PLANNING BASICS
CONVEYING GOOD

Conveying good
This chapter is intended to provide support in the planning of
conveyor systems and the selection of matching products.
The properties of the conveying good, the requirements withregards the conveyor system and the ambient conditions are thebasis for the planning of the system.

Length and width of conveying good

· Minimize the roller pitch as much as possible to ensure that the
products are conveyed smoothly with as large a base surface
as possible.
· Avoid rapid acceleration and harsh braking. Use MultiControl
or ConveyorControl as far as possible for controlling EC5000.
These control systems allow for purposeful matching ofacceleration and deceleration of the RollerDrive.
· With inclined conveyor tracks, determine the center of gravityof the conveying good and check whether there is a risk of it
tipping.

The length and width of the conveying good have an effect onseveral factors:

Weight and weight distribution of the conveying
goodStraight running: The higher the ratio of length to width, themore stable will be the straight running of your items. With
smaller length to width ratios, it may be necessary to put in place
additional measures to stabilize the straight running of theconveying goods.

The weight of the conveying good must be distributed on anumber of conveyor rollers so that the maximum load capacity of
the individual conveyor roller and RollerDrive is not exceeded.
This may mean that more than three conveyor rollers must
support the conveying good.

Reference length: As a rule, the reference length corresponds tothe conveyor width +50 mm or for large conveying goods, suchas pallets, +100 mm. In curves, Interroll recommends the use oftapered conveyor rollers and RollerDrive whose length must be
calculated separately (see page 192).

In principle the weight of the conveying good should be
distributed as evenly as possible. The more uneven the weight
distribution is, the more difficult a reliable conveyance is.

Roller pitch: To transport the conveying good without problems,
the roller pitch must be selected so that the conveying good is
carried by three conveyor rollers at any given time.
Surface pressure: The different Interroll Conveyor Rollers andRollerDrive can be loaded with different forces. The static load
capacity can be taken from the respective chapter. The values
are based on the assumption that a conveying good rests on thecomplete usable tube length and not just on a part of it. If aconveying good has contact with less than approx. 50 % of theusable tube length, please have the application checked byInterroll beforehand.
Very long conveying goods generally do not rest on all conveyor
rollers and RollerDrive that are located under them. If, forexample, 20 conveyor rollers are under a piece of conveying
good, but the conveying good contacts only 15 conveyor rollers,then the load capacity of a roller must be greater than onefifteenth of the conveying good weight. For very long conveying
goods, the tolerance of the roller fastening height for conveyor
rollers and RollerDrive should be kept as low as possible so thatas many conveyor rollers as possible can carry the conveying
good.

Height of conveying good
The greater the height of the conveying good in relation to its
bottom area, the higher is the risk of it tipping over whentraveling on the conveyor. The following must be taken into
consideration:

182

If the weight of the goods is mostly at the front, then it is very
likely that the rollers at the end of the load carrier support only
very little weight. In the worst case scenario, the rollers at thestart of the load carrier could be overloaded.
The load capacity increases with larger tube diameter. For heavy
conveying goods, RollerDrive with a diameter of 60 mm should
be used instead. The load capacity is increased by rollers withthreaded shafts. In addition, the shafts reinforce the conveyor
and act as a cross tie.
Drive elements, such as round belts or toothed belts, must also be
selected while taking the conveying good weight into
consideration. Interroll recommends PolyVee belts for conveying
containers and cardboard cartons. Their service life and torquetransmission is significantly higher compared to round belts.

Material of conveying good
The material, and especially the condition of the base, has aneffect on the rolling and starting resistance.
Hard materials, such as polymer containers, feature lower rollingand starting resistances than soft materials, such as cardboard
cartons. This has a direct impact on the required drive output andmust be included in its calculation. The softer the underside of theconveying good, the higher is the drive output required for a
product with the same weight but with a hard underside. In
principle, the softer the conveying good, the smaller the roller
pitch needs to be.

© 12 | 2021 Interroll

General technical information

PLANNING BASICS
CONVEYOR REQUIREMENTS

Conveyor requirements
The following fundamental parameters determine theconfiguration of the conveyor:

13%

24%

13%

The topic of environmental conditions is discussed below.

Static charging
In principle, conveyance via rollers creates electrostatic charging
which, among other things, depends on the properties of theconveying good and the tube material.
To prevent electrostatic charging from occurring or dissipate it
immediately and without creating sparks, Interroll offers antistatic
versions for rollers with steel tube. RollerDrive feature anantistatic design in principle. Sleeves, lagging and gray tapered
elements do not feature an antistatic design. For this reason,
Interroll recommends the use of black tapered elements forcurves.
Antistatic conveyor rollers and RollerDrive require the proper
manufacturing and check of the conducting connection between
shaft and side profile and the grounding of the side profile by thesystem manufacturer.

Noise level
13%

24%

13%

Fig.: Support of 2 runners

8%

12%

8%

12%

20%

12%

8%

12%

8%

Noise is created by different components of a conveyor and theconveying good itself.
Every drive creates noise. The RollerDrive is designed withdecoupling elements which reduce the noise of the gear box. In
most cases, the noise level of the RollerDrive is below 50 dBA.
More and more zero-pressure accumulation conveyor systems
are converted from pneumatic solutions with a centrally arranged
drive to a RollerDrive solution. The significantly lower noise levelis a deciding factor here.
The following applies to the noises of drive elements: A chain
drive causes more noise than a belt drive. At high accelerations
and decelerations, slipping round belts can cause squealing
noises. Interroll recommends reducing the acceleration anddeceleration of RollerDrive or using PolyVee belts. In this case, therisk of squealing noises is greatly minimized.

Fig.: Support of 3 runners© 12 | 2021 Interroll

Rollers | Conveying elements | Accessories

When checking whether a roller has sufficient load capacity for
an application, it is important to take the condition of theconveying good into consideration. Conveying goods with anuneven bottom generally do not rest on all rollers that arelocated under them. With pallets, it must be ensured that only therollers under the bulk of the pallet are actually bearing the load.
The following diagram shows which runner load distribution
occurs for an evenly loaded euro-pallet.

Maximum throughput per time unit
Geometry of conveying good
Weight and weight distribution of the conveying goodControl requirements
Environmental conditions

183

Planning basics

Ribs, keyways, strips or grooves in the bottom of conveying goods
that run parallel to the direction of conveyance, do not pose a
problem concerning transportability. The required drive output
increases depending on their shape. Cross ribs can negatively
impact the transporting. It may be necessary to determine theroller pitch empirically.

·
·
·
·
·

PLANNING BASICS
DRIVE CONCEPTS

Very quiet rollers, RollerDrive and drive elements are of little use
if the conveying good on the conveyor creates noise. Various
measures can counteract it. The following should be observed inthis case:· A small roller pitch generally causes less noise than a large
roller pitch.
· Keep height tolerances at transitions from conveyors and at thefastening of rollers/RollerDrive as small as possible.
· Fitting the rollers/RollerDrive with noise-reducing materials, e.g.
with a PVC or PU sleeve· Use of noise reduction inside of rollers for rollers with adiameter of 50 mm.

Humidity
Humidity can occur in different forms as a result of the following:· moist conveying goods, e.g. bottle crates stored in the rain
· moist environment, e.g. sculleries· applications that become moist, e.g. because of cleaning or
tripped sprinkler systems
If humidity can be expected in a system, then all components
should be checked for corresponding resistance.
Interroll offers a series of products that are suitable forapplications with humidity, water exposure, or water jets:
Tube material: Rollers and RollerDrive can be manufactured
from rust-free material, such as stainless steel. In addition,materials can be protected with different finishing processes, suchas zinc-plating.
Shaft material: Shafts for conveyor rollers can be manufactured
from rust-free material, such as stainless steel.
Drives: The RollerDrive already has a high degree of protection
with protection rating of IP54. If water jets can be expected in theapplication, Interroll recommends the design with protection
rating IP66.
Bearing: All rollers with precision ball bearings are well
protected against moisture and dust. For systems with constanthumidity or moisture, Interroll offers designs with stainless steel
ball bearings.

Applications in deep freeze area
Applications with an ambient temperature of approx. –28 °C are
particularly prevalent in the food processing sector. Many items
must be taken into account in the so-called deep freeze area:· Changed starting torque of conveyor rollers and drives.
· Increased viscosity of greases, e.g. in ball bearings or gearboxes.
· Possibly frozen and, therefore, less flexible components, such as
drive elements.
· Functional safety of all components through different
contraction of various materials.
The solutions from Interroll
Materials: For various products, Interroll offers variants that are
particularly suited for deep freeze applications. The tapered
elements for conveyor rollers and RollerDrive are manufactured
impact-resistant. Conventional materials used are often brittle
and break easily. The bearing housings of series 1700 are
designed as high impact-resistant for deep freeze applications.
Drive elements: Before using a drive element, its suitability fordeep freeze applications should be checked. It should also beensured that the friction at temperatures below zero is sufficientand the drive elements cannot freeze since frozen drive elements
could pose unplanned torque requirements for the drive. The
PolyVee belts offered by Interroll are suitable for deep freeze
application (see page 180).
Bearing: The precision ball bearings used also work in deep
freeze conditions. However, the startup of the roller is higher inthis case than at an ambient temperature of 20 °C. RollerDriveare either designed for this higher startup, or oiled ball bearings
are being used. The oiled bearings run significantly smoother attemperatures below zero.
Under deep freeze conditions, materials such as steel andpolymer contract in different ways. For functional reliability, a
PolyVee drive head for a RollerDrive is not only pressed into thesteel tube, but it is also flanged. Additional security is provided bya metal star. This star, which is being produced with laser cutting,is engaged in the drive head and channels itself into the insidewall of the tube. This innovative solution inside the tube allows
avoiding interfering edges on the outside contour of the tube.
This solution is available as an option for various designs series
3500 and 3500KXO.

Drive concepts
With respect to drives, Interroll distinguishes between drives (suchas round belts, PolyVee belts, chains, etc.) and the actual drive.
Different drives are used in conveyor systems, such as drum184

© 12 | 2021 Interroll

respect to personnel and conveying good safety as well asprocess reliability. Interroll offers different products for thispurpose. The rollers of series 1100 are designed for use ingravity conveyors.

Gravity conveyors
A gravity conveyor differs significantly from the other concepts. It
is not horizontally aligned, but always mounted at an incline.
There are driven and non-driven gravity conveyors. Driven
gravity conveyors can be driven with RollerDrive. If theRollerDrive and, as such, the conveyor is stopped, the conveying
goods remain in place and do not slide downward. The EC5000
holds its position with a certain torque which prevents any
downward sliding. The different gear boxes and powers offerdifferent continuous blocking torques. It must be ensured thatconveying goods do not slide over standing rollers; if necessary,
friction must be increased, e.g. with PVC sleeve on rollers and RD.
Gravity conveyors use the potential energy of conveying goods.
This means that other technology must first move the conveying
good to a corresponding spatial height.
The conveying good rolls without additional drive as a result of
the potential energy up to the end of the conveyor or up to thepreceding conveying good. The speed and the restart capabilityof conveying goods is heavily influenced by:· The incline of the conveyor· The already existing speed of a conveying good when placed
upon the gravity conveyor· The ease of movement of the rollers· The conveyor length· The condition of the underside of a conveying good
· The weight of the conveying good
· Other properties
On the one hand, the conveying good must reach the end of theconveyor. It must not stop because its weight is too low to startmoving rollers at rest. If many conveying goods are already on a
gravity conveyor and, as a result, a piece of conveying goodstops in the last section of the conveyor, then it must be ensured
that the last item will start again and reach the end of the gravity
conveyor after the first conveying goods have been conveyed.

The magnetic speed controller MSC 50 enables the restart ofconveying goods starting at 0.5 kg and reliably decelerates
conveying goods up to 35 kg depending on the properties of theconveyor. If conveying goods are lighter than 0.5 kg or heavier
than 35 kg, it is also possible to use the RollerDrive series
EC5000.
The driven RollerDrive ensures that every lightweight conveying
good, regardless of its weight, can be moved or moved again.
When decelerating heavy conveying goods, the energy
recovered by the RollerDrive must not be too high. If one orseveral RollerDrive are used within a gravity conveyor, it also
provides the advantage of accumulation pressure reduction. If a
RollerDrive, which may be connected with additional rollers via
drive elements, is stopped, then the conveying goods stop. This
allows reducing the pressure on conveying goods that are
already on the conveyor or on the stop at the end of theconveyor. On long gravity conveyors, it may be advisable to use
several RollerDrive in order to reduce the accumulation pressure
even further. If the incline is so high that conveying goods slide
over the steel tube of stopped RollerDrive or rollers, then thefriction may be increased with a PVC sleeve on the tube.
In principle, it is recommended to test every gravity conveyor
design under original conditions.

Fixed drive conveyor
If a conveying good moves in harmony with the drive, then it isgenerally a fixed or constantly driven conveyor. The drive headof the rollers used is permanently connected with the tube. If the
fixed drive heads are replaced with friction drive heads, theycreate a friction conveyor. Many different types of fixed drive
conveyors are possible. They generally differ with respect to theselected drive element, such as chains, PolyVee belts, round belts,
etc., and the drives used.

Planning basics

On the other hand, the speed of the conveying goods must not
be or get too high. There is the risk that a conveying good hits
another jammed conveying good or the end stop at the end of
the conveyor. This creates an injury risk for employees who may
want to remove the conveying good by hand, as well as the riskof damaging the conveying good.
Establishing the matching properties of a gravity conveyor
becomes a challenge if different conveying goods have to be
moved. Generally, the conveying goods on a gravity conveyor
differ by at least one of the following properties: Weight, size,
material and base condition. A mixture of different conveying
goods can also be transported by a gravity conveyor with© 12 | 2021 Interroll

Rollers | Conveying elements | Accessories

motors, gear motors, motor rollers, etc. Furthermore, the potential
energy of conveying good, e.g. on gravity conveyors, is also
being utilized.

General technical information

PLANNING BASICS
DRIVE CONCEPTS

185

PLANNING BASICS
DRIVE CONCEPTS

For all current fixed drive conveyors, Interroll offers matching
conveyor rollers, with the RollerDrive EC5000, the Pallet Drive
and PolyVee belt even drives and drive elements. When using aRollerDrive as drive, it is recommended to place it in the middle ofthe driven conveyor rollers (for information about the Pallet
Drive, see the separate product documents). If many rollers haveto be driven, then PolyVee belts offer advantages over roundbelts. The use of PolyVee belts reduces the number of roller
revolutions with increasing distance to the RollerDrive.

level of energy can be expected for this ZPA solution since thepowerful gear motor must also be powered if, for example, only
one conveying good has to be moved on a 40-zone section.

Friction conveyor

Another concept is the use of decentral drives. Motor rollers areoften used for this purpose. In this case, drives which are directly
driving the respective rollers, are installed in one or several
rollers of a zone. A drive element connecting the entire conveyor
is redundant. The remaining rollers of a zone are generally
connected with the motor roller(s) using PolyVee or round belts.
The zones can be activated or deactivated by purposefully
switching the motor rollers on or off.

Friction conveyors are generally used to transport andaccumulate materials. The special thing about friction conveyors isthat an accumulation of materials can be accomplished with only
little accumulation pressure when the drive is switched on. The
same situation on a fixed drive conveyor would cause thematerials that were stopped first to receive so much pressure
from the subsequent materials that fragile cardboards could bedamaged. Friction conveyors are well suited for buffer sections
with non-uniform loading and unloading.
Friction conveyor rollers are available with many different drive
elements, see page 190. Even a conveyor with drive shaft can beused as friction conveyor. The guide wheel of series 2600 enables
not only guiding a round belt, but it also enables the drive shaft
to turn while the wheel remains at rest. It must be ensured thatthe round belt does not slip through as this could significantly
shorten its service lie. For additional information, see page 189.
For some application's, it is a disadvantage if the materials touch,even if the accumulation pressure is reduced by the friction
operation. In this case, a conveyor working at zero pressure
accumulation may be better suited – see the next chapter (foradditional information about friction conveyors, see page 190).

Zero pressure accumulation conveyor
The zero pressure accumulation conveying is often abbreviatedas ZPA. A ZPA conveyor is generally divided into zones. The zone
length is based on the length of the conveying good or the
longest conveying good. Each zone features an option ofidentifying conveying goods, e.g. via a photo cell. In addition,
every zone can be switched on and off. The zones are driven indifferent ways, see the examples below.
One option consists of a central drive, often a gear motor, thatdrives a flat belt. The flat belt is pressed onto the rollers using aswitchable unit or guided past them. In the case of bypassing, therollers are also often decelerated. It is feasible that the flat belt ispressed onto only a few rollers of a zone and the remaining
rollers are connected with them by means of other drive
elements. In many cases, this switching unit consists of pneumatic
valves. They frequently cause an undesired noise level. A high186

Another option always presses the flat belt against a section of aroller in every zone. The remaining portion of the roller isswitched in or out via a coupling. The remaining rollers of every
zone are connected with the driven roller via other drive
elements.

Depending on the length of the conveyor, the design with central
drive usually falls below the investment costs of a solution withmotor rollers. However, the operating costs tend to be higher due
to the constant turning of the drive, even when nothing may be
conveyed at the time. For most solutions with motor rollers, higher
investment costs are possibly amortized after a short time.
Not only the lower energy consumption speaks in favor of asolution with motor rollers, but also the compact design. The
motor is installed in a roller and does not have to be placed next
to or below the conveyor.
Compared to gear motors, motor rollers are maintenance-free,they do not have to be greased and generally offer a higher
safety level with a protected extra-low voltage.
But solutions with motor rollers can also have disadvantages. For
solutions with many motor rollers per zone, the availability
decreases – the more motors are being used, the higher the
probability that a motor roller fails.
For this reason, Interroll recommends the use of the RollerDrive
EC5000. In this case, one RollerDrive per zone is generally
sufficient, and flexible control concepts are available.
Furthermore, the controls offer many other options, such aschange of direction of rotation or start and stop ramps which are
not being offered by conventional ZPA conveyors.

© 12 | 2021 Interroll

Drive elements
With respect to drives, Interroll distinguishes between the actual
drive, such as RollerDrive, drum motor, Pallet Drive, gear motor,
etc. and the drive elements. Drive elements refers to different
types of the torque transmission. Only the following drive
elements are considered in this chapter:· Toothed belt
· PolyVee belt
· Round belt

Based on the overall efficiency of this system, long drive lengths
should be avoided. In many cases, drive lengths of more than 15
m have proven to be problematic.
FMAX can be determined with the permissible breaking load FB ofthe chain used. A safety factor of 7 (for which the wear of thechain is also within an acceptable range) is generally used for thispurpose so that FMAX can be determined as follows:

Fmax =

General technical information

PLANNING BASICS
DRIVE ELEMENTS

Fb
7

ChainsConveyor rollers with flanges welded on are often used for
guiding pallets. Guiding pallets via flanges increases the power
demand and must be taken into account during the dimensioningof the drive and drive elements.

Chain designation

Breaking load FB

FMAX

06B (3/8")

9100 N

1300 N

08B (1/2")

18,200 N

2600 N

10B (5/8")

22,700 N

3243 NThe drive output "P" required for maximum length can becalculated as follows:P=

L · μ · FttTangential transmission of force
The maximum drive length to be moved by a drive is limited by
the permissible load of the chain. The following factors determine
the maximum drive length "L":· The permissible tensile load of the chain FMAX in N
· The gravitational force of the individual material to betransported FT in N
· The roller resistance µ of the conveyor track, whereby a valueof 0.1 is generally selected· The projected conveying speed "S" in m/s· The placement cycle "t" of the materials (in S), i.e. the time
between two successive pieces of material to be conveyed
The maximum drive length "L" is being calculated:

L=

Fmax · S · t
Ft · μ

1

2

3

4

5

6

The tangential chain drive is characterized by its good level of
efficiency and simple design. The drive head (2) consists only of
one sprocket. For this reason, the installation length of theconveyor roller is shorter for a roller-to-roller drive. A single
chain (1) drives all of the rollers in a conveyor. The chain is
guided to the sprockets by a chain guide profile. The chain guide
profile (5) is usually made of special plastic and must guide thechain extremely precisely.

If the drive station is positioned in the middle of the conveyor forthe drive from roller to roller, then twice the drive length cantheoretically be implemented. The sprockets that transfer thedrive output must not be overloaded in such a case.

© 12 | 2021 Interroll

187

Rollers | Conveying elements | Accessories

Chains are not maintenance-free and are relatively loud inoperation. They must be lubricated regularly in order to achieve
an optimum service life. The noise created by a chain as drive
element increases with increasing speed. For this reason, speeds
higher than 0.5 m/s are not recommended.

According to DIN, the following breaking loads must be assumed:

Planning basics

The chain is a tried and trusted method for driving conveyor
rollers and conveyor elements in conveyor systems. Chains arecharacterized by their robustness and durability and are notsensitive to dirt and environmental influences. Very high levels of
power can be transmitted with a chain. It is recommended toprotect the chain drive against inadvertent contact.

PLANNING BASICS
DRIVE ELEMENTS

When used in fixed drive conveyors, the sprockets arepermanently connected with the tube of the conveyors. Friction
conveyors use rollers whose sprockets are not permanently
connected with the outside tube. 1 to 2 teeth of the sprockets
mesh into the chain and only transfer the driving power required
for the individual roller. The chain can be guided either along the
top of bottom of the conveyor rollers. The precise positioning of
the chain guide in relation to the conveyor rollers is extremely
important. The maximum play in terms of height is 0.5 mm. The
central motor station (4) must be installed in such a way that thedriving side of the chain is as short as possible. It is advisable toprovide the motor station with additional equipment for adjusting
the chain tension. Idler pulleys (3, 6) guide the chain at the drive
and/or end of conveyor in the corresponding direction. It is also
possible to use the last conveyor rollers as chain deflection. In thiscase, it must be ensured that these rollers feature a DIN gearing.
Idler pulleys, which have to carry not only the load of thematerial to be conveyed, but also the chain traction forces, must
be checked specifically with regard to their permissible bearing
load. The driven conveyor length is restricted by the permissible
breaking load of the chain and by the weight of the material tobe conveyed.
The roller spacing (roller pitch) can be selected as required with
tangential drives. Compared with roller-to-roller drives, theconveyor rollers are easy to fit and remove with tangential drives
since they are not wrapped by the chain.

t = Pc ·

t
nc
nt
Pc

nc – nt
2= Roller pitch=- Number of chain links= Number of teeth of drive head
= Chain pitch

The maximum conveyor length depends on the drive output of the
motor station (3) and the permissible breaking load of the chain.
The chain experiences its maximum load at the motor station. The
tolerances for the roller pitch "Pr" and the breaking load arelisted in the following table.

Chain pitch/
designation

Pc
[mm]

Tolerance
of Pr
[mm]

Breaking
load
[N]

Fmax

06B (3/8")

9.52

0 to –0.4

9100

1300 N

08B (1/2")

12.70

0 to –0.5

18200

2600 N

10B (5/8")

15.88

0 to –0.7

22700

3243 NPc
Pr= Chain pitch= Roller pitch

Toothed belt
Starting at 1,000 operating hours, a lengthening of the chain of
up to 2 % can be expected.
Wrapped force transmission

1

2

3

With wrapped force transmission, every conveyor roller isconnected to the next one by a chain (1). For this reason theconveyor rollers require double sprocket heads (2). They needmore space than with a tangential drive, so that the installation
length of the roller is longer. Double sprocket heads always
feature a DIN gearing (standard gearing).
An additional chain guide is not required. The roller pitch is
subject to very tight tolerances and depends on the chain pitch.

188

The share of toothed belts as drive element in roller conveyor
systems is declining. Toothed belts are generally used from roller
to roller and are unable to negotiate curves. Compared to roundor PolyVee belts, the power requirement of a toothed belt issignificantly higher because of its design. This must be taken into
account in the selection of the drive. Toothed belts pose a highdemand on the tolerance of the roller pitch since the toothengagement is form-fit with the profile of the drive head. Interroll
recommends obtaining the tolerances to be followed from the
manufacturer of the selected toothed belt.
One advantage of the toothed belt compared to round and
PolyVee belts, is the fact that it passes movements withoutslipping when used properly. On top of that, toothed belts are
low-noise and maintenance-free, lubricating or retensioning is not
required.
The drive length of a conveyor with toothed belt drive should be
dimensioned so that the overall load of 12,000 N conveying
good being conveyed at the same time is not being exceeded.
For the roller series 3500 and the RollerDrive EC5000, a
maximum toothed belt width of 12 mm and a Poly-Chain GT
gearing is recommended.

© 12 | 2021 Interroll

PolyVee belts are ribbed V-belts that are generally used for thetorque transmission from roller to roller in roller conveyor
systems. The belts must feature a flexible tension member which
renders them significantly less flexible than most round belts.
Nevertheless, they can accept tolerances within the roller pitch
because of their flexibility and used as drive elements in curves.
For the installation of PolyVee belts, Interroll recommends the useof a PolyVee tensioning device, see page 181.
Compared to round belts, PolyVee belts can transfer a higher
torque of up to 300 %, the service life is longer and, when usedproperly, a PolyVee belt does not slip over the drive head. In
start-stop operation, the rollers can be stopped more precisely
and, compared to round belts, a higher number of conveyor
rollers can be driven because of the high torque transmission.
Due to the design of the PolyVee drive head and the small widthof the belts, they can be placed very close to the side profile. This
leads to an optimal tube utilization for conveying goods. With thesmall diameter of the PolyVee drive head, any contact of PolyVeebelt and conveying good is generally ruled out.
In container conveyor systems, 2-rib and 3-rib PolyVee belts are
generally used. Interroll offers PolyVee belts for these designs forthe most common roller pitches, see page 180. The 9-rib drive
head also allows using 4-rib belts. The ability of high torquetransmission also carries with it a high demand on safety. Injuries,
such as jammed fingers between PolyVee belt and drive head,must be avoided. Interroll offers a finger guard for the mostcommon roller pitches. It does not have to be fastened to the side
profile and, for this reason, can be used for almost all side
profiles, see page 181.

Round belt
Round belts, also referred to as O-rings, are available in different
materials, colors and diameters. They are often used for thetorque transmission from roller to roller. Round belts are costeffective with respect to their purchase, are very flexible and canbe installed with ease. The disadvantage is a relatively poor
power transmission and relatively short service life. For thisreason, the use of PolyVee belts predominates in conveyor
systems.

The round belt drive head offers a higher conveyance for mostbelts because of its material. This significant advantage must be
taken into account if acceleration and deceleration for start-stop
operation are so high that the belt briefly slips and wears out
because of it. The better the conveyance from the guide, thehigher the wear in this case. Groove solutions in tubes and also
the round belt drive head offer 10 mm wide grooves. This allows
using round belts with a maximum diameter of 6 mm. In case ofhigher round belt diameters, there is the risk of two contact pointsof the round belt – at the bottom and at the side of the groove.
In this case, the belt is subjected to two different speeds andexperiences above average wear.

Flat belt
Flat belts are used for tangential force transmission. In this case,the flat belt is guided under the rollers and, in each case, pressedagainst a part of the roller. This can be the tube or a drive head.
Flat belts are used to construct fixed drive conveyors and friction
conveyors. It is also possible to drive zero-pressure accumulation
conveyors with flat belts. In such a case, the flat belt ispermanently driven. Stopping subsections is done by decoupling
the roller with the moving flat belt. Given the constantly turning
central drive, this type of zero-pressure accumulation conveying
leads to significantly higher energy consumption. Interroll
recommends the use of RollerDrive as an alternative.
Flat belts hardly ever need any maintenance. A precise guiding of
the belt is required. The flat belt is generally put in motion by agear motor can must be brought to a pretension of approx. 1 %with a tensioning device. The drive power is generally transmitted
more reliably if the loop angle of the flat belt on the roller can beincreased with narrowing wheels.
Interroll offers different products for the use of flat belts. The
conveyor rollers of series 1700 are frequently used for fixed
drive conveyors. The series 3500 as fixed drive head is available
with a flat belt drive head. The series 3800 offers friction
solutions for flat belts. And the series 2600 offers several
pressure rollers to guide and press on flat belts.

© 12 | 2021 Interroll

Planning basics

The round belt guides with the RollerDrive EC5000 can be
carried out via grooves in the tube or a round belt drive head.
The drive head made from polyamide offers the advantage thatthe round belts can be guided closer at the end of the RollerDriveor at the side profile of the conveyor. In this case, it is more likely
to separate torque transmission and running surface of conveying
goods. Furthermore, the concentric precision is increased since nomechanical change of the tube occurs compared to grooves inthe tube.

Rollers | Conveying elements | Accessories

PolyVee belt

General technical information

PLANNING BASICS
DRIVE ELEMENTS

189

PLANNING BASICS
FRICTION ROLLERS

Friction rollers
Introduction
If materials are accumulated on a roller conveyor and the rollers
continue to be driven, it creates accumulation pressure. Thisaccumulation pressure continues to grow the more materials arebeing driven by rollers. As a result, it can damage the undersideof the material to be conveyed. In addition, it is possible that thefirst piece of material, which is generally stopped by a mechanicalstopper, will be squashed. Friction rollers prevent these problems
by reducing the accumulation pressure.
Friction rollers are based on the principle of the slip coupling. In
this case, the friction force in the coupling must overcome therolling friction between material and roller. Friction rollers offer
the option of setting up accumulation conveyors with minimal
accumulation pressure. When materials are stopped, the rollers
will also stop. The drive of the friction rollers continues to turn inthis case. When the stop is canceled, the complete roller units turnagain and move the materials. In this case, the conveyance isload-dependent.
The bearing housing of the series 3800 is designed as a greasedfor-life slip coupling and guarantees the roller's constantconveyor force. A tangential drive has proved itself to be
especially economical when used on friction conveyors. For thispurpose, a central drive moves a long chain or a flat belt. The flat
belt or the chain are guided past the drive unit underneath theconveyor rollers so that all conveyor rollers are operating.

Application notes· Conveying goods– Even and stable bases of the conveying goods are ideal sothat each friction roller carries the material evenly. Soft,lightweight or uneven conveying goods, e.g. cardboards,
can be unsuitable for a friction conveyor.
– Only those conveying goods can be used that prevent a
mutual lifting out because of their shape. If necessary, thenumber of conveying goods to be accumulated must be
restricted.
– Round conveying goods are generally not suitable since
they distribute randomly on the conveyor during
accumulation. To prevent round conveying goods fromfalling off of the conveyor during accumulation, a suitableside guide is required.

190· The conveyor force, which is produced by the friction roller bymeans of friction, regulates itself relative to the weight of theconveying good. The conveyor force is seriously affected by
the following factors:– Weight of conveying good
– Base condition of conveying good
– Position of conveying good
– Humidity– Temperature– Percentage of accumulation mode over the entire running
time
These factors have, to an extent, a considerable effect on theoperation and operational lifespan of the conveyor roller. The
task is to find out the sufficient conveyance for the respective
conveying good to be conveyed. A dimensioning test under
original conditions is generally required for this purpose.
· To enable starting up the conveyor even with complex
conveying goods, the following measures may be helpful:– Selection of the correct friction roller. An adjustable or a
double friction roller may be better suited.
– Reducing the roller pitch: With less load on each roller, itsconveyance ability is also reduced.
– Creating a contact pressure from the drive head onto thebearing housing in axial direction.
– Design of a minor incline in conveying direction· Duration of accumulation mode
– Accumulation mode should only be used for as long as isnecessary. When it can be seen that no conveyance willtake place, then the central drive should be switched off. No
energy will be used and the service life of the conveyor
system will be increased. An overtemperature of theabrading polymer elements must be avoided.
– For long accumulation mode, steel sprocket drives offer an
improved dissipation of the friction heat.
· Placement of conveying good
– If the conveying good is significantly narrower than thefriction roller, it can affect the conveyance ability. With
single friction rollers, the conveyance decreases the further
away the conveying good is from the friction drive.
– The same applies to the center of gravity of a conveying
good. The closer the center of gravity is to the friction drive,the better the conveyance.
· Friction roller– Flanges as well as other side guides cannot be used for
friction rollers. The friction that is being created could
possibly not be overcome by the conveyor force of thefriction coupling.
– The use of friction rollers represents a minimum requirementon the tolerance of the installation height of the rollers. If afriction roller that is installed at a low level is followed by aroller installed slightly higher, this may represent aninterfering edge to the conveying good that cannot be
overcome.
– When using tube sleeves (e.g. PVC sleeves), a maximum
sleeve material thickness of 2 mm is recommended.
· The maximum permissible conveying speed is 0.5 m/s.

© 12 | 2021 Interroll

· Use only under dry conditions· The bearing housings that are part of the friction element,
contain pockets. These pockets are filled with special grease.
The grease must not be removed! It allows better startup
values, due to the high adhesive force of the grease. In
addition, friction heat that is being created, is dissipated better
through the grease, and the wear of the polymer parts is
reduced.
· The conveyance values listed below are non-binding. They
refer to standard climate (65 % relative humidity and atemperature of +20 °C) and conveying good positioned in thecenter.

the nut tensions the spring, which exerts an axial force from thedrive head onto the bearing housing. This axial force increases
the conveyance to up to 12 % of the roller load. The more thenut is tightened, the earlier the tube is turning.

General technical information

PLANNING BASICS
FRICTION ROLLERSThe product description of the series is located on page 112.
FrictionØ Friction roller
[mm]

4–6%

One-sided friction element

50

2–5%

One-sided friction element60

8 – 13 %Two-sided friction element

30/50/60/80

4 – 6 % (12 %)One-sided, adjustable friction
element

50/60

Series 3800 light
The series 3800 light offers a single friction solution as well as a
double friction solution. The rollers have a diameter of 30 mm.
The single friction rollers are equipped with steel sprocket heads
and the double friction rollers with polymer drive heads for flat
belts. The operating principle of the single friction corresponds tothat of series 3800 and that of the double friction to that ofseries 3870.

Functional differences
Series 3800

If the material is stopped, the tube stops and the drive head turns
inside the bearing housing.

The product description of series 3800 light is located on
page 108.
Series 3870
Series 3870 offers different polymer sprocket heads. A drive
head and a bearing assembly on the other side are pressed into
an internal tube. This unit is integrated into the external tube. The
operating principle corresponds to series 3800, whereby theinternal tube rotates in the two bearing housings of the external
tube. If a material to be conveyed is stopped, the drive headturns together with the internal tube, and the external tube isstanding still. The advantage of this solution is that both sides of
the roller feature a friction unit and conveyor force is generated
with an off-center load.

Planning basics

Series 3800 offers different drive heads. A drive head is set inmotion using a drive element and turns inside the bearing
housing. The bearing housing applies force onto the drive headwith the weight of tube and material to be conveyed. This friction
force causes the conveyance of bearing housing and tube. The
material to be conveyed is moved through the rotation of thetube.

The product description of series 3800 is located on page 112.
Series 3800 – adjustable
With the adjustable series 3800, a 1/2“ steel sprocket drive headwith 14 teeth is available, whereby the operating principle
corresponds to the one described above. In addition, a malethreaded shaft protrudes from the roller on the other side of thedrive head. There is a nut and a spring on the shaft. Tightening© 12 | 2021 Interroll

Rollers | Conveying elements | Accessories

Conveyorforce

The product description of series 3870 is located on page 124.

191

PLANNING BASICS
HOW TO BUILD A CURVE?

Curve dimensioning

How to build a curve?
It is possible to build roller curves with cylindrical rollers. With
such a design, materials to be conveyed are not conveyed in thecenter of the curve, but alongside a required side guide. Thisrequires more energy and it poses the risk of damage to the side
guide or material that is being conveyed. For this reason, thedesign with tapered conveyor rollers is recommended.

Based on this curve diagram, Interroll recommends the following
steps:Po

The diameter of the tapered rollers increases towards the
direction of the outside curve diameter. With the increasing
diameter, the circumferential speed increases. This allows
materials to be transported through the curve without losing theirorientation. With the usual speeds (max. 0.8 m/s) and ideal curve
design, a side guide is not required.

L

W

Pi

SeriesBased on Ø[mm]Conicity

Drive elements

3500KXO light

20

1.8°

Round belt

1700KXO

50

1.8° and 2.2°

Round belt

3500KXO

50

1.8° and 2.2°

Round belts, PolyVeebelts, chains

9Interroll offers different curve-capable rollers that feature thedesignation KXO. These are rollers with cylindrical steel tube onto
which tapered elements are pushed. The following series are
suitable for use in roller curves.

0°

Ri

EL
Ro

EL

Ri

Internal radius of the curve

L

Installation length of theconveyor roller
Max. conveying good length

Po

W

Max. conveying good widthPi

Roller pitch on the external
diameterRoller pitch on the internal
diameterRo

External radius of the curve

1.

Curve definition– Driven or non-driven curve– With driven curves, determination of the drive elements (seesub-chapter Drive elements on page 193)
2. Selection of the roller series (drive element, based on adiameter of 20 or 50 mm)– Series 3500KXO light see page 92– Series 1700KXO see page 66– Series 3500KXO see page 96
3. Determining the dimensions of the largest possible conveying
good
4. Selecting the inside radius (note under "Radii")
5. Calculating the minimal outside curve radius Ro
RO = 50 mm + (R + W)2 + L 2
2

()

6.

7.

192

Calculating the minimal installation length of the conveyor
rollers
Installation length ELMIN = Ro – Ri
The reference lengths of the rollers are calculated based on
the lengths of the tapered tube sleeves. The lengths must be
greater than the calculated installation length.

© 12 | 2021 Interroll

8.

Calculating the actual installation length of the selected curveroller (see the note in the respective chapter of the roller
series)
9. Calculating the actual outside curve radius Ro
Ro = EL + Ri with selected standard EL
10. Determining the roller pitch at the inside diameter or angle
between the rollers
11. Calculating the roller pitch at the outside diameter Po
R
Po = Pi ∙ o
Ri

The most frequent solution is the PolyVee belt. For use in curves,
2-rib and 3-rib flexible belts are suitable. The belts must occupy
the first grooves from the direction of the inner curve radius. A
distance of one groove is required between the two belts.

Length of tapered elements
1.8° elements: The first tapered element has a length of 45 mm
or 95 mm. All additional elements have a length of 100 mm. The
total length of the tapered elements can be selected in incrementsof 50 mm. The different lengths of the first tapered elements
result in 2 different inside curve radii.

General technical information

PLANNING BASICS
HOW TO BUILD A CURVE?

Installing the rollers/RollerDrive

Radii
Different inside curve radii can be created with the different
Interroll Curve Rollers. A material will be conveyed perfectly
through a curve only if the radii are being maintained.

The installation length of curved sections must be longer than thatof straight sections to ensure that the conveying good does nottouch the side guide in the curve. Please select the next larger
installation length grid.

Drive
The RollerDrive has established itself as the drive for poweredroller curves. It allows implementing a cost-efficient, compact andquiet curve. RollerDrive in conjunction with PolyVee belts as drive
element are the simplest solution for torque transmission in
curves. Such curves can be constructed and set up in an easy way– for constantly rotating as well as for curves for start-stop
operation.

Curve rollers of series 1700KXO and 3500KXO can be
manufactured with a tube projection. It is possible that the tube
projection is located on the side of the tapered element with thesmaller diameter. The first tapered element will then have thecorresponding distance to the curve side profile. With this design,
it must be taken into account that the inner curve radius must be
reduced with a tube projection of more than 20 mm. A tube
projection on the side of the tapered element with the larger
diameter does not have any effect on the inner curve radius.
Inside curve radii for rollers with PolyVee or round belt
drive head
Inner curve
radius

Conicity

Roller series

Roller reference
lengths[mm]

660 mm

2.2°

3500KXO

190, 240, 290, 340,
440, 540, 640, 740

820 mm

1.8°

3500KXO

150, 250, 350, 450,
550, 650, 750, 850,
950

770 mm

1.8°

3500KXO

200, 300, 400, 500,
600, 700, 800, 900,
1000

Drive element
Round belts and PolyVee belts are suitable as drive element.
Round belts can be guided via grooves which are located in thearea of a tube projection. As an alternative, round belts can also
be guided via a drive head at the inside radius.

Planning basics

For the curve construction, it must be taken into account that the
top side of the curve RollerDrive is level. Hence, the fastening
shaft is not horizontal. As a result, vertically arranged side
profiles do not have a 90° angle. For this reason, Interroll
recommends an angle compensation so that the fastening shaft
does not experience any warping. The EC3500 with protection
rating IP54 is exclusively available for installation in the curve.

PolyVee belts are exclusively guided via a drive head, also at theinside radius.

© 12 | 2021 Interroll

Rollers | Conveying elements | Accessories

1,8˚

2.2° elements: The length of the first tapered is always 140 mm.
Hence, the inner curve radius does not vary.

193

PLANNING BASICS
HOW TO BUILD A CURVE?

Roller pitch

Inner curve radii for non-driven rollers

The roller pitch depends on the selected drive element.
Inner curve
radius

Conicity

357 mm

1.8°

3500KXO
light

150, 250, 350, 450,550

357 mm

1.8°

3500KXO
light

200, 300, 400, 500,
600

690 mm2.2°

1700KXO

190, 240, 290, 340,
440, 540, 640, 740

850 mm

800 mm1.8°

1.8°

Roller series

1700KXO

1700KXO

Roller reference
lengths[mm]

150, 250, 350, 450,
550, 650, 750, 850,
950
200, 300, 400, 500,
600, 700, 800, 900,
1000

Inner curve radii for rollers driven via chain
Inner curve
radius

Conicity

Roller series

Roller reference
lengths[mm]

690 mm

2.2°

3500KXO

190, 240, 290, 340,
440, 540, 640, 740

850 mm

1.8°

3500KXO

150, 250, 350, 450,
550, 650, 750, 850,
950

800 mm

1.8°

3500KXO

200, 300, 400, 500,
600, 700, 800, 900,
1000

PolyVee belt: For example, if a PolyVee belt is used in the curve
for a roller pitch of 75 mm, then a hole pitch of 73.7 mm must beplanned at the inside radius. When using rollers with a conicity of
2.2° and PolyVee belts for a roller pitch of 60 mm, then a hole
pitch of 58.7 mm must be planned at the inside radius. The roller
pitch at the outside radius can be calculated using the following
formula:R
Po = Pi ∙ o
Pi
Po
Pi
Ro

= Roller pitch on the outside diameter= Roller pitch on the inside diameter= Outside radius of the curveInterroll recommends an angle of 5° between two rollers. The
angle must not be greater than 5.5°.
Round belts: Any length can be used here. To ensure a sufficientdistance of the rollers, Interroll recommends not to plan morethan 22 rollers in a 90° curve. This also applies to non-driven
curves.
Chains: The chain as drive element allows only a limited numberof roller pitches. The roller pitch is always a multiple of the½“ chain pitch and can be calculated as follows:

PChain =PchainNc
NT(NT – Nc)
2

∙ 12,7= Chain pitch= Number of teeth=- Number of chain links

Inside curve radii for rollers with grooves
Grooves are applied within a tube projection at the inner curve
radius. The table "Inside curve radii for non-driven curves" lists
the curve radii for the rollers of series 1700KXO. The tube
projection must then be subtracted from the corresponding curve
radius.

The calculation of the roller pitch is performed at the outsideradius. With a roller-to-roller drive, the inside and outside
sprockets are used alternatingly. The roller pitch should be
dimensioned so that a chain on the outside sprockets is perfectly
tensioned. With the same roller pitch in the curve, the chain on
the inside sprockets will be tensioned a little bit less because of
the reduced distance of the sprockets to each other.
The roller pitches at the inside and outside radius must be
calculated on the basis of the chain pitch.

194© 12 | 2021 Interroll

The following information on the number of conveyor rollers
required relates to a 90° curve on which a higher surface to the
90° angle of the side frame has been designed in forequalization.

Pitch measured on the sprocket
[mm]

EL

7x

Ri

7x

½
9

7x½

" (1

19

16

14

713
x½

20

18

16

14

450/500

19

17

15

550/600

21

18

650/700750

250/300
m),7m
2(1 350/400

The following theoretical pitches (measured at the sprocket with apitch of 1/2" and 14 teeth) have been proven and tested:

Number of chain links

Pitch measured on the sprocket
[mm]

28

88.9

30

101.6

32

114.3

34

127.0

36

139.7

38

152.4

" (1

139.7

152.4

2,13
14

13

17

15

14

20

18

16

15

21

19

17

16

19

17

16

20

18

17

T = 88,9 (7 x ½ ")Number of rollers
2,

T = 88,9 (7 x ½ ")© 12 | 2021 Interroll

127.0

850/900

m)
7m

0°

114.3

800

Ro

m)
,7m
12
"(

101.6

The calculation or determination of the roller pitch and the angleof the roller curve result in the number of rollers to be used,which is not always an even number. In this case, the value must
be rounded up or down.
If a PolyVee belt is used in the curve for a roller pitch of 73 mm(based on a straight conveyor line), it results in an even roller
count for the following curve angles:

BracketNumber of rollers

30°

6

45°

9

90°

18

180°

36

Planning basics

9
Highersurface

0°

"

88.9

m)
7m

½

Pc

ha

in

Reference
length[mm]

Rollers | Conveying elements | Accessories

Highersurface

General technical information

PLANNING BASICS
HOW TO BUILD A CURVE?

195

PLANNING BASICS
DIMENSIONING OF MAGNETIC SPEED CONTROLLER

Speed
For a conveying good to be conveyed perfectly through thecurve, the curve speed and the speed of the straight conveyor
line must be identical before and after the curve. The curve speed
refers to the average speed. If the speeds of straight and curve
are different, the conveying good can loose its orientation and,as a result, reach the side guide.
Different forces occur in a curve. If the centrifugal force is greaterthan the static friction force, conveying goods will almost always
loose their orientation. This occurs at speeds over approx.
0.8 m/s. At that point, conveying goods will no longer be
conveyed through the center of the curve and come into contact
with the side guide at the outside radius. This depends on various
factors, such as material and condition of the underside of theconveying good, and these factors should also be taken into
account during the planning of the curve.
Tapered elements of conventional curve rollers carry the risk ofshifting on the tube. Interroll secures the tapered elements without
creating an interfering edge that is visible on the outside.

Deep freezing
Roller curves can also be operated in the deep freeze area. An
ideal drive is the RollerDrive EC5000 in deep freeze design.
Driven rollers should feature oiled ball bearings so that therequired drive power is not increased unnecessarily. Interroll
recommends PolyVee belts as drive element. They have to bewatched for suitability for deep freezing and that the belt tension
is not too high.

Dimensioning of magnetic speed
controller
The Magnetic Speed Controller MSC 50 is a mechanical speed
controller that ensures a controlled speed on gravity conveyors
with conveying goods weighing up to 35 kg.
In contrast with conventional products, the speed controller
operates without a gear box, thus enabling startup for very
lightweight containers starting at 0.5 kg. The maximum
mechanical output is 28 W, thus providing the requiredconsistently high braking power for heavy containers. The
operating principle is based on an eddy current brake. A double
shielding of the magnets enables a uniform braking action.
Conventional products often contain brake shoes. The heavier aconveying good, the stronger the braking of these brakeelements. This purely mechanical braking process causes wear. It
means that such products have to be replaced after a certain
time since the brake shoes are worn off. Such a wear does nottake place in the MSC 50.

196

The hexagon shaft used serves the torque within the side profile.
A loose, form-fit installation of the hexagon shaft is possible withhexagon holes in the side profiles. A hole size of 11.5 mm is
required for an oblique installation. With a fixed installation using
a female threaded shaft, a minimum torque of 20 Nm must be
applied. Interroll recommends the additional use of a screw
locking device.
The speed controller without PU sleeve is manufactured with atube diameter of 51 mm. Together with conveyor rollers of
50 mm diameter, a minimum higher surface of 0.5 mm is created.
This provides sufficient contact to the conveying good, whichleads to an optimal braking function.
The distribution, number and design of the speed controller in aconveyor track depends on many parameters:
·
·
·
·
·

Incline of conveyor trackRoller pitch
Infeed speed, e.g. by a sorter
Conveying good weight
Condition of the underside of the conveying good

The data listed below has been determined by means of
numerous tests. Conveying goods with optimal undersides wereused for this purpose. The data is intended to provide a reference
point for the dimensioning of applications, whereby the
combination of critical parameters is very large. Due to themultitude of influencing factors, Interroll cannot provide specificinformation about conveying speeds and, for this reason,recommends to empirically determine the final layout:· Lightweight conveying goods can run very slowly (approx.
0.01 m/s).
· Under optimal conditions, heavy conveying goods can run at
0.5 m/s.
· The design with PU sleeve is intended to improve the static
friction for smooth plastic containers. The PU sleeve isparticularly recommended in combination of conveyor tracks
with large inline and high conveying good weights.
· For cardboards and many other conveying goods, the friction
in combination with zinc-plated steel tube is sufficient.
· Inclines from 5 % to 10 % were examined in numerous tests.
The following distances between the Magnetic Speed
Controllers were tested successfully:

Conveying good weight[kg]

Distance of MSC 50[mm]

0,5 to 10

Maximum 2000

10 to 20800 to 1500

20 to 35

Adjusted to the length of theconveying good

© 12 | 2021 Interroll

General technical information

PLANNING BASICS
DIMENSIONING OF MAGNETIC SPEED CONTROLLER

Planning basics

Rollers | Conveying elements | Accessories· With infeed speeds into the gravity conveyor greater than
1 m/s, Interroll recommends the installation of three to four
MSC 50 at the beginning of the gravity conveyor. The
placement on the first 1,000 mm is used for immediate
reduction of the speed. On the rest of the gravity conveyor, thedistance values specified above can be applied as guidevalues.

© 12 | 2021 Interroll

197

PLANNING BASICS
MATERIAL SPECIFICATION

Material specification
Tubes
Material

Standards

Specification

Uncoated steel, zinc-plated steel

DIN EN 10305-1
DIN EN 10305-2
DIN EN 10305-3

Limited tolerances and material specifications by Interroll

Zinc-plating

DIN EN ISO 2081
DIN 50961

Galvanized zinc sleeve with additional blue passivation (chromium IV-free)Sleeve complies with RoHS regulations
Plating thickness 6 to 15 μm

Stainless steel

DIN EN 10312

1.4301 (X5CrNi18-10) and 1.4509 (X2CrTiNb18)
Limited tolerances by Interroll

Aluminum

DIN 755

AW 6060 T66 (AlMgSi 0.5 F22)
For 20 mm E6/EV1, stained, natural and anodized
Surface layer thickness 20 μm, isolating and non-conductive
For 50 mm mill-finished, unfinished, thus conductive

PVC–

PVC-U (rigid polyvinyl chloride, softener-free, silicon-free, highly impactproof)
Contains only materials, which have been tested and registered to comply
with the REACH Directive (EC No. 1907/2006)
RAL7030 (stone gray)
RAL7024 (dark gray)
RAL5015 (sky blue)

Bearings
Precision ball bearings, lubricated (689 2Z, 6002 2RZ, 6003 2RZ, 6204 2RZ, 6205 2RZ), used by Interroll:Standard

DIN 625

Material

Rings and balls are made of stainless steel of material grade 100Cr6
Hardness: 61 ± 2 HRC, with metal cages

Bearing play

C3

2RZ Seal

Non-grinding 2-lip seal with labyrinth effect manufactured from steel-reinforced acrylonitrile-butadiene rubber(NBR)

2Z SealNon-grinding cover discs made of sheet steel

Lubrication

Multi-grade grease, silicon-free

198© 12 | 2021 Interroll

Precision ball bearing, lubricated (6002 2RZ)
Standard

DIN 625

Material

Rings and balls are made of stainless steel of material grade 100Cr6
Hardness: 61 ± 2 HRC, with metal cages

Bearing play

C3

2RZ Seal

Non-grinding 2-lip seal with labyrinth effect manufactured from steel-reinforced acrylonitrile-butadiene rubber(NBR)

Lubrication

Multi-grade oil, silicon-free

General technical information

PLANNING BASICS
MATERIAL SPECIFICATION

Standard

DIN 625

Material

Rings and balls made of stainless steel, material 1.4125 (X105CrMo17), with a material grade to comply withAISI 440C
Hardness: 58 ± 2 HRC, with polyamide cages

Bearing play

C3

2RZ Seal

Non-grinding 2-lip seal with labyrinth effect manufactured from steel-reinforced acrylonitrile-butadiene rubber(NBR)

Lubrication

Multi-grade grease, silicon-free

Steel conical mountMaterial

Wheel body material DX53D + Z, zinc-plated
Bearing parts, hardened

Lubrication

Multi-grade grease, silicon-freeRollers | Conveying elements | Accessories

Precision ball bearings made of stainless steel, lubricated (6002 2RZ, 6003 2RZ)

Polymer bearing
External ring and cone made of polypropylene
Balls made of carbon steel or stainless steel

Lubrication

Multi-grade grease with low viscosity, silicon-free, FDA-tested

Planning basics

Material© 12 | 2021 Interroll

199

PLANNING BASICS
MATERIAL SPECIFICATION

ShaftsMaterial

Standards

Specification

Uncoated steel, zinc-plated steel

DIN EN 10277-3

1.0715 (11SMn30)
Limited tolerances and material specifications by Interroll

Zinc-plating

DIN EN 12329
DIN 50961

Galvanized zinc sleeve with additional blue passivation (chromium IV-free)Sleeve complies with RoHS regulations
Plating thickness 6 to 15 μm

Stainless steel

DIN EN 10088-23

1.4305 (X5CrNi18-9)
Limited tolerances by Interroll

Polymers
Interroll uses components made of polymer in almost all conveyor elements. Polymer has many advantages over steel:
·
·
·
·
·
·

Sound reduction
Easy to clean
Excellent impact strength
Corrosion resistanceLightweight
High quality design

Properties and applications
Polymer

Properties

Uses

Polyamide (PA)

•
•
•
•

Outstanding mechanical properties
Excellent wear resistanceLow coefficient of friction
Good chemical resistance

Sprocket drive heads, seals and bearing seats

Polypropylene (PP)

•
•
•
•

Low specific weight
Excellent heat resistanceNot hygroscopic
Good chemical resistance

Wheels, seals and bearing seats

Polyvinyl chloride (rigid PVC)

• Scratch-resistant• Impact-resistant• Good chemical resistanceTubes for polymer conveyor rollers

Polyoxymethylene (POM)

•
•
•
•
•
•

Toothed belt drive head and slide bearing

200

Outstanding mechanical properties
Excellent wear resistanceLow coefficient of friction
Very dimensionally stable
Minimal absorption of water
Used on parts which require a very high level ofprecision© 12 | 2021 Interroll

Resistance
SymbolMeaning

Explanation++

Very good resistanceContinuous exposure to the medium causes no damage+

Generally resistantContinuous exposure to the medium can cause damage, which is reversible when no longer
exposed to the medium−

Mostly non-resistant

Only resistant if there are optimum ambient and application conditions but generally somedamage is to be expected−−

Completely non-resistant

The medium may not come into contact with the polymer

General technical information

PLANNING BASICS
MATERIAL SPECIFICATION

Planning basics

Rollers | Conveying elements | Accessories

The resistance of the polymers is affected by temperature, exposure to force, UV exposure, and the duration of exposure andconcentration of the medium.

© 12 | 2021 Interroll

201

PLANNING BASICS
MATERIAL SPECIFICATION

A thorough suitability test of the polymer to be used by the user is indispensable. The following overview serves as orientation aid.

Product

Polyamide (PA)Polyoxymethylene (POM)

Soft PVC

Rigid PVC

Polypropylene (PP)

Ethers

++

++

−

++

−

Lower alcohols

++

++

++

−

++

Petrol

++

+

−−

++

−

Esters

++

−−

−−

−−

−

Fats

++

++

−

++

+

Hydrofluoric acid

−−

−−

−

−

−

Ketones

++

−

−−

−−

++

Aliphatic hydrocarbons

++

++

−−

++

++

Aromatized hydrocarbons

++

+

−−

−−

−

Chlorinated hydrocarbons

−

++

−−

−−

−−

Unsaturated, chlorinated hydrocarbons

+

++

−−

−−

−−

Weak bases

+

++

++

++

++

Strong bases

−

++

−

++

++

Mineral oil

++

++

−

++

−

Oils

++

++

−

++

+

Oxidizing acids

−−

−−

−

−−

−−

Weak acids

−−

−

++

++

++

Strong acids

−−

−−

++

−

−−

Strong, organic acids

−

++

−

+

++

Inorganic salt solutions

++

++

++

++

++

Turpentine

−

−

−−

−−

−−

Fuel mixture

+

++

−−

−−

−

Water

++

++

++

++

++

202

© 12 | 2021 Interroll

Planning basics

Rollers | Conveying elements | Accessories

General technical information

PLANNING BASICS
MATERIAL SPECIFICATION© 12 | 2021 Interroll

203