Motorized rollers with integrated motors for zone-controlled conveyor systems, zero-pressure accumulation, and automated sorting systems.
Compatible with CNG belts, Poly-V belts, and chain drives.
A motorized roller (or motorized drum) is an industrial roller that incorporates an electric motor, a gearbox, and often a control system within its housing. Unlike rollers with external drive systems (belt or chain drive), in a motorized roller all the mechanical components are sealed inside the housing: the result is a compact, quiet, and easy-to-install system.
The motorized roller is typically installed every 3 to 6 idler rollers on a conveyor, driving them via CNG round belts, Poly-V belts, or a chain drive. This configuration—known as MDR (Motorized Drive Roller) —makes it easy to create independent conveying and accumulation zones, which can be controlled by a simple PLC or dedicated controllers.
NUOVA OMEC integrates motorized rollers into its systems by designing the optimal drive configurations for each application, in collaboration with leading manufacturers of 24V DC and brushless motorized rollers.
The drive roller transmits motion to the adjacent idler rollers using three main technologies, selected based on capacity, speed, and environmental conditions:
The most widely used solution for MDR roller conveyors. A Ø4–5 mm polyurethane belt runs in grooves machined into the roller shell. Quiet, lubrication-free and replaceable without tools. Ideal for loads of up to 50 kg per package and speeds of up to 1 m/s. A friction-driven version is available for zero-pressure accumulation.
A multi-ribbed belt designed for high torque and efficient power transmission on heavy-duty rollers. It provides a significantly larger contact surface than a round belt. Suitable for high loads of 100–300 kg per package and roller conveyors with intensive operating cycles.
Chain transmission with a sprocket integrated into the motor-driven roller and sprockets fitted to the end caps of adjacent rollers. The most robust solution for heavy loads and demanding environments. It requires periodic lubrication and supports speeds of up to 0.5 m/s.
The LGS series serves as the standard platform for most MDR systems built with NUOVA OMEC components. Here are the main configurations available:
| Publication Acronym | Type | Function | Typical Application |
|---|---|---|---|
| HP | Fixed-mount engine | Drive unit with CNG pinion — fixed left or right | Unidirectional zones |
| HPF | Reversible motorized | Interchangeable left/right head | Versatile configurations, suitable for all sides |
| FRZ | Fixed Clutch | ZP Accumulation Clutch — Fixed Head | Zero-pressure accumulation zones |
| FRZF | Reversible clutch | Left/right interchangeable clutch | ZP accumulator in flexible configurations |
The integrated motor and belt drive eliminate externally moving metal components. MDR systems typically operate below 65 dB(A), even at high speeds.
Each conveyor zone—typically comprising one to three idle rollers per motor-driven roller—operates independently. The PLC or MDR controller manages starting, stopping and speed for each zone without affecting the others.
Inactive zones consume only the energy required to maintain their position or switch off completely. Brushless EC motor-driven rollers provide efficiency levels exceeding 90%.
No external gearbox, no main drive belt and no periodic lubrication for CNG systems. Each motor-driven roller can be replaced individually without dismantling the entire roller conveyor.
It depends on the belt width and the type of drive. With a 5 mm diameter CNG belt, a standard motorized roller typically drives 3 to 5 idler rollers in the same zone. With a Poly-V belt, it is possible to drive 6 to 8 rollers in longer zones. An accurate calculation requires verifying the available torque and the tension on the belt.
The most widely used MDR systems employ 24V DC motorized rollers (the de facto standard in the logistics industry) or three-phase voltage for high-power systems. NUOVA OMEC designs its drive systems to be compatible with all major 24V motorized rollers (Interroll, Hytrol, SEW, etc.) and brushless EC motors.
In the accumulation zone, the idler rollers are connected to the motorized roller via a friction clutch (FRZ). When a package stops, the clutch allows the belt to slide over the roller’s pinion without transmitting torque. The motorized roller continues to rotate, but the rollers beneath the stationary package come to a stop. When the package downstream starts moving again, the clutch automatically reengages and the accumulated package moves forward.
