Accumulation Conveyor Part 2 | Calculations & Engineering Guide |
In Part 1 of this series, we covered the working principle of accumulation conveyors and the different chain configurations available. In Part 2, we walk through the actual engineering calculation process using real project values so you can understand how a conveyor system is properly sized from specifications to chain and leg pitch selection.
How to calculate parts of accumulation conveyor?
Specifications required (values bellow are real life values)
Every accumulation conveyor design starts with a clear set of specifications. The values below are taken from a real-world project and will be used throughout the calculations in this post.
|
Parameter |
Value |
|
Pallet weight |
20 kg |
|
Pallet width |
652 mm |
|
Pallet length |
652 mm |
|
Pallet height |
39 mm |
|
Pallet payload (workpiece) |
150 kg |
|
Accumulation feature |
Yes |
|
Required transfer speed |
20 m/min |
|
Conveyor length |
10 m |
|
Number of stations |
6 |
|
Station pitch |
1 m |
|
Maximum pallets on conveyor |
8 |
With these inputs defined, the design process can begin systematically.
Understand What Needs to Be Calculated and Why
Before running numbers, it is important to understand what each parameter drives in the design. Skipping this step leads to under-specified components or oversized, costly systems.
a) Maximum Load Per Meter on the Conveyor
This determines the weight acting on each individual roller and on the conveyor section as a whole. Both the roller load rating and the section structural capacity must be verified against allowable limits. This is where chain selection begins.
b) Weight of Pallet + Workpiece (Total Conveyed Mass)
The combined pallet and payload weight is the primary input for motor power calculation, chain tension analysis, and the load per meter calculation in point (a). In this case: 20 kg (pallet) + 150 kg (payload) = 170 kg per carrier.
c) Environmental Conditions
The operating environment defines the material selection for the chain and conveyor frame. A washdown environment, for example, requires stainless steel chain. A standard dry indoor environment allows carbon steel with standard lubrication. This step is often overlooked and leads to premature corrosion or wear in the field.
d) Material of the Pallet
The pallet surface material directly affects the selection of the chain roller material and durometer. Steel pallets running on standard nylon rollers behave differently than aluminum or plastic pallets. Roller wear rates, noise levels, and coefficient of friction are all influenced by this pairing.
e) Conveyor Speed
The required transfer speed of 20 m/min feeds into both motor power calculation and the chain tension analysis. Higher speeds increase dynamic loads and the required drive system capacity.
f) Conveyor Length
At 10 m, the conveyor length determines the total chain weight in the system, the accumulated tension from friction along the run, and the required drive power. Longer conveyors demand more careful tension management, especially in accumulation zones.
g) Accumulation Stations
With 6 stations at 1 m pitch and a maximum of 8 pallets on the conveyor simultaneously, the accumulation scenario creates the worst-case loading condition. All backed-up pallets create the maximum chain tension state, which is the governing case for motor and drive selection.
For defining motor power and chain tension
