e.g., 24V DC motorized rollers) to drive movement.
• Zoned Control: The conveyor is divided into zones, each independently controlled to start, stop, or slow rollers as needed.

Accumulation Technology

• Zero-Pressure Accumulation (ZPA): Sensors (e.g., photo eyes) detect items and stop rollers in a zone when an item is present, preventing collisions or pressure buildup.
• Low-Pressure Accumulation: Rollers slip or slow under load, allowing items to accumulate with minimal contact force.

Conveyor Frame

• Constructed from sturdy materials like steel or aluminum, supporting the rollers and load while accommodating zoned sections.

Control Systems

• Equipped with programmable logic controllers (PLCs), sensors, or pneumatic systems to manage zone activation and item flow.

Roller Spacing

• Adjustable to suit the size and shape of items, ensuring stable accumulation without gaps or instability.

Safety Features

• Includes emergency stops, guards, and sensors to prevent jams or overflows, protecting both goods and operators.

Modularity

• Can be integrated with straight, curved, or inclined sections to fit complex layouts.

This picture is simple layout of accumulation roller conveyor layout.

• Prevents Damage: Zero- or low-pressure accumulation protects fragile or sensitive items by avoiding collisions or excessive force.
• Improved Workflow: Allows buffering or queuing, ensuring downstream processes aren’t overwhelmed and upstream production continues uninterrupted.
• Automation-Friendly: Easily integrates with sensors, robotics, and control systems for seamless operation in automated environments.
• Flexible Control: Zoned design enables precise management of item flow, adapting to varying production speeds or bottlenecks.
• High Throughput: Maintains efficiency in high-volume settings by staging items without slowing the overall system.
• Versatility: Handles a range of load types, from small packages to heavy pallets, depending on the roller and drive design.

• Warehousing and Distribution: Buffers packages before sorting, packing, or shipping, preventing bottlenecks in high-volume operations.
• Manufacturing Assembly Lines: Stages parts or products between workstations, allowing time for assembly or inspection without halting upstream flow.
• E-commerce Fulfillment Centers: Accumulates orders at packing stations, ensuring workers can process items at their own pace while maintaining system efficiency.
• Food and Beverage Processing: Queues delicate items like bottles or trays before packaging, using zero-pressure accumulation to avoid damage.
• Automotive Production: Holds heavy components (e.g., chassis parts) between robotic assembly steps, syncing with production timing.
• Pharmaceutical Handling: Manages sensitive products like vials or boxes, staging them for labeling or quality checks without risk of crushing.
• Airport Baggage Systems: Accumulates luggage at sorting or loading points, preventing jams and ensuring smooth flow through terminals.