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RollerDrive drive selection


The RollerDrive is are often used on zero pressure accumulation conveyors.

The principle of ZPA (Zero Pressure Accumulation) conveyors is based on the segmentation of the conveyor into zones. The zone length is determined by the length of the package to be conveyed plus its run-on. One zone essentially comprises a RollerDrive, a sensor, idlers (rollers without their own drive), torque transmission belt and a controller.

A typical ZPA conveyor consists of a number of zones, such as this, which communicate with each other by means of ZoneControls, and ensure that only a minimal number of RollerDrives are in operation, or as many as are needed to transport the material to be conveyed.

This zonal principle thus differs fundamentally from conventionally driven conveyors, on which the central drive is running constantly, thus creating substantial energy consumption. The ZPA principle guarantees excellent availability of the materials to be conveyed at the discharge point. It is primarily used where the feed frequency runs asynchronously to the picking frequency of the material to be conveyed on the conveyors. The ZPA principle thus acts as a buffer.

RollerDrive Zones

1 Start photo cell (optional)
2 RollerDrive connection
3 Photo cell connection
4 Communication cable (Easy-Bus)
5 24 V bus system







The following diagrams show two examples of zone control.

In individual pull-off mode, a control PCB communicates with an upstream and a downstream zone.

individal pull-off-mode

1 Zone 1 receives a start signal.


2 Container A leaves the conveyor segment.


3 Zone 2 receives a start signal from Zone 1.Container B moves to Zone 1.


4 Zone 3 receives a start signal from Zone 2. Container C moves to Zone 2.


5 Zone 4 receives a start signal from Zone 3. Container D moves to Zone 3.




In block pull-off mode, a control PCB can receive a start/accumulation signal from the furthest away downstream zone and then gives a start/accumulation signal to the furthest away upstream zone. The following example shows zone 1 in individual pull-off mode.

block pull-off-mode

1 Zone 1 receives a start signal.


2 Container A leaves the conveyor segment.

3 Zone 1 gives a start signal to the upstream zones 2, 3 and 4. Containers B, C and D move forwards.

4 Zone 1 receives a start signal and container B leaves the roller conveyor section.

5 Zone 1 gives a start signal to the upstream zones 2, 3 and 4. Containers C and D move forwards.



RollerDrive BT100

With a continuous power output of 11 W, the BT100 represents the first unit in the RollerDrive range. It is the optimum solution for applications with lower throughputs. Due to the simplicity of its control, the BT100 can be integrated simply and easily into the most diverse schemes.

No special controller with current limitation is needed. With an operational lifetime of 6,000 hours, the BT100 can convey up to 14 million items over an average zone length. Operating at a noise level of 47 dB(A), the BT100 is the quietest RollerDrive. This is achieved by means of a single- and two-stage helical polymer gear box and decoupling.

The RollerDrive BT100 is widely used for returning empty containers, accumulation sections, buffer sections and for supply for order picking. Many IP66-compliant applications can also be achieved. Owing to its very low noise level, the BT100 is ideally suited for applications in assembly plants, where the automated conveyor is often the only moving mechanism.

The BT100 represents a particularly cost-effective and attractive solution when combined with the BT Z-Card 4-zone accumulation controller.

RollerDrive EC310

The RollerDrive EC310 is the best choice for a wide range of applications. The product portfolio has been significantly shored up in the electronically commutated sector to provide a product and control range for practically all applications. With a mechanical output of 32 watts and new and different gear stages, it is now possible to coordinate the drive perfectly with the application.

Energy recovery is the key to optimising the motor. When the EC310 switches to braking mode, this means that there is no longer a driving signal at the drive so that the movement energy of the materials being conveyed is converted into electrical current. This is then returned to the DC mains and is again available to other RollerDrives and consumers. With all RollerDrive models to date, the motor winding is used as braking resistance and thus the movement energy of the materials being conveyed are purely converted into heat in the motor. This results in the thermal balance of a drive such as this being additionally impacted by the braking. It has been possible with the EC310 to remove this energy from the drive and reuse it. Under the best conditions in cyclical operation, this provides an energy saving of approx. 30%.

At the same time the drive heats up considerably less. The braking and acceleration power of the RollerDrive EC310 is also significantly superior to other 24 V drives. In order to prevent harmfully high voltage building up in the DC mains and thereby possibly damaging other connected components, all Interroll controls (DriveControl 20, DriveControl 54 and ZoneControl) include brake choppers. A brake chopper is a voltage-switched load resistance that is activated when a DC bus voltage of 27 V is exceeded and prevent the voltage from rising above 30 V. In the majority of applications, the chopper does not become active as there are several consumers on a power unit and the energy that is fed back is absorbed and does not lead to an increase in voltage in the DC mains.
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