Zero-Pressure Accumulation Zones
Zoned accumulation built on brushless motor rollers with slaved idlers, so cartons queue without touching.
The problem
On a line that accumulates against a stop, every carton pushes the one in front. Light packs crush, heavy ones jam and the release surge overloads the next machine. Zoning the line so each zone stops independently removes the pressure entirely.
How the specification is built
Set zone length
Each zone holds one product with clearance, so zone length comes from the longest carton plus the gap you want between them.
Choose the motor roller
24 V or 48 V brushless for constant start-stop, sized on tractive force at the working speed rather than top speed.
Slave the idlers
Poly-V, O-belt or sprocket end caps pass drive from the powered roller to the idlers in that zone.
Wire the control cards
One driver card per zone, with sensor input and the logic that releases a zone only when the one ahead is clear.
Size the power supply
Sized for the number of zones that can start simultaneously, not for the average running current.
Prove the release
Run a full line stop and release to confirm zones clear in sequence without shunting.
Groups used in this solution
DGBL Motor Roller
13 models
Motor Roller
49 models
Drive Roller Plastic Bearings
14 modelsPoly V Roller Bearings
4 models
O Belt Roller Bearings
2 modelsDiameter 60 Mm 76mm Direct Current 24V/48V High Torque Motor Roller
24v/48v Direct Current Brushless Gear Reduction Rubber Coated Motor Roller
Motor Power: 40WDM216 Belt Conveyor Oil Cooling Motor Roller
Material: carbon Steel & Galvanized and painting…
DM165 Belt Conveyor Oil Cooling Motor Roller
Plastic Multi-Belt End Cap Shaft:15
Plastic Multi-Belt End Cap Shaft:12
Plastic O-Belt End Cap Shaft:15
Plastic O-Belt End Cap Shaft:12
Frequently Asked Questions
Can an existing gravity section be converted?
Yes — replace one roller per zone with a motor roller and fit drive end caps to the idlers in that zone.
24 V or 48 V for a long line?
48 V carries more power down the same cable and suits longer runs and heavier cartons.
Send us the layout
Give the load, product size and line length and we will specify the components.