Conveyor Automation Guide

Conveyor System Types

Belt conveyors transport bulk or unit loads over long distances. Roller conveyors use zone controllers for accumulation without product damage. Chain conveyors handle heavy pallets and harsh environments.

• Zero-pressure accumulation (ZPA) — no product contact during accumulation
• Sortation — divert modules for routing to destinations
• Merge — combine streams from multiple infeed lines

Zone Controller Architecture

Each zone operates as an independent motor drive with photo-eye inputs for product detection. Upstream zones release product only when downstream zones have capacity — preventing jams and product damage.

Zone controllers communicate via fieldbus to a line PLC or dedicated conveyor controller for coordinated start/stop and speed matching.

Integration with Factory Systems

Conveyor lines integrate with MES for order routing and with WMS for pick-to-light and put-to-light operations. OPC UA and MQTT gateways bridge OT conveyor controllers to IT systems.