CEMA

STANDARD
ANSI / CEMA 404-2003 (R2009)
NO. 404-2003 Reaffirmation of ANSI / CEMA 404-2003
( Approved January 22, 2009)

CHAIN DRIVEN LIVE ROLLER CONVEYORS

Unit Handling Conveyors

®
Conveyor Equipment
Manufacturers Association
ISBN 978-1-891171-30-7
 CONVEYOREQUIPMENTMANUFACTURERSASSOCIATION
(CEMA)

DISCLAIMER

Theinformationprovidedhereinisadvisoryonly.

These recommendations provided by CEMA are general in nature and are not intended as a
substitute for professional advice.  Users should seek the advice, supervision and/or
consultationofqualifiedengineers,safetyconsultants,andotherqualifiedprofessionals.

Anyuseofthispublication,oranyinformationcontainedherein,oranyotherCEMApublication
ismadewiththeagreementandunderstandingthattheuserandtheuser’scompanyassume
full responsibility for the designs, safety, specifications, suitability and adequacy of any
conveyor system, system component, mechanical or electrical device designed or
manufacturedusingthisinformation.

Theuserandtheuser’scompanyunderstandandagreethatCEMA,itsmembercompanies,its
officers,agentsandemployeesarenotandshallnotbeliableinanymannerunderanytheory
ofliabilitytoanyoneforrelianceonoruseoftheserecommendations.Theuserandtheuser’s
companies agree to release, hold harmless and indemnify and defend CEMA, its member
companies, successors, assigns, officers, agents and employees from any and all claims of
liability,costs,fees(includingattorney’sfees),ordamagesarisinginanywayoutoftheuseof
thisinformation.

CEMAanditsmembercompanies,successors,assigns,officers,agentsandemployeesmakeno
representationsorwarrantieswhatsoever,eitherexpressedorimplied,abouttheinformation
contained herein, including, but not limited to, representations or warranties that the
informationandrecommendationscontainedhereinconformtoanyfederal,stateorlocallaws,
regulations,guidelinesorordinances.

      END  
 FOREWORD

Chain driven live roller conveyors are used for the controlled movement of a great variety of regular or irregular
shaped commodities, from light and fragile to heavy and rugged unit loads.

The path is usually level, but it can be slightly inclined or declined, limited by the coefficient of friction between the
rollers and the load. Chain driven live roller conveyors are used for transportation, as a pacesetter for assembly
operation, and as a timing medium for integrated handling systems.

The purpose of this standard is to establish recommended minimum standards for use in the design and application
of chain driven live roller conveyors.

For additional information relating to definitions and selection of common components, see latest edition of the
following publications: CEMA Standard No. 401, Roller Conveyors-Non Powered; CEMA Standard No. 402, Belt
Conveyors; CEMA Standard No. 403, Belt Driven Live Roller Conveyors; and CEMA Standard No. 102, Conveyor
Terms and Definitions.

The illustrations throughout this book are schematic in nature and represent the general nature of a particular
device. The illustrations are not intended to represent the recommended safety configurations since guarding has
been omitted to permit clarity in showing the operational characteristics of the device. Refer to the current editions
of ANSI/ASME B20.1, Safety Standard for Conveyors and Related Equipment; ANSI/ASME B15.1, Safety Stan-
dard for Mechanical Power Transmission Apparatus; and ANSI Z244.1, American National Safety Standards for
Lockout/Tagout of Energy Sources - Minimum Safety Requirements; Title 29, Code of Federal Regulations (29
C.F.R.) Part 1910.147, The control of hazardous energy (lockout/tagout); Title 29, Code of Federal Regulations (29
C.F.R.) Part 1910 Subpart O, Machinery and Machine Guarding.

TABLE OF CONTENTS
Section Page

DEFINITIONS 1 1
Chain Driven Live Roller
Continuous Chain Type
Roll-to-Roll Type
Mechanical Elements of Chain Driven Live Roller

APPLICATION DATA 2 2
General Application Engineering Data
Roll-to-Roll Construction
Continuous Chain Construction
Live Shaft Construction
Chain Driven Live Roller Curves
Transfers
Accumulating Chain Driven Live Roller
Diagrams:
Roll-to-Roll Construction
Continuous Chain Construction
Transfer Selection Data

TECHNICAL DATA 3 9
Chain Pull and Horsepower Calculations
Table I Combined Friction Factor
Table II Factor For Determining Value “Q”
Table III Minimum Sprocket Teeth per Roller Diameter
Table IV Minimum Roller Centers

CONVEYOR EQUIPMENT MANUFACTURERS ASSOCIATION

5672 Strand Court, Suite 2
Naples, Florida 34110
Web Site: http://www.cemanet.org

Standard No. 404 - Copyright 2009

Printed in the U.S.A.
ISBN 1-891171-30-7
i
 Note - CEMA Has Reaffirmed the 2003 Edition.
This 2009 Edition is Identical to the 2003 Edition

SUMMARY OF CHANGES IN 2003 EDITION

A summary of the major changes in this edition:

All drawings have been cleaned up and enhanced for clarity where necessary.

Foreword:

Updated to include Safety Label Requirements Notice.

Section 1: Definitions

Terms and Definitions have been expanded, regrouped for ease of understanding, and revised to
conform with those in ANSI/CEMA Standard No. 102, Conveyor Terms and Definitions.

Section 2: Application

Figures have been redrawn and, in some cases, regrouped for clarity.

Section 3: Technical Data

No changes

CEMA Standard No. 404-2009 (PDF)

Reviewed by
Unit Handling Section
of the
CEMA Engineering Conference

ii
 Section I

DEFINITIONS

Chain Driven Live Roller - Conveyors which use a roller bed for the carrying surface. The unit loads ride directly upon the
roller surfaces, and the rollers are driven by chains and sprockets.

Roll-to-Roll Type - A chain driven live roller conveyor in which power is transmitted from roll to roll via short chain loops,
each of which encircles the sprocket attached to the adjacent driven rollers, causing each to rotate. Two sprockets are required
for each driven roller. (see Figures 1 through 8, Page 6)

Continuous Chain Type - A chain driven live roller conveyor driven by one continuous strand or loop of chain, engaging a
sprocket attached to each driven roller, causing the roller to rotate. One sprocket is required for each driven roller. (see Figures
9-17, Page 7)

Mechanical Elements of Chain Driven Live Roller

Chain - A series of links pivotally joined together to form a medium for conveying or transmitting motion or power.

Riveted: A chain in which the ends of the pins are “headed” and/or swagged or riveted so that the chain cannot be
disassembled without cuffing off the pin.

Roller: A chain having a roller encircling the barrel or bushing of each joint.

Tension: The actual pull existing at any point in a chain.

Link: A chain unit of one pitched length.

Conveyor Bed - Carrying rollers that support the load while it is being conveyed (see also “Width, Effective Conveyor”).

Differential Curve - A curved section of roller conveyor having a conveying surface of two or more concentric rows of rollers.

Drive - An assembly of the necessary structural, mechanical and electrical parts which provide the motive power for a con-
veyor.

Frame Rails - Members that support the conveying components of non-powered or powered roller conveyors. Rollers are the
supported components on roller conveyors.

Guard - A covering or barricade for safety purposes such as gear, chain, or nip guards.

Holddown - A wear-member located over the driving (top) side of chain and sprockets to prevent chain disengagement from
the sprocket teeth. Used on continuous chain construction chain driven live roller conveyor.

Horizontal Curve - A curved roller conveyor section used to change the direction of travel.

Idler - A pulley, sheave, sprocket, or wheel around which a chain passes in changing direction of travel; chain-supporting
sprocket.

Intermediate Drive - A drive that transmits motive power to a conveyor at a point other than the terminals.

Live Roller Conveyor - A series of rollers over which objects are moved by the application of power to all or some of the
rollers.

Plates, Fill-in - Closely fitted plates positioned between the rollers of powered or non-powered roller conveyors.

Return Run - That portion of the chain which returns from the discharge to the loading end of a conveyor.

1
Return Track - A track supporting the conveying medium (chain) on the return run.

Roller - A round part free to revolve its outer surface. The face may be straight, tapered, crowned, concave or flanged,
corrugated, ribbed or fluted. Typically, a cylindrical member with internal bearings mounted on a non-rotating shaft. Rollers can
have live shafts and outboard bearings. In a chain driven live roller conveyor, rollers are powered via sprockets attached to
either or both ends of the roller or live shaft.

Carrying: The conveyor roller upon which the object being transported is supported.

Driven: Any carrying roller driven by chain or other propelling medium.

Idler: Any carrying roller of a live roller conveyor which is not driven.

Tapered: A conical conveyor roller for use in a curve with end and intermediate diameters proportional to their distance
from the center-point of the curve.

Sprocket - A wheel with suitably shaped and spaced cogs, or teeth, to engage with the links of a chain.

Driven: A sprocket propelled by the chain.

Return Idler: A sprocket that supports the return run of the chain.

Take-up - The assembly of the necessary structural and mechanical parts which provides means to compensate for stretch, or
wear, and to maintain proper chain tension. Adjustment is usually manual and is employed on continuous chain driven live
roller construction only.

Transfer Medium - Any mechanism that transfers objects onto or off a conveyor line or from one conveyor line to another.

Wearing Bar - A bar attached to a track or trough which may be replaced when worn, thus protecting the main members (chain)
from damage due to wear.

Width, Effective Conveyor - The clear dimension across the conveyor bed and parallel to the carrying rollers where the unit
load may be conveyed; on chain driven live roller conveyor, the dimension between side rail and chain cover plate.

Section 2

APPLICATION DATA

1. GENERAL APPLICATION ENGINEERING DATA

Chain driven live roller conveyors are used to carry loads with a flat, smooth, and firm bottom riding surface at controlled
speeds. They are better suited than belt driven live roller conveyors in applications where heat, dirt, oil, water, and other
contaminants are present. Chain driven live roller conveyors are ideal for carrying heavy or bulky loads.

Conveyors may be spring mounted to absorb shock when being loaded or unloaded with heavy unit loads. They are ideal
conveyors when the application requires right angle transfers, such as disappearing chain transfers, push-on or push-off trans-
fers, or converging sections.

This construction is commonly used for the carrying bed of transfer cars, for powered beds in rollovers, upenders, dump units,
turntables, and vertical reciprocating conveyors. Two sections of chain driven live roller may be tilted to form V-trough
construction for handling cylindrical loads.

Since power is transmitted to the carrying bed rollers by chain and sprockets, unit loads are always positively driven at a
controlled speed.

2
These conveyors work best when they are installed horizontally; however, depending on the unit load handled, they may be
slightly inclined or declined.

Several conveyors may be assembled in a line, and by controlling each conveyor, they can accumulate loads at zero storage line
pressure by “cascading”, holding one load on each conveyor.

Chain driven live roller conveyor may also be designed to accumulate loads by “indexing” or start-stop operation, resulting in
zero storage line pressure between loads. Electric controls are provided at the receiving end of the conveyor to allow a load to
index forward onto the conveyor approximately one load length, then shutting down the conveyor. This indexing operation is
repeated until the conveyor is filled. The entire train of accumulated loads is then indexed, leaving an empty conveyor so the
indexing cycle may be repeated.

A combination of previously described “cascade” and “indexing” operations may also be used to provide accumulation at zero
storage line pressure.

Ideally, three (3) rollers should be under the load at all times. Occasionally, two (2) rollers will be sufficient, depending on the
unit load (product) handled. Carrying rollers are normally spaced 4" to 12" on centers. For centerlines between rollers greater
than 12", considerations may be required to compensate for chain sag between the rollers.

Conveyors are normally run at speeds between 30 and 60 fpm; however, greater or lesser speeds may be used. For greater
speeds, precision bearings and/or chain lubrication may be required. Chains and sprockets must be guarded.

Fill-in plates may be added between the carrying rollers to assure that the leading edge of a unit load will ride on the carrying
roller and not sag between rollers.

There are many variations in drive arrangements. A common practice is to use a gear motor with output shaft connected by loop
chain drive to the sprocket(s) on the drive roll(s). Another option is the use of shaft mounted reducers.

When variable speed is required, a mechanical speed changer between the motor and reducer may be used. Electrically, the
speed may be changed using variable frequency drives.

Close center roller construction must have all rollers driven. If all rollers are not positively driven, in-running nip points are
created at every roller to roller interface.

2. ROLL-TO-ROLL CONSTRUCTION (Figures 1 - 8, Page 6)

In this type construction, two plate sprockets are attached to each roller, and individual loops of chain connect pairs of rollers
in a staggered pattern along the length of conveyor.

This construction is ideal for handling heavy loads and for applications requiring frequent stopping or reversing service. It is
ideal for low elevation applications, with the driving unit mounted beside or above the conveyor frame.

For very wide loads, two conveyors may be set side-by-side (referred to as “two-lane, four-rail” construction) having a counter-
shaft with loop chain drive from each lane and driven from one drive unit through the countershaft. “Two-lane, three-rail”
construction may also be used, where a common mid-rail acts as the frame for adjacent conveyor beds.

Normal construction calls for the chain and sprocket cover guard to extend above the carrying surface of the rolls. However,
large diameter sleeves may be attached to the driven rollers to provide carrying surface above chain cover guard.

It is recommended that the drive be located near the center of the conveyor length to keep the chain pull to a minimum. End
drives may be used on short conveyors.

3. CONTINUOUS CHAIN CONSTRUCTION (Figures 9 - 17, Page 7)

In this type construction, a single plate sprocket is attached to each roller, and a continuous strand or loop of chain drives all
3
rollers by engaging just the top teeth of each driven sprocket.

This construction can be used for moderate weight unit loads. It allows closer centerlines on carrying rollers than roll-to-roll
construction. The construction is not intended for frequent stopping (except for emergency stopping) and starting applica-
tions.

Contact with the sprocket teeth is maintained by a continuous cover plate with wearing bar hold-down. Chain is usually
returned in a return track. An adjustable chain take-up is required with this construction.

The end-rollers in this type construction should be equipped with precision ball bearings.

Drives are normally located at head end of conveyor, but an intermediate drive on the return strand of chain may be used.

“Double-strand” construction is also available. It consists of two (2) single strands of chain, or a single strand of double width
chain, used to drive single rack tooth sprockets attached to each roller, with rack tooth sprockets on alternate rollers offset. This
construction is used to obtain closer centerlines on the carrying rollers (see Figure 13, Page 7).

4. LIVE SHAFT CONSTRUCTION (Figure 6, Page 6)

Live shaft construction may be either roll-to-roll or continuous chain type, with the roller (or tube) attached to a rotating shaft
mounted in outboard flange or pillow block bearings and having the sprockets keyed to the shaft. The rollers for this type
construction may be machined from solid round bar stock turned down on each end for mounting in bearings and attaching the
driving sprockets.

Normally used as roll-to-roll construction for handling very heavy loads, this construction may also be used when chain and
sprocket cover guard must be below the top of carrying rolls.

5. CHAIN DRIVEN LIVE ROLLER CURVES (Figures 3, 4, 5, 7 & 8, Page 6, and Figures 11, 14-17, Page 7)

Chain driven curves may be either roll-to-roll construction or continuous chain construction and may have driving sprockets
attached to rollers on the inside or outside radius of curve. Standard side bow chain and thin tooth plate sprockets are used for
this construction.

Normal construction has straight faced rollers; however, to prevent loads from riding the outside guide rail, true tapered rollers
may be used. A true tapered roller provides the proper speed differential between the in side and out side of the load as it travels
around the curve.

Differential roller construction may also be used to compensate somewhat for the speed differential or for wide conveyors.
This construction consists of a lane of driven rollers on the outside of the curve and a lane of non-powered idler rollers on the
inside of the curve. It is recommended that the driven lane be approximately 2/3 of the total effective width of the conveyor,
thus allowing 2/3 of the load width (and weight) to be on the driven roller lane.

It is recommended that chain driven live roller curves be horizontal or with a slight decline.

6. TRANSFERS (Figures 18 - 32, Page 8)

There are many types and variations of transfers used with chain driven live roller conveyor to transfer loads onto or off the
conveyor at intermediate positions:

A) Disappearing pitched gravity roller section, where several lanes of idler rollers are set at right angles to the
carrying rollers and are raised and lowered manually or by a power device (see Figure 32, Page 8).

B) The disappearing roller section may be horizontal, instead of pitched gravity, and equipped with a powered pusher
to transfer loads at right angle to the direction of main conveyor (see Figure 28, Page 8).
4
 C) Disappearing chain transfer has two or more strands of chains set parallel to the carrying rollers and between the
carrying rollers. Chains are usually driven by a gearmotor and are normally raised and lowered by pneumatics,
hydraulics, or motorized mechanisms. (see Figure 26, Page 8).

D) Light loads may be pushed off the chain driven live roller conveyor at right angles to the direction of travel by
means of a powered push-off device without the disappearing roller transfer feature. A disappearing plate stop is
normally used in this application to stop the travel of the load and position it while being transferred; or the main
conveyor may be stopped during the “push transfer” cycle (see Figure 29, Page 8).

E) Light loads may also be deflected off the chain driven live roller conveyor by means of a fixed, manually oper-
ated, or power operated deflector consisting of a bar pivoted to swing out over the conveyor (see Figures 20 and 22,
Page 8).

F) A chain driven live roller spur is a section of conveyor set at approximately 30 degrees to the direction of travel
of the main conveyor, with odd length rollers as required to mate with the side of the main conveyor. It is used to
transfer loads onto a conveyor; or it may also be used to transfer loads off a powered conveyor with the use of a
deflector (see Figures 20 and 21, Page 8).

G) Other types of transfers are depicted on Page 8, “Transfer Selection Data.”

7. ACCUMULATING CHAIN DRIVEN LIVE ROLLER

For application data regarding common uses of chain driven live roller as accumulating conveyor, refer to previous articles
discussing “cascade” and “indexing” accumulation (see Section 2, “Application Data: General,” Page 2).

Other low (or zero) storage line pressure accumulating chain driven live roller conveyor construction is available. However,
most such construction is proprietary or patented.

5
 ROLL - TO - ROLL CHAIN DRIVEN LIVE ROLLER CONVEYOR
PACKAGE TRAVEL COVER
EFFECTIVE CONVEYOR WIDTH
PLATE
A
SPROCKET
CENTER
ROLLER
DRIVE
SUPPORT
FIG. 1

PACKAGE TRAVEL
A

COVER PLATES
SUPPORT
END DRIVE
VIEW AT A - A
FIG. 2

SIDE VIEWS TYPICAL CHAIN DRIVEN LIVE ROLLER TYPICAL STRAIGHT AND CURVE
FIG. 1 & 2 FIG. 5

COVER
PLATE EFFECTIVE CONVEYOR WIDTH
ROLLER

BEARING
B LE
R SI
VE
RE B
SHAFT
CENTER
DRIVE
SPROCKET

LIVE SHAFT
FIG. 6

B
DRIVE
CHAIN EFFECTIVE CONVEYOR WIDTH
LOOP
DRIVE
SPROCKET
VIEW OF DRIVE AT B - B

RADIUS
90.0
000
°

90O

PLAN VIEW 90 DEGREE CURVE STRAIGHT-FACED ROLLER CURVE

FIG. 3 FIG. 7

EFFECTIVE CONVEYOR WIDTH

ROLLER TO ROLLER CONSTRUCTION TAPERED ROLLER CURVE

FIG. 4 FIG. 8

6
 CONTINUOUS CHAIN DRIVEN LIVE ROLLER CONVEYOR

CHAIN RETURNS
COVER
IN CHANNEL PLATE
PACKAGE TRAVEL EFFECTIVE CONVEYOR WIDTH
GUIDES TAKE-UP
HOLD A
DOWN
SPROCKET
CENTER
DRIVE ROLLER
SUPPORT

FIG. 9
CHAIN RETURNS RETURN CHAIN WEARING
IN CHANNEL PACKAGE TRAVEL BAR
GUIDES
TAKE-UP

A
COVER
SUPPORT PLATES
END DRIVE

FIG. 10

FIG. 9 & 10 VIEW AT A - A

CHAIN DRIVEN LIVE ROLL CURVE DRIVE

SINGLE-STRAND, CONTINUOUS CHAIN TYPE TYPICAL STRAIGHT AND CURVE
FIG. 14
LE
RS T
IB
VE N O

EFFECTIVE CONVEYOR WIDTH

RE

CHAIN GUIDE

DRIVE END TAN.

EACH
END

RADIUS
90.1
363
°

90O CHAIN DRIVE ON OUTSIDE RADIUS OF CURVE

FIG. 15

PLAN VIEW 90O CURVE

EFFECTIVE CONVEYOR WIDTH
FIG. 11
CHAIN
GUIDE

SPROCKETS IN
LINE

CHAIN DRIVE ON INSIDE RADIUS OF CURVE

PLAN AND SIDE VIEWS OF SINGLE SIDE CHAIN FIG. 16
FIG. 12

EFFECTIVE CONVEYOR WIDTH

CHAIN GUIDE

SPROCKETS
STAGGERED

TAPERED ROLLER CURVE

PLAN AND SIDE VIEWS OF TWO-SIDED CHAIN
WITH CHAIN DRIVE ON OUTSIDE RADIUS
FIG. 13
FIG. 12 & 13 FIG. 17

7
 TRANSFER SELECTION DATA
ROLLER CONVEYOR CURVE SWITCH SECTION ROLLER CONVEYOR
RAISE / LOWER,
WITH PUSHER

FIG. 18 FIG. 23 FIG. 28

CHAIN DRIVEN LIVE ROLLER CURVE TRANSFER CAR STOP AND PUSHER

FIG. 19 FIG. 24 FIG. 29

DIVERTER AND SPUR CHAIN CONVEYOR RIGHT ANGLE (“BUTT”)

RAISE / LOWER SECTION
OF CDLR

FIG. 20 FIG. 25 FIG. 30

CHAIN DRIVEN LIVE ROLLER SPUR CHAIN CONVEYOR: TURNTABLE

RAISE / LOWER

FIG. 21 FIG. 26 FIG. 31

DIVERTER: CHAIN CONVEYOR ROLLER CONVEYOR:

PARALLEL LANES WITH PUSHER LUGS RAISE / LOWER

FIG. 22 FIG. 27 FIG. 32

8
 Section 3

TECHNICAL DATA

SYMBOLS

a Number of non-powered rollers per driven roller

Ci Number of non-powered rollers per foot of conveyor

Cd Number of driven rollers per foot of conveyor

Dr Diameter of rollers, inches

Ds Pitch diameter of sprockets on driven rollers, inches

F Friction factor (see Table I)

HP Horsepower

i Roller chain loss factor

L Conveyor length, feet

n Number of driven rollers in roller-to-roller chain driven live roller conveyor

Pc Chain pull for continuous chain drive, pounds

Pn Chain pull for roller-to-roller drive, pounds

n
(1 + i) -1
Q (See Table II)
i
Rd Unit weight of driven roller and sprocket, less shaft, pounds

Ri Unit weight of non-powered roller, less shaft, pounds

v Conveyor speed in feet per minute

W Rd + a Ri + (a + 1) Wr + We = Weight driven by each powered roller, pounds

Wc Weight of chain, pounds per foot

Wm Weight of conveyed material, pounds per foot

Wr Weight of conveyed material, pounds per roller

We Weight of chain in one roller-to-roller loop

METRIC CONVERSION
Calculations must be performed in the English System, and the results must then be converted to metric.

9
 CHAIN PULL AND HORSEPOWER CALCULATIONS

Equation 1: Continuous Chain Construction

The drive chain pull for a continuous chain driven live roller conveyor is given by the following equation:
D
Pc = FL Dr ( Wm + Wc + Rd Cd + RiCi ) + 0.25 LWc (1)
s

Equation 2: Roll-to-Roll Construction

The drive chain pull for a roll-to-roll chain driven live roller conveyor with “n” driven rolls is given by the following
equation:
D
Pn = FWQ Dr (2)
s

For both Equation 1 and Equation 2 above:

F = Friction Factor (from Table I, Page 11)

W = Rd + a Ri + (a + 1) Wr + We
n
(1 + i) -1
Q = i (see Table II, Page 11)

i = Roller Chain Loss Factor *

Dr
Ds = Ratio of roller diameter to sprocket pitch diameter

*Roller chain loss will usually range between one percent (1%) and three percent (3%), depending on conditions of service.
Under ideal conditions with well-lubricated chain, one percent (1%) can be used. Use 3% if operating conditions are severe
and chain cannot be properly lubricated or maintained.

In analyzing the developed relationship for chain pull in Equation 2, it is seen that chain pull develops exponentially with the
number of progressively driven rollers. For this reason, the working strength of the chain will limit the number of loops. A
practical maximum is approximately 150 loops or driven rollers in either direction from the drive sprocket.

It is important that the value “n” be only the number of driven rollers. When idler rollers exist between the driven rollers,
their weight and the load they support should be included as part of the total load driven by each powered roller. That is, the
term “W” in the equation should represent the total weight of the driven roller, the live load on the driven roller, plus the
weight of the idler roller and live load weight supported on each idler roller.

In deriving the chain pull per Equation 1 or Equation 2 above, the following assumptions have been made:

1. The total live load is uniformly distributed on all the rollers.

2. The load imposed on each bearing by the driving chains is negligible except for the roller or rollers coupled to the drive.

3. The pull required to turn each roller results from a combined rolling resistance between roller and bearing and roller and
load.

4. The chain transmission efficiency factor is constant.

5. The conveyor is horizontal and level.

Note: Different companies use different factors. These calculations serve as a starting point for your company's design
team.

10
Equations 3 and 4: Horsepower Calculations

After determining chain pull from previous calculations (Equation 1 or 2), to determine horsepower at head shaft, apply one of
the following equations:

HP = Pc v Ds for Continuous Chain construction (3)

33,000 Dr

HP = P n v Ds for Roll - to - Roll construction (4)

33,000 Dr
Increase horsepower requirements calculated above to compensate for friction loss in reducer or gearmotor. Consult manufacturer’s
literature for friction loss factor or percentage.

TABLE I: FRICTION FACTOR “F”

Total Weight on Each Roller SURFACE ON UNIT LOAD CONTACTING ROLLER

(includes Weight of Rollers)
in Pounds) Smooth Metal Wooden Pallet Cardboard
0- 25 0.040 0.045 0.050
26-100 0.030 0.035 0.050
101-200 0.025 0.030 0.045
201 and higher 0.020 0.025 0.040

TABLE II: FACTOR FOR DETERMINING VALUE OF “Q” IN EQUATION 2

Driven ROLLER CHAIN LOSS FACTOR "i"

Rollers "n" .010 .015 .020 .025 .030
10 1.05 1.07 1.09 1.12 1.15
20 1.10 1.16 1.21 1.28 1.34
30 1.16 1.25 1.35 1.46 1.59
40 1.22 1.36 1.51 1.69 1.89
50 1.29 1.47 1.69 1.95 2.26
60 1.36 1.60 1.90 2.27 2.72
70 1.44 1.75 2.14 2.65 3.29
80 1.52 1.91 2.42 3.10 4.02
90 1.61 2.09 2.75 3.66 4.93
100 1.70 2.29 3.12 4.33 6.07
110 1.81 2.51 3.56 5.14 7.52
120 1.92 2.76 4.07 6.12 9.36
130 2.04 3.04 4.66 7.32 11.70
140 2.16 3.35 5.36 8.78 14.68
150 2.30 3.70 6.17 10.65 18.50

The value for “Q” is obtained by multiplying the actual number of driven rollers “n” by the factor obtained from the chart using
the next larger multiple of driven rollers and the appropriate factor for “i”.

Example: For “n” = 83 and “i” = .01, then “Q” = (1.61) 83 = 133.63

The value obtained is correct for a drive located at one end of the conveyor (see Figure 2, Page 6).

To minimize chain pull and drive HP requirements, the drive can be located in the center of the conveyor (see Figure 1, Page 6).
“Q” with a center drive is obtained by multiplying the actual number of driven rollers “n” by the factor obtained from the chart
for 1/2 the quantity of driven rollers.

11
 TABLE III: MINIMUM SPROCKET TEETH PER ROLLER DIAMETER

ROLLER DIAMETER (INCHES AND MILLIMETERS)

A.S.A.
CHAIN PITCH 1-3/4" 1.9" 2" 2-1/4" 2-1/2" 2-9/16" 3-1/2"
SIZE
44.45 48.26 50.80 57.15 63.50 65.09 88.90

# 40 1/2" 16 17 19 21 21 21 28

# 50 5/8" 15 15 15 17 17 17 23

# 60 3/4" 13 13 13 15 15 15 19

# 80 1" 13 13 16

# 100 1-1/4" 13

MINIMUM ROLLER CENTERS

For roll-to-roll chain driven live roller conveyors, the minimum centers must be a multiple of 1/2 of chain pitch and must
provide clearance between chains wrapped around sprockets on adjacent roller (see Figure 4, Page 6, and Table IV, below).

Roller centers can be reduced by driving every other roller (see Figure 5, Page 6). The pinch point between the powered roller
and idler roller must be guarded. However, this is not a recommended solution. The recommended method is to drive

Alternate routes may be driven from each side of the conveyor to obtain close spaced powered rollers.

For continuous chain driven live roller conveyors, the minimum centers need only provide clearance between teeth of sprockets
on adjacent rollers (see Figure 14, Page 7). The centers can be reduced by driving every other roller (not recommended); or
staggered sprockets driven by a single strand of double width chain or two (2) single strands of chain can be used to drive every
other roller at the closest possible centers (see Figure 15, Page 7).

TABLE IV: MINIMUM ROLLER CENTERS WITH ROLL-TO-ROLL CONSTRUCTION

MINIMUM CENTERS "C" (INCHES AND MILLIMETERS)

A.S.A.
CHAIN NUMBER OF SPROCKET TEETH
SIZE
13 15 16 17 19 21 23 28
# 40 3-1/4" 3-1/2" 3-3/4" 4" 5-1/4"
82.55 88.90 95.25 101.60 133.35
# 50 3-11/16" 4-1/16" 5-1/16"
93.66 103.19 134.94
# 60 4-1/8" 4-1/2" 5-5/8" 6-3/8"
104.77 114.30 142.87 161.92
# 80 5-1/2" 6-1/2"
139.70 165.10
# 100 6-7/8"
174.62

Refer to CEMA Standard No. 401 for

Conveyor Frame Calculations and Roller Bearing Capacity

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