PAT E N T

PENDING

553 FLEXTOP
Multidirectional Modular Belt

ENGINEERING MANUAL
 553 FLEXTOP
Multidirectional Modular Belt
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Changing direction
can improve
the performance of your job
TABLE OF CONTENTS

553 FLEXTOP
Multidirectional Modular Belt

INTRODUCTION
Overview . . . . . . . . . . . . . . . . . . . . . ..................................................................................................................................................................................................... 10
Features . . . . . . . . . . . . . . . . . . . . . . . .................................................................................................................................................................................................... 11
Suitable goods . . . . . . . .................................................................................................................................................................................................... 12
Application examples and Industries ..................................................................................................................................................... 13-14

MAIN FUNCTIONALITIES
Belt and Sprockets specification ................................................................................................................................................................... 15
Basic controls . . . . . . . . . . . ................................................................... ................................................................................................................................. 16
Goods dimensioning ............................................................................................................................................................................................... 17

MOVEMENTS
Divert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................................................................................................................................................................................................... 18
Static Rotation. . . . . . . . . . . . ................................................................... ................................................................................................................................. 18
Dynamic Rotation . . . .................................................................................................................................................................................................... 19
Accumulation . . . . . . . . . . . . . .................................................................... ................................................................................................................................ 19
Acceleration/Deceleration .................................................................................................................................................................................... 19

ADVANCED CONTROLS
Divider – Merger . . . . . .................................................................................................................................................................................................... 20
Sorter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................................................................... ................................................................................................................................ 21
Divider - Merger - Sorter - Complete dimensioning solution and Example ................................................................. 22-23
Static Rotation - Complete dimensioning solution and Example ....................................................................................... 24-25
Dynamic Rotation - Complete dimensioning solution and Example ................................................................................ 26-27

CONVEYOR CONSTRUCTION & MAINTENANCE

Sprockets position .................................................................................................................................................................................................... 28
Wear Strips and Machined Plates ............................... ................................................................................................................................. 29
Return rollers . . . . . . . . . . . . .................................................................................................................................................................................................... 30
Maintenance . . . . . . . . . . . . . ................................................................... ................................................................................................................................. 31

NOTES
A page for your notes
. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................................... ................................................................................................................................ 32

ENGINEERING MANUAL
 Overview

The new Movex® 553 FlexTop modular belt

with self-locking spheres is specifically
designed for high-precision material
handling, suitable for several applications
like logistic centers, packaging stations (food
and beverage) and corrugated industries,
easily to be integrated into existing systems.

The 360° movement possibility makes

the belt suitable for diverting, rotating,
accumulation and acceleration applications
and minimize required maintenance and
downtimes.

The small pitch between the spheres

(diameter 12,7 mm and pitch 25,4 mm) allows
every type of good transfer and is ideal for
small and light packages, unlike traditional
roller conveyors.
Density: 1.600 spheres/m2.

The complete closed sliding belt surface

is the perfect solution to carry carton
boxes, crates, cans and bottles shrink-wrap
packaging and any kind of polybag with Top-
Accuracy package control.

10 ENGINEERING MANUAL
Features

Perfect
High Self Great Long Reduced
good
strength cleaning versatility durability downtimes
control

Design and features of 553 FlexTop make it ideal for

the transport of several type of goods (e.g. polybags,
shrink-wrap packaging).

The small pitch between the spheres allows for a great

goods control.

A complete closed sliding surface , in combination with

self-locking spheres, makes the belt design flexible and
robust.

553 FlexTop belt can be used over a fixed support area

to accelerate transport speed or with additional belts
and rotating plates to fully express its potential.

With a directional belt underneath the FlexTop belt you

can control the direction and more precisely the speed
of the spheres, making this belt 100% versatile.
This function is very useful when goods must be separated
from each other but also to transfer your package laterally
without external guides and pushers. This scenario is ideal
for several applications requiring rapid 90° transfer of
the conveyed items.

Using two parallel running belts positioned

underneath 553 Flextop belt, and running in opposite
directions, goods in the middle of the belt will rotate
quickly without interrupting the main transport movement
(rotation with good moving).

553 FlexTop belt can also be used in combination with

a rotating plate to have an optimum control of the
rotation of the good (rotation with item stopped).

In this manual, you will find more details for each option.

ENGINEERING MANUAL 11
 Suitable goods

VERSATILITY

The main advantage of the Movex® 553 FlexTop

modular belt is its maximum flexibility to
meet your needs.

Ideal to transport cardboard boxes and

small packages, the 553 FlexTop belt is also
the right solution when you have to transport
polybags, papers, plastic cases, containers,
rubber parts (tires), shrink packs of bottles
and cans, etc…

What’s important is understanding if the

good sliding surface is suitable with the 553
FlexTop surface, because that will determine
the success of the application.

To do this, the goods bottom surface must

have flat parts able to run completely on at
least one sphere with a minimum of 6 spheres
per good.

Another important aspect is the total weight

of the good: most of the times is suitable with
the max working load of the belt, especially
of the spheres. Anyway, we always suggest
to double check that the total weight of the
good does not exceed the max load of the
spheres, 15N/ea.

We have several machines in our showroom

that can be used for testing your goods with
all the type of movements available with 553
FlexTop belt (sorting and rotation).

12 ENGINEERING MANUAL
Application examples and Industries

AUTOMATIC STORAGE SYSTEM

• Distribution system
• Sorting
• Lane divider

The goods can be guided over the 553

Flextop in 3 different directions: straight,
left or right, bases on the correct exit to be
taken.

GOOD ORIENTATION
• Casing machines
• Palletizers

The goods can be oriented on the right

side. This can be done by static rotation or
dynamic rotation, based on the required
quality output and the process speed.

GOOD POSITIONING
• Labelling
• Printing
• Barcodes Reading

The goods needs to be guided first on the

right and then on the left. This can be done
by using two separate modules or one single
solution.

REJECT STATION
• Inspection equipment
• Measuring devices

The goods can be rejected on its left/right.

ENGINEERING MANUAL 13
 Application examples and Industries

The 553 FlexTop modular belt is ideal for all those applications where a dedicated movement
is required.

Its versatility with different movements offer great use in different application areas.

The most used are logistic and distribution centers, food and beverage and corrugated.

At the same time, whevener a dedicated movement is required and the good sliding surface is
suitable to the 553 FlexTop belt, it can be used as well.

Logistic and distribution centers

With more and more consumers buying from

the web, logistics and distribution centers
are becoming more efficient. The 553 FlexTop
modular belt is ideal when different product
sizes and sliding surface are running over,
keeping the efficiency at the maximum value
and avoiding machines and robots which may
result very expensive.

Safe design, very high speed, low noise.

Food and beverage

In the packaging area of the food and

beverage industries, the 553 FlexTop modular
belt can help creating different actions with
one machine only: orientate the package to
the right side, align with the group, reject in
case of non-conformity, move side to side,
everything done by keeping always one eye
on safety aspect.

Safe design, high speed, high working load.

Corrugated

The corrugated industry is the most traditional

system where the 553 FlexTop can be used.
With this belt all type of stack of cardboards
can be easily handled and with only one
machine the good can have 3 different exit
directions: straight, left or right, without the
needs of having different conveyors, head to
tail transfers and the risk of downtimes.

Safe design, low speed, very high working load.

14 ENGINEERING MANUAL
Belt and Sprockets specification
CODE STRUCTURE GUIDE Backflex radius min.: 25 mm
(Example)

5530 27 0042 A 25.4 mm

PITCH
Series *Material Width Version

Material
W (inch)
W (inch)
LFG - Code 27 6”
6”
Low friction Acetal
M=3”
M=3” 8,78,7
Max working load: 27500 N/m (1850 lbs/ft) 0.34
Weight: 10 Kg/m² (2.04 lbs/ft²)
0.34
Temp. range dry: -40÷80 °C (-40÷176°F)
Temp. range wet: -0÷65 °C (+32÷149°F)
Pin material: PBT white

25,4
1.00
25,4
1.00
Belt available also in RAL 5005 (Blue)

Sphere material

High-tech Polyamide 12,7

12,7
Max working load: 15 N (3.37” lbs) Supplied coil length: Width ≤ 30” : 1.524 m (60 pitches) - Width > 30” : 1.016 m (40 pitches) 0.50.5
Sphere Diameter: 12,7 mm (0.50”) On request wider belts are available with 3” increments.

Version A - Standard
Series Material Width Version Series Material Width Version Series Material Width Version Series Material Width Version

5530 27 0003 A 5530 27 0036 A 5530 27 0069 A 5530 27 0102 A

5530 27 0006 A 5530 27 0039 A 5530 27 0072 A 5530 27 0105 A
5530 27 0009 A 5530 27 0042 A 5530 27 0075 A 5530 27 0108 A
5530 27 0012 A 5530 27 0045 A 5530 27 0078 A 5530 27 0111 A
5530 27 0015 A 5530 27 0048 A 5530 27 0081 A 5530 27 0114 A
5530 27 0018 A 5530 27 0051 A 5530 27 0084 A 5530 27 0117 A
5530 27 0021 A 5530 27 0054 A 5530 27 0087 A 5530 27 0108 A
5530 27 0024 A 5530 27 0057 A 5530 27 0090 A 5530 27 0111 A
5530 27 0027 A 5530 27 0060 A 5530 27 0093 A 5530 27 0114 A
5530 27 0030 A 5530 27 0063 A 5530 27 0096 A 5530 27 0117 A
5530 27 0033 A 5530 27 0066 A 5530 27 0099 A
Continue >> Continue >> Continue >>

Drive split sprockets - Machined and molded

24 21
S
S

OD
PD
OD
PD

B B

• Easy clean and installation

• Heavy duty design 6
6

Bore PD OD S Bore PD OD S
Art-Nr. Z- (mm-in) (mm-in) (mm-in) (mm-in)
Art-Nr. Z- (mm-in) (mm-in) (mm-in) (mm-in)

40x40 98,1 97,6 44,5 40x40 146,3 146,0 68,5

166108 12 166511 18
1.57x1.57 3.86 3.84 1.75 1.57x1.57 5.76 5.75 2.70
60x60
40x40 122,2 121,9 56,5 166510
166208 15 2.36x2.36
1.57x1.57 4.81 4.80 2.22
60x60
166210
2.36x2.36

40x40 146,3 146,0 68,5

166308 18 Material: Reinforced polyamide
1.57x1.57 5.76 5.75 2.70
60x60
166310
• Optimized hygenic 2.36x2.36
• Quick replacement 65x65
166311
2.56x2.56
Machined sprockets with round
Material: Polyamide
Screws: Stainless steel Nuts: Zinc plated steel
bore are available on request.

ENGINEERING MANUAL 15
 Basic controls

When the 553 FlexTop modular belt is running over a static

support, directional belt or rotating plate, its spheres start
changing direction and speed. It is very important to give
Good
enough friction to the spheres to better control them.
In case of acceleration, 553 FlexTop belt spheres can run
on a Polyethylene support plate (wear strips or machined Rotating sphere
plate, min 15mm thickness). In case of lateral movements,
553 FlexTop belt
553 FlexTop belt spheres can run on a PVC or Polyurethane
coating belt with hardness of 60-70ShA.
To guarantee the same speed of the spheres (then of the Fixed strip or conveyor
goods), it is always suggested to cover the support plate
with the same material of the directional belt (different
friction may cause different goods speeds).

Legend:
For a better indication of possible directional belts, FlexTop belt
their performances (maximum speed), as well as Directional belt or Rotating plate

minimum thickness of the coating, please enquire your Transported good by 553 FlexTop belt
553 FlexTop belt direction
belting supplier.
Directional belt or Rotating plate direction
Belts speed and direction

Basic formulas to control goods speed/direction

Transport Speed Transport Speed Transport Speed

Y= 2X Y= 2X + Z Y= 2X - Z

X X X

Z Z

553 FlexTop belt running over fixed 553 FlexTop belt mounted over a 553 FlexTop belt mounted over a
surface. longitudinal conveyor running in longitudinal conveyor running in the
opposite direction. same direction.

Y= √ (2X) + Z
2 2
αY = αX

X
Rotating plate
Z 553 FlexTop belt
553 FlexTop belt
Directional Belt

553 FlexTop belt with directional belt mounted perpendicularly 553 FlexTop belt with a 360° rotating plate underneath
The difference in speed between the 553 FlexTop belt and the Useful option used to easily positioning the good.
directional belt determines the direction angle of the good.

Belt spheres run in the opposite direction of the directional belt (to go on the left the directional belt must run
! on the right) and of the rotating plate (to go clockwise the rotating plate must turn counter clockwise).

Combine different movements to get the required direction for your business!

16 ENGINEERING MANUAL
Goods dimensioning

The type of the goods to be transported over the 553 FlexTop belt must be checked carefully.
In general, there are a few recommendations need to be followed to check if the good can be transported:

• Bottom surface of the goods – relatively flat

• Center of gravity of the goods – relatively distributed (+/-20% around the nominal one)
• Weight – suitable with spheres – maximum 15N per sphere
• Contact – goods running on at least 6 spheres

Goods contact surface

Contact with the spheres is a necessary condition

As a rule, there must be at least 6 spheres in contact with the good surface at the same time, so almost 6in2
(38cm2) 1in2 per sphere (6,4cm2 per sphere).

To guarantee sliding properties, it is very important to calculate the sliding contact surface of the good.
! It must be bigger than 38cm2.

Example:

Good suitability assessment of a polystyrene box weight 18kg

with bottom surface – external contact.

• External Length 10cm

• Internal Length 8cm
• External width 16cm
• Internal width 13cm

Calculation:
Surface in contact: (10x16) - (8x13) = 56cm2 > 38cm2 OK
This can be transformed in N° of spheres in contact 56/6,4=8,75 8 spheres (would result 8 full sphere in contact)
Weight: 18Kg * 9,81= 176,6N 176,6/15=11,77 minimun 12 spheres required

Output:
This type of goods can’t be transported.
!
!

Because of the weight, this

box cannot be transported.
Possible solutions to meet the requirements: You have two options to
solve the problem:
• Increase the dimension of the box to achieve 76,8 cm2 sliding surface (12 spheres x 6,4 cm2).
• Reduce the box weight to maximum 120N (8 spheres x 15N).

For more support or particular applications you can contact our engineering department.

ENGINEERING MANUAL 17
 Movements

Divert – lateral movement

By using a directional belt underneath the 553 FlexTop

belt, running square to the travel direction, the goods
can be transferred left and right.

The combination of the speed of modular belt and

directional belt will determine the direction of the exit.

PRECISION SPEED

1
2

PRECISION SPEED PRECISION SPEED

1
2 3

Straight exit PRECISION SPEED Inclined exit PRECISION SPEED Curved exit PRECISION SPEED

To get a completely straight exit, the To get a 45° inclined direction, the speed of To get a straight exit without loosing relatively
directional belt2 must be activated when 553 the directional3 belt must be the same as too much time, 4 the directional belt can be
FlexTop is not running.
PRECISION SPEED the speed of the 553 FlexTop and theySPEED
PRECISION have to activated also when the 553 FlexTop
PRECISION SPEED is
work contemporary. running, while is reducing speed.
The combination of the two speeds will
3 4 5
determine the exit curve dimension.
PRECISION SPEED PRECISION SPEED PRECISION SPEED

4 5
Static Rotation 6

PRECISION SPEED PRECISION SPEED PRECISION SPEED

By using a rotating plate underneath the 553 Flextop

5 6 belt, the goods will start rotating.
7
PRECISION SPEED PRECISION SPEED PRECISION SPEED
Such a movement can be done by having a Rotating
6 7 Plate turning at the opposite direction than what has
PRECISION SPEED PRECISION good direction. For a high-precision rotation,
to be the SPEED
it is suggested to active the Rotating Plate when the
7 modular belt is stopped. 1

PRECISION SPEED
PRECISION SPEED

1
2
PRECISION SPEED PRECISION SPEED

2 3
PRECISION SPEED PRECISION SPEED

3
4
PRECISION SPEED
PRECISION SPEED

4 5

Controlled rotation PRECISION SPEED Uncontrolled rotation PRECISION SPEED

To get a controlled roation, the rotating plate must be activated when 553 If the rotating plate get activated while the modular belt is running, the
5
FlexTop is not running. good will rotate in more space. 6
PRECISION SPEED Be sure the product is running over the plate till its rotation is completed.
PRECISION SPEED

6
7
PRECISION SPEED
PRECISION SPEED

7
18 PRECISION SPEED
ENGINEERING MANUAL
Movements

Dynamic Rotation

By using two directional belts1 underneath the 553

Flextop belt, running at opposite direction, the good
PRECISION SPEED
will start rotating.
1 2
This option is ideal for high speed lines, while the
PRECISION SPEED PRECISION SPEED
goods needs to be rotated to correct sides without
slowing down the production line. Based on the
2 3
combination of speeds between the 3 belts, the good
PRECISION SPEED PRECISION SPEED
will rotate in a different distance. It is suggested to
keep the directional belts speed always the same.
3 4

PRECISION SPEED PRECISION SPEED

4 5

PRECISION SPEED
PRECISION SPEED

5 6
PRECISION SPEED PRECISION SPEED

6 7

Clockwise direction: PRECISION SPEED Counter clockwise direction: PRECISION SPEED

To get a dynamic rotation to the right, the two directional belts must To get a dynamic rotation to the left, the two directional belts must run
run like the picture. 7 like the picture.
PRECISION SPEED

Accumulation

For a limited time, in case of needs or special application

(e.g. rejected table), the 553 FlexTop belt can work as
accumulation.

In that case spheres must be free to run, so the belt

has to be supported by wear-strips positioned between
spheres (see page 29).

Maximum wear-strip width 8mm.

Acceleration/Deceleration

By using a static plate or a directional belt underneath

the 553 FlexTop belt, the good can accelerate or
decelerate.

Static plate Directional belt

By using a static plate, the By using a directional belt,
good speed will result the good speed can be
double than the 553 accelerated or decelerated
FlexTop belt speed. independently from the 553
FlexTop belt speed.

ENGINEERING MANUAL 19
 Advanced Controls

DIVIDER - MERGER In case of different movement required, please

Below sketch of the typical schemes can be done with provide information to your sales representative
the 553 FlexTop belt. and you will receive required support.

DIVIDER MERGER DIVIDER MERGER

1 to 2 - centered 1 to 2 - aside

1 553 FlexTop belt - 1 Directional belt 1 553 FlexTop belt - 1 Directional belt

1 to 3 - centered 1 to 3 - aside

1 553 FlexTop belt - 1 Directional belt 1 553 FlexTop belt - 1 Directional belt

2 to 3 - centered 2 to 3 - aside

1 553 FlexTop belt - 2 Directional belts 1 553 FlexTop belt - 2 Directional belts

20 ENGINEERING MANUAL
Advanced Controls

SORTER In case of different movement required, please

Below sketch of the typical schemes can be done with provide information to your sales representative
the 553 FlexTop belt. and you will receive required support.

More bays can be created in two different ways:

• Single unit – more directional belts

• Single unit – single directional belt

Both will have related advantages, the single unit with more directional belts results easier to program and
handle; the single unit with single directional belt results quicker from maintenance point of view (easy to replace
and avoid downtimes).

90° SORTING - One side - more directional belts

1 553 FlexTop belt - 3 Directional belts

One side sorting can also be done with single directional belt (see the example below)

90° SORTING - Two sides - single directional belt

1 553 FlexTop belt - 1 Directional belt

Two sides sorting can also be done with more directional belts (see the example above)

When using a single directional belt, goods can take the exit only one by one and the next good can’t run over
! the directional belt if the previous one is on its exiting direction (that will compromise its direction).
ENGINEERING MANUAL 21
 Divider - Merger - Sorter - Complete dimensioning solution

Below sketch of the typical schemes can be done with

the 553 FlexTop belt. In case of different movement required, please
provide information to your sales representative
and you will receive required support.

Complete dimensioning solution

Below the main functional scheme for a typical application of product lateral movements.
Shown formulas help calculating main information to create a complete unit.
In black are indicated required input, in red are indicated output that can be calculated with the following formulas:

LI Wd LO

Sg We
Legend:

Lg Good length
Wb
Wg Wg Good width
Wb FlexTop belt width
Sb Lg Wd Directional belt width
Sd
Sd Directional belt speed
Sg Good speed
Sb FlexTop belt speed
553 FlexTop belt Good Directional belt

!
Lg
Goods length corresponds to
the running side, not always
to the longer side of the goods!
contact with Directional belt

Inputs: Formulas:
• Lg Goods length (mm) • FlexTop belt width (bigger than goods width, multiple of 3” standard measure):
• Wg Goods width (mm) Wb ≥ Wg to catalog width
76,2
• C Capacity - n° of goods per minute (N°/min)
(or Sg goods speed m/min)
• Directional belt width (at least 1,5 times the goods length): Wd = 1,5 * Lg
• Pg Goods pitch (mm)
• Goods pitch (if not provided as input, at least long as Wd): Pg = Wd

Pg
• Goods speed (if not provided as input, can be calculated from capacity): Sg = 1000 * C
Outputs:
• FlexTop belt speed (considering all spheres running on a flat plate): Sb = 21 * Sg
• Wb FlexTop belt width
L
• Wd Directional belt width • Climbing time: Tc1 = g
Sg
• Sd Directional belt speed Wd
• Crossing time: Tc2 =
• Sb FlexTop belt speed Sg

• Tc1 Climbing time • Useful time (net available time for directioning): Tu = Tc2 – Tc1
• Tc2 Crossing time
Wb
• Exit width (considering the good coming in the middle of the FlexTop belt): We =
• Tu Useful time 2
• We Exit width [We + (Wg / 2)]
• Directional belt speed: Sd =
Tu * 1000
• Li Infeed length
• Infeed length (mandatory): Li ≥ Lg
• Lo Outfeed length
• Ltot Total conveyor length Li
• Outfeed length (optional): Lo =
2
• We Exit width
• Total conveyor length: Ltot = Li + Lo + Wd

22 ENGINEERING MANUAL
Divider - Merger - Sorter - Example

Sorter - Complete dimensioning solution - EXAMPLE

Inputs:
• Lg Goods length (mm) = 380mm !
• Wg Goods width (mm) = 420mm
Don’t forget to check if the
• C Capacity - n° of goods per minute (N°/min) = 25pcs/min (or Sg goods speed) goods weight and dimensions
are suitable: maximum weight
• Pg Goods pitch (mm) = n.a. 15N per sphere and minimum 6
spheres fully in contact.

Outputs:
• Wb FlexTop belt width: !
Wg 420
Wb ≥ to catalog width = 5,51 6 * 76,2 = 457,2mm (Belt width 18” – Art. Nr 5530270018A) If the next good is running over
76,2 76,2 the directional belt before the
first one is already out, it will
start rotating and then the final
• Wd Directional belt width: Wd = 1,5 * Lg 1,5 * 380 = 525mm position won’t be as programmed.

The wider is the directional belt, the more will be the time available for the goods to be moved.

• Pg Goods pitch (mm): Pg = Wd > 525 600mm

The pitch between goods is very important to give enough time to a goods to realize the right movement

Pg 600
• Sg Goods speed: Sg = *C 25 = 15 m/min
1000 1000 * 2X

!
• Sb FlexTop belt speed: Sb = 21 * Sg 1
2 * 15 = 7,5 m/min
If the spheres are touching a
static support (strips or plate)
Lg 380 60
• Tc1 Climbing time: Tc1 = S 15 * 1000 = 1,5 s
their speed will result double than
g
the speed of the FlexTop belt.
That’s why the FlexTop belt
speed (Sb) results half of the
• Tc2 Crossing time: Tc2 = W
Sg
d 525
15
60
1000 = 2,1 s
Fig. A
goods speed (Sg).

• Tu Useful time: Tu = Tc2 – Tc1 1,5-1,08 = 0,6 s

• We Exit width: We = W
2
b 457,2 = 228,6mm Fig. B
2

We + (Wg /2) 228,6 + (420/2)

• Sd Directional belt speed: Sd = = 0,7 m/s 44 m/min
Tu * 1000 0,6 * 1000

• Li Infeed length: Li ≥ Lg 380 mm

• Lo Outfeed length: Lo = Li 380 = 190 mm

2 2

• Ltot Total conveyor length: Ltot = Li + Lo + Wd 380 + 190 + 525 = 1.095 mm

Fig. A Tc2 Crossing time Fig. B

Tc1 Climbing time Tu Useful time

We

Wg / 2

44 m/min

ENGINEERING MANUAL 23
 Static Rotation - Complete dimensioning solution

Below sketch of the typical schemes can be done with

the 553 FlexTop belt.
In case of different movement
required, please provide information to
your sales representative and you will
receive required support.

For a movement completely under control, the static

rotation is the best way to rotate a product. Obviously,
this is also the slower solution, because the goods
needs to arrive in the middle of the disc, stop, turn
and start again.

Complete dimensioning solution

Below the main functional scheme for a typical application of goods rotation.
Shown formulas help calculating main information to create a complete unit.
In black are indicated required input, in red are indicated output that can be calculated with the following formulas:

LI Dt LO

Legend:

Lg Goods length
Wg Goods width
Wb FlexTop belt width
Dt Rotating plate diameter
St Rotating Plate speed
Wg Wb
Sb FlexTop belt speed

St
Sb Lg !
Lg
Goods length corresponds to
the running side, not always
to the longer side of the goods!
Good Rotating Plate 553 FlexTop belt

Inputs: Formulas:
• Lg Goods length (mm) • FlexTop belt width (bigger than goods width, multiple of 3” standard measure):
• Wg Goods width (mm) Wg
Wb ≥ to catalog width
76,2
• C Capacity - n° of goods per minute (N°/min)
(or Sg Goods speed m/min)
• Pg Goods pitch (mm)
• Rotating Plate diameter: Dt ≥ √ Lg2 + Wg2

• α Rotation angle • Goods pitch (if not provided as input, at least long as Dt): Pg = Dt

Pg
• Goods speed (if not provided as input, can be calculated from capacity): Sg =
1000 * C

Outputs: • FlexTop belt speed (considering all spheres running on a flat plate): Sb = 1 * Sg
2
• Wb FlexTop belt width
Pg
• Dt Rotating Plate diameter • Useful time (net available time for rotation): Tu = 1000 * S
g

• Sb FlexTop belt speed α

• Rotating Plate speed: St =
Tu
• Tu Useful time
• St Rotating Plate speed • Infeed length (optional): Li = Lg
• Li Infeed length L
• Outfeed length (optional): Lo = 2i
• Lo Outfeed length
• Ltot Total conveyor length • Total conveyor length: Ltot = Li + Lo + Dt

24 ENGINEERING MANUAL
Static Rotation - Example

Complete dimensioning solution - EXAMPLE

Inputs:
• Lg Goods length (mm) = 380mm
!
• Wg Goods width (mm) = 420mm
Don’t forget to check if the
• C Capacity - n° of goods per minute (N°/min) = 25pcs/min (or Sg Goods speed) goods weight and dimensions
are suitable: maximum weight
• Pg Goods pitch (mm) = n.a. 15N per sphere and minimum 6
spheres fully in contact.
• α Rotation angle = 90°

Outputs:
• Wb FlexTop belt width:
!
If the next goods is running over
Wg to catalog width 420
Wb ≥ = 5,51 6 * 76,2 = 457,2mm (Belt width 18” – Art. Nr 5530270018A) the directional belt before the
76,2 76,2 first one is already out, it will
start rotating and then the final
position won’t be as programmed.
• Dt Rotating Plate diameter: Dt = Dt ≥ √ Lg2 + Wg2 √ 3802 + 4202 = 566,4 600mm
The wider is the Rotating Plate diameter, the easier will be that the goods is perfectly center on it.

• Pg Goods pitch (mm): Pg = Dt 600mm

Pg 600
• Sg Goods speed: Sg = C 25 = 15 m/min
1000 * 1000 * 2X

1
• Sb FlexTop belt speed: Sb = 2 * Sg * 15 = 7,5 m/min
!
If the spheres are touching a
static support (strips or plate)
Pg 600
• Tu Useful time: Tu = = 0,04 min * 60 2,4 s their speed will result double than
1000 * Sg 1000 * 15 the speed of the FlexTop belt.
π That’s why the FlexTop belt
α 2 speed (Sb) results half of the
• St Rotating Plate speed: St = = 0,65 rad/s = 39 rad/min goods speed (Sg).
Tu 2,4

• Li Infeed length: Li = Lg 380 mm

Li
• Lo Outfeed length: Lo = 380 / 2 = 190 mm
2

• Ltot Total conveyor: Li + Lo + Dt 380 + 190 + 600 = 1.170 mm

ENGINEERING MANUAL 25
 Dynamic Rotation - Complete dimensioning solution

Below sketch of the typical schemes can be done

with the 553 FlexTop belt.
In case of different movement
required, please provide information to
your sales representative and you will
receive required support.

For a faster rotation of the goods, the two parallel belts

can be activated while the goods is still running on the
553 FlexTop belt.
This will result to be faster than the static one, but the
rotation precision won’t be as high as the first solution,
for obvious reasons.
Complete dimensioning solution
Below the main functional scheme for a typical application of goods rotation.
Shown formulas help calculating main information to create a complete unit.
In black are indicated required input, in red are indicated output that can be calculated with the following formulas:
LI Ld1 , Ld2 LO Legend:

Lg Goods length
Sd1 Ld1 Directional belt length
Wd1
side A α Ld2 Directional belt length
Wg Goods width
Wb FlexTop belt width

side A
side B
D

Wg Sg Wd1 Directional belt width

Wb Wd2 Directional belt width
side B
Sb Sd1 Directional belt speed
Lg Wd2 Sd2 Directional belt speed
Sd2
Sb FlexTop belt speed

553 FlexTop belt Directional belts Good

!
Lg
Goods length corresponds to
the running side, not always
to the longer side of the goods!
contact with directional belts

Inputs: Formulas:
W
• Lg Goods length (mm) • FlexTop belt width (bigger than good swidth, multiple of 3” standard measure): Wb ≥ 76,2 g
to catalog width
• Wg Goods width (mm)
• C Capacity - n° of goods per minute (N°/min) • Goods pitch (if not provided as input, at least long as goods diagonal D): Pg ≥ √ Lg2 + Wg2
(or Sg Goods speed m/min)
• Pg Goods pitch (mm) • Directional belt widths: Wd1 and Wd2 < Wb
2
• α Rotation angle
• Directional belt lengths: Ld1 and Ld2 = 1,5 * D

• Goods speed (if not provided as input, can be calculated from capacity): Sg = Pg * C
Outputs: 1000

• Wb FlexTop belt width • FlexTop belt speed (considering all spheres running on a flat plate): Sb = 21 * Sg
• Wd1, Wd2 Directional belt width
Ld
• Ld1, Ld2 Directional belt length • Useful time (net available time for directioning): Tu =
1000 * Sg
• Sd1, Sd2 Directional belt speed
• Turning goods speed: Ω = Tαu
• Ss1, Ss2 Sphere belt speed
Pg
• Sb FlexTop belt speed • Speed to rotate goods: (S s1 - S s2 ) = Ω * 2

• Tu Useful time • Sphere belt speed: S s1 = 2 * S g + S d1 S s2 = 2 * S g + S d2

• Ω Turning goods speed
• Infeed length (mandatory): Li ≥ Lg
• Li Infeed length
• Lo Outfeed length • Outfeed length (optional): Lo ≥ Wg
• Ltot Total conveyor length • Total conveyor length: Ltot = Li + Lo + Ld

26 ENGINEERING MANUAL
Dynamic Rotation - Example

Complete dimensioning solution - EXAMPLE

Inputs:
• Lg Goods length (mm) = 380mm
!
• Wg Goods width (mm) = 420mm Don’t forget to check if the
• C Capacity - n° of goods per minute (N°/min) = 25pcs/min (or Sg Goods speed) goods weight and dimensions
are suitable: maximum weight
• Pg Goods pitch (mm) = n.a. 15N per sphere and minimum 6
spheres fully in contact.
• α Rotation angle = 90°

Outputs:
• Wb FlexTop belt width:

Wb ≥ Wg to catalog width 420

= 5,51 6 * 76,2 = 457,2mm (Belt width 18” – Art. Nr 5530270018A)
76,2 76,2

• Pg Goods pitch (mm):

Pg = √ Lg2 + Wg2 √ 380 + 420

2 2 = 566,4 600mm

The pitch between goods is very important to give enough time to a goods to realize the right movement !
Pay attention: if the pitch is not
Pg 600 correct, the goods may be touch
• Sg Goods speed: Sg = C 25 = 15 m/min
1000 * 1000 * each other and then comprosime
a controlled rotation.

1 1
• Sb FlexTop belt speed: Sb = * Sg * 15 = 7,5 m/min 2X
2 2

!
• Ld1, Ld2 Directional belt length: Ld1, Ld2 = 1,5 * D 1,5 * 600 = 900mm
If the spheres are touching a
static support (strips or plate)
their speed will result double than
the speed of the FlexTop belt.
Ld 900 That’s why the FlexTop belt
• Tu Useful time: Tu = 3,6 s
1000 * Sg 1000 * 15 = 0,06 min * 60 speed (Sb) results half of the
goods speed (Sg).

π
α 2
• Ω Turning goods speed: Ω= = 0,44 rad/s = 26 rad/min
Tu 3,6

• (Ss1 - Ss2) Required different speed to rotate goods:

900
Pg 2
(Ss1 - Ss2) = Ω * 0,44 * 1000 = 0,2 m/s = 12 m/min
2

From the relation of the speeds:

(Ss1 - Ss2) = 2 * Sg + Sd1 - (2 * Sg + Sd2) = Sd1 + Sd2 = 12 m/min
Ss1 = 20 m/min (decided value, in case the calculated speed results too high or too low, recalculate it)
Ss2 = Ss1 + 12 m/min = 20 + 12 = 32 m/min

• Sd1 Directional belt speed:

Ss1 = 2 * Sg + Sd1 Sd1 = Ss1 - 2 * Sg 20 - (2 * 7,5) = 5 m/min

• Sd2 Directional belt speed:

Ss2 = 2 * Sg - Sd2 Sd2 = Ss2 - 2 * Sg 32 - (2 * 7,5) = 17 m/min

• Li Infeed length: Li = Lg 380 mm

• Lo Outfeed length: Lo = Wg 420 mm

• Ltot Total conveyor: Ltot = Li + Lo + Ld 380 + 420 + 900 = 1.700 mm

ENGINEERING MANUAL 27
 A B B B C A

Sprockets Position

Standard Belt width

(in/mm)
Recommended n°
of sprockets

3 / 76.2 1
W (inch)
6 / 152.4 2
6” BOT TO M V IE W
9 / 228.6 3
Contact point
M=3” 12 / 304.5 4
15 / 381.0 5
18 / 457.2 6
21 / 533.4 7
24 / 609.6 8
27 / 685.8 9
30 / 762.0 10
33 / 838.2 11
36 / 914.4 12
39 / 990.6 13
42 / 1066.8 14
45 / 1143.0 15
48 / 1219.2 16
A: 0,99” (25,2 mm)
B: 3” (76,2 mm) 51 / 1295.4 17
A B B B C C: 2” (50,6 mm) 54 / 1371.6 18

HEAVY
DUTY
W (inch)

6”

M=3”

IMPORTANT
Add sprocket positions
every 76,2 mm according to
76,2 mm width increments of
the belt corresponding with
76,2 mm conveyor track pitch
system.

It’s NOT possible to place

the sprockets in this position.
A: 0,99” (25,2 mm)
If more sprockets are required
B: 3” (76,2 mm)
the Heavy duty position can be
A B B B C A C: 1” (25,4 mm) followed.

HEAVY DUTY position is ideal in case the load of the application is close to the belt limit or in case there is an high
number of starts/stops during production.

28 ENGINEERING MANUAL

W (inch)
Wear Strips and Machined Plates

Wear strips
Wearstrips are ideal to guide the 553 FlexTop belt as well as create a stable sliding support.
They can be installed in 2 different positions, for accumulation or driven. Below only an example of wearstrips
that can be used: for the complete product range, please refer to the Movex general catalogue.

Position scheme for accumulation Position scheme for driven

6 12

25,4 25,4 25,4 76,2

PART 103 PART 1000/1002 PART 1060

Delivery: Easy Standard

Z-clip profile without nose Fit on 2,5 to 3,5 mm

3
PART
Part Article-Nr. Colour Availability Supply

10
1.5
103 10301 black Stock item 60 m coils

103 103
103
103
10302
10303
10300B-30
green
white
BluLub
Stock item
Stock item
Stock item
60 m coils
60 m coils
30 m coils
21
13.5

Bar cap 1.5 mm Fit on 1.5 mm 6.35

PART
Part Article-Nr. L Colour Availability Supply 2
1000 100003-30 30 m white On request 30 m coils

1000

8.6
6.35
Bar cap 3 mm Fit on 3 mm 6.35

PART
Part Article-Nr. L Colour Availability Supply 3.3

1002 100203-30 30 m white On request 30 m coils

1002 6.35
8.6

U-profile On request available in white color

PART
Part Article-Nr. L Colour Availability Supply 72
5

1060 106001C 3m black Stock item 3 m bars

1060
10

1060 106001 6m black On request 6 m bars 55

1060 106002C 3m green Stock item 3 m bars
1060 106002 6m green On request 6 m bars

For the complete profile range, please see the Movex general catalogue.

Machined plates
Machined plastic plate can be used to support spheres. They can be machined with grooves (accumulation) or
flat (driven). In the both case we suggest to have a minimum thickness of 15mm to guarantee minimum required
flatness. Movex can machine these plates based on your inputs.

Position scheme for accumulation Position scheme for driven

Pay attention: different sliding material (directional belt and support plate) may have differences in friction, therefor
! spheres may run with different speeds. To keep the same speed, it is suggested to use the same material (same hardness).

ENGINEERING MANUAL 29
 Return rollers

553 FlexTop belt

Directional belt
or Rotating plate
Transfer module
with rollers
553 FlexTop sprockets
PART 368
PART 166 PART 369

C
A

Drive shaft
Return rollers with grooves
Return rollers with grooves and seals
Part Article ØE ØA Part Article ØE ØA
Return rollers with rubber
236 23601 50 25 237 23701 53 25
Part ØE
236 23602 50 30 237 23702 53 30
236 23603 60 25 220 47 237 23703 63 25
236 23604 60 30 203 57 237 23704 63 30
236 23605 70 25 204 67 237 23705 73 25
236 23606 70 30 237 23706 73 30
See Movex General Catalog to find the
ØA
article number that meets your needs. ØA

Ø50 - Ø60 - Ø70 Ø47 - Ø57 - Ø67 Ø53 - Ø63 - Ø73

25,4 ØE ØE 25,4 ØE

Return rollers fixation PART 215

See Movex General Catalog to find the
PART 215 article number that meets your needs.

1 3
2

Belt width + 2 mm

1 Fix the first split collar on the shaft. 2 Slide in the shaft required number of 3 Fix the second split collar at a distance
Return Rollers (e.g. for belt width 15”, 15 of “Belt width +2mm” (this will guarantee
rollers are required). enough play between rollers and belt
spheres).

For our 553 FlexTop Conveyor solution, contact your sales representative.

30 ENGINEERING MANUAL
Maintenance

Assembling/Disassembling
Below the main steps required to mount and dismount 553 FlexTop modular belt.

Sequence for disassembling the 553 belt. To disassemble it, follow the instructions in reverse order.

1 2 3

Insert a flat screw driver into the red clip Insert a pin punch and push to extract the Once the white rod is removed, the belt can
mounted at the sides of the belt, turn it white rod from the opposite side. be opened easily.
by 90° to leave it from the clip fixation and
remove it.

! Before proceeding to remove the rod, ensure that the belt ends cannot slip away due to its weight.

Cleaning PAT E N T E D
CLOSED GAP
To guarantee the belt functionality and then the rotational properties of
the sphere, clean condition must be respected.

If the belt is mounted on the conveyor system, the best

choice is to use compressed air or damp cloth, acting with a
soft brush on the spheres if required. Try to avoid pressure
water since it could compromise internal electronical parts.

In case the belt results still uncleaned, then we suggest to

dismount it, lay out on the floor and clean with water and
soap (also with high pressure jet, keeping at safety distance)
and let it completely dry (with the help of compressed air).
Patented closed gap helps reducing
maintenance frequency and increasing
In case of residual dirt still visible on the spheres, repeat the productivity.
operation with the help of a soft brush.

Pay attention: a non-dry belt housing will compromise the belt functionality and non-cleaned belt housing spheres will not
! guarantee correct performances of the required movement.

Minimize Downtime and increase Productivity thanks to the patented system.

ENGINEERING MANUAL 31