Roller conveyors handle some of the harshest duty cycles in modern logistics and heavy manufacturing — pallets of steel sheets, engine blocks, filled drums, and bulk containers launched onto powered rollers multiple times per minute. Every collision creates a momentary shock torque that propagates back to the drive unit. A worm gear reducer selected for roller conveyor duty must not only deliver sustained torque, but withstand thousands of impact events per shift without fatigue. This page details how our worm drive reducers are specifically engineered for roller conveyor applications across automotive, steel, warehousing, and heavy logistics sectors.
Powered roller conveyors use one of two drive architectures: line-shaft drive (a single worm gearbox rotates a long line shaft that belt-drives all rollers) or individual motorised rollers (small worm drive reducers built into each roller). Our product range covers both configurations.
In line-shaft layouts, the worm gear unit is mounted at one end of the conveyor section and must handle the combined inertia of all rollers plus the full pallet load. Output torque requirements are correspondingly high — typically 400 N·m to 2 500 N·m for heavy-duty pallet lines. The critical engineering challenge is shock load absorption: when a 1 500 kg pallet drops from a lift truck onto the live rollers, the instantaneous torque spike can be 5–8× the steady-state value. Our cast-iron housing worm gear drives include reinforced output shaft bearings (deep-groove + angular-contact combination) and a bronze worm wheel with a slightly higher tooth backlash than standard to absorb shock without tooth fracture.
Centrifugally cast phosphor bronze GB ZCuSn10Pb1 — exceptional impact toughness vs. sand-cast alternatives.
20CrMnTi alloy steel, case-carburised to 58–62 HRC, precision-ground thread profile.
EN-GJL-250 grey cast iron — CNC machined bearing bores for consistent alignment under heavy radial loads.
Double-lip NBR seals on input and output shafts; optional V-ring seals for dusty environments.
| Specification | Standard Range | Heavy-Duty Roller Conv. | Notes |
|---|---|---|---|
| Gear Ratio | 5:1 – 100:1 | 20:1 – 60:1 | Matches roller line speed 15–40 m/min |
| Output Torque | 10 – 4 500 N·m | 400 – 2 500 N·m | Apply SF 1.5–2.0 for pallet impact |
| Input Shaft | 11 – 55 mm | 28 – 48 mm | IEC B5/B14 flange compatible |
| Output Shaft | 18 – 120 mm | 50 – 90 mm | Solid or hollow-bore options |
| Housing | Aluminium / Cast iron | Cast iron GJL-250 | Higher rigidity for shock loads |
| IP Rating | IP65 / IP66 | IP65 standard | IP66 for outdoor logistics yards |
| Mounting | Foot / Flange / Shaft | Foot or torque-arm | Torque arm prevents housing rotation under shock |
Service Factor Guide: Light duty (smooth load, ≤8 h/day) SF = 1.0; Moderate duty (minor shock, 8–16 h/day) SF = 1.25; Heavy duty (pallet drop, 16–24 h/day) SF = 1.75; Severe duty (continuous impact, 24/7) SF = 2.0+
Our worm gear drives for roller conveyor applications carry the following certifications:
| Standard | Scope |
|---|---|
| ISO 9001:2015 | Full manufacturing QMS |
| CE Declaration | EU Machinery Directive 2006/42/EC |
| IEC 60034 Motor Flanges | Direct motor coupling |
| IP65 / IP66 (IEC 60529) | Ingress protection sealing |
Challenge: Steel stamping pallets (1 200 kg each) dropped onto roller conveyor every 45 seconds; previous helical gearboxes suffered bearing failure at 4-month intervals. Solution: Our SF 2.0 heavy-duty cast-iron worm reducer with reinforced taper-roller output bearing. Outcome: First replacement interval pushed past 28 months; production line OEE improved 6 %.
Challenge: Steel coils up to 3 000 kg needed precise slow-speed positioning onto uncoilers; existing drives overheated in the 45 °C mill environment. Solution: Ratio 50:1 worm gear unit with synthetic PAO 220 lubricant and external cooling fins. Outcome: Thermal limit increased 18 °C; zero heat-related shutdowns over 2 years of operation.
Challenge: 24/7 operation, 500 kg parcels, frequent start-stop — three different reducer models had failed within a year. Solution: NMRV 130, ratio 30:1, IP65 sealed, with VFD input for soft-start. Outcome: 22 months of continuous operation, noise level 64 dB(A), energy saving 11 % vs. previous fixed-speed drive.
Challenge: Washdown-intensive environment; standard gearboxes corroded within months in the humid, detergent-spray hall. Solution: IP66 worm reducer with stainless steel shaft extension and corrosion-resistant epoxy coating on housing exterior. Outcome: No corrosion failures in 3 years; maintenance time cut by 60 %.
Challenge: ESD-sensitive trays required extremely smooth, jerk-free roller motion; gear noise had caused vibration-induced cell damage. Solution: Precision-lapped worm gear unit, ratio 40:1, with vibration-damping rubber mounting pads. Outcome: Cell rejection rate due to vibration dropped from 0.8 % to 0.05 %; noise below 60 dB(A) in the clean room.
No distributors, no mark-ups. Direct from our 18 000 m² facility with 200+ CNC machining centres.
CMM dimensional inspection and run-in testing on every unit; gear mesh confirmed before shipping.
Non-standard ratios, special bore sizes, custom paint finishes, and private-label nameplate available.
Submit your load data and our engineers will provide a written selection report and 3D model within 48 hours.
Multiply the rated output torque requirement by an SF of 1.75–2.0 for pallet-drop applications. Then verify the chosen reducer’s rated torque at the selected ratio exceeds the SF-corrected value. Also check that the thermal power rating is not exceeded for your ambient temperature and operating hours. We provide a free selection worksheet — contact us to request it.
Overheating is most often caused by: (1) selecting too small a frame size, leaving insufficient surface area for heat rejection; (2) using mineral oil at high ambient temperatures — switch to synthetic ISO VG 220; (3) continuous operation at high ratio (≥ 50:1) without supplementary cooling. Our engineering team can calculate thermal capacity for your specific duty cycle.
Yes. We supply IP66 versions with corrosion-resistant housing finish and the option of food-grade H1 lubricant fill. For zones where incidental food contact may occur, select models with stainless steel shaft extensions. Full documentation (material data sheets, lubricant safety data sheets) provided on request.
Allowable radial load depends on the frame size and distance from the shaft end. For example, our size 110 cast-iron model allows up to 8 500 N at the shaft centre. When a sprocket or chain drive is used (common in line-shaft roller conveyors), ensure the chain tension is included in the radial load calculation. Refer to our technical catalogue or request application assistance.
Each unit ships with a detailed installation manual and mounting dimension drawing. Our technical team is available via video call to support first-time installations at no charge. For large-volume OEM customers, on-site commissioning support can be arranged separately.
Tell us your pallet weight, roller speed, motor power, and operating hours — we’ll handle the selection and provide certified documentation.
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