Product Name: Heavy-Duty 2-Stop Automated Roller VRC
Product Model: Gradin 2SRV Series
Load Capacity: 800 – 8000kg (Customization Available)
An automated roller VRC acts as a continuous vertical bridge, allowing multi-ton payloads to transition seamlessly between two conveyor elevations without requiring manual forklift intervention. Gradin engineers these heavy-duty lifts to autonomously receive, elevate, and discharge palletized materials or heavy manufacturing fixtures. By integrating onboard powered roller decks with closed-loop PLC logic and photo-eye sensors, the carriage executes precise electronic handshakes with your adjacent horizontal conveyors. Every roller pitch, drive torque, and structural mast is custom-sized to your exact payload footprint, ensuring zero-impact load transitions and sustaining unmanned, high-volume production cycles
| Technical Category | Key Parameters | Referência padrão | Gradin Bespoke Options (ETO) |
| I. Core Performance | Rated Payload Capacity | 2.000 kg (2 toneladas) | Scalable up to 150,000kg (150T+) |
| Raising/Lowering Speed | 0.15 m/s | Ultra-High Speed up to 1.2 m/s+ | |
| Precisão de posicionamento | ± 10 mm | Millimeter-Level Calibration (± 1 mm) | |
| Noise Emission Level | < 75 dB | Ultra-Quiet Operation (< 60 dB) | |
| II. Structural & Material | Drive Medium | Standard Roller Chain | Synchronized Servo-Mechanical / Rigid Drive |
| Mast Engineering | Double Rail Steel | FEA-Optimized Quad-Mast Alloy Steel | |
| Acabamento da superfície | Industrial Powder Coat | C5-M Marine / Stainless Steel / Anti-Static | |
| Conveyor Interface | Standard Gravity Roller | Motorized Roller (MDR) / Heavy Chain Drive | |
| III. Control & Intelligence | Control System (PLC) | Basic PLC | Siemens S7-1500 / Allen Bradley / 5G |
| Protocolo de comunicação | Basic Wi-Fi | Profinet / EtherCAT / TCP-IP Integration | |
| System Connectivity | Standalone | Full WMS / MES / Industry 4.0 Integration | |
| Feedback Mechanism | Limit Switches | Absolute Encoders / Laser Rangefinders | |
| IV. Environment & Safety | Operating Temperature | -10°C to +40°C | Extreme Cold (-30°C) / ATEX / Cleanroom |
| Safety Gate Logic | Manual Interlock | Fully Automated High-Speed Power Gates | |
| Emergency Measures | Standard Limits | Multi-Layer Protection / Brake Motors / Anti-Fall | |
| Compliance Standard | Local Standards | Full OSHA / ASME / CE / AS3000 Compliance |
FEA-Validated Structural Integrity and Dynamic Load Absorption
Transferring a rolling load onto a vertical reciprocating conveyor introduces significant lateral and eccentric forces. Every Gradin Automated Roller VRC System undergoes rigorous Análise de Elementos Finitos (FEA) to ensure the structure survives the kinetic shock of high-speed pallet transfers and rapid acceleration.
Moment-Resistant Chassis: We utilize high-tensile box-section steel for the carriage, ensuring the motorized roller bed remains perfectly level (zero-tilt) as heavy loads cross the threshold.
Vibration-Dampening Masts: Optimized mast geometry absorbs the harmonic resonance generated by integrated conveyor motors, preserving the precision of the lift’s vertical alignment.
Heavy-Duty Foundation Logic: Our structural design neutralizes the torque generated by high-inertia roller starts, preventing long-term fatigue in the facility’s anchor points and floor slabs.
Integrated Motorized Roller Decks and Precision Handshake
The VRC is not a standalone machine; it is a synchronized node in your automated material handling network. Gradin’s Bespoke Interface Tooling ensures the carriage functions as a seamless extension of your horizontal conveyor flow.
Active Conveyor Handshaking: Utilizing Siemens S7-1500 PLC logic, the VRC communicates with infeed/outfeed conveyors to anticipate arrival, pre-position the carriage, and match roller speeds for zero-impact transfers.
Synchronized Millimeter Leveling: Absolute encoders and laser rangefinders ensure a ±1mm flush floor transition, preventing pallet jams or damage to sensitive cargo during high-speed sortation cycles.
Bespoke Roller Engineering: Rollers are customized for diameter, pitch, and coating (e.g., polyurethane for noise/anti-slip) to match your specific palletized units, from lightweight e-commerce totes to 150T steel blanks.
Industry 4.0 Connectivity and Digital Twin Readiness
Modern automated hubs require real-time data visibility. Every Gradin VRC features an open-architecture control system designed for high-stakes industrial integration and predictive analytics.
Real-Time Data Handshake: Native support for Profinet and EtherCAT allows the VRC to report real-time status on drive torque, vertical coordinates, and roller motor health directly to your MES.
Autonomous Traffic Control: The system manages sequencing autonomously, pre-staging loads and optimizing “Z” or “C” configuration flows to maximize vertical throughput per hour.
Predictive Maintenance Monitoring: Integrated sensors track cycle health and motor temperature, alerting maintenance teams before a fault occurs to guarantee 99.9% uptime in 24/7 high-stakes facilities.
[E-commerce & Logistics] – High-Velocity Multi-Level Sortation
The Challenge: High-frequency sortation hubs need to move 300+ totes per hour vertically between automated mezzanine levels without manual intervention.
Gradin Solution: An ultra-quiet, high-speed VRC with MDR (Motorized Driven Roller) technology. The system operates below 60 dB and executes a sub-second handshake with the sortation system, ensuring continuous vertical flow.
[Automotive Manufacturing] – Heavy Palletized Component Transfer
The Challenge: Moving 5T+ engine blocks or chassis components from ground-level assembly to second-story robotic cells with absolute positional accuracy.
Gradin Solution: A heavy-duty quad-mast VRC with an integrated high-torque motorized chain-conveyor deck. The FEA-validated structural frame maintains ±1mm leveling, allowing robotic arms to pick components directly from the VRC platform.
[Pharmaceuticals & Food] – Oil-Free Cleanroom Vertical Transit
The Challenge: Transporting sensitive goods in an environment where hydraulic oil or metal shavings from chain-stretch would result in total batch contamination.
Gradin Solution: A bespoke Belt-Driven Automated Roller VRC with lubrication-free polyurethane rollers and stainless-steel cladding. The system functions as a cleanroom-compliant vertical airlock.
Q1: How does the system handle high-tonnage point loads during roller transfer?
A: Every Gradin system uses FEA-validated anti-deflection structural decks. We reinforce the carriage with internal cross-members that distribute the concentrated weight of heavy rollers directly into the quad-mast frame, ensuring zero platform tilt during high-inertia movement.
Q2: Can the Automated Roller VRC be integrated with existing AGVs or AMRs?
A: Absolutely. Our Siemens S7-1500 control architecture supports native handshake protocols with AGV traffic controllers. The VRC platform can include specialized docking sensors and “Flush-Leveling” logic to ensure a seamless drive-on/drive-off transition for autonomous robots.
Q3: What maintenance is required for high-cycle automated operations?
A: By utilizing Steel-Core Polyurethane Belts or precision-sealed mechanical drives instead of standard chains, we reduce maintenance intervals by up to 60%. Integrated sensors provide predictive maintenance data, alerting operators to belt wear or motor torque anomalies before they cause downtime.
Redundant Safety Architecture and Active Monitoring Logic
Safety in high-tonnage, high-speed automated vertical logistics is our most critical engineering priority.
Multi-Layer Drive Redundancy: We utilize mechanically synchronized, redundant lifting lines (Belts or Rigid Chains) engineered with a 5:1 safety factor.
Active Obstacle & Jam Detection: Integrated safety light curtains and conveyor torque sensors execute an immediate controlled stop if a pallet jam or unauthorized object is detected.
Fail-Safe Mechanical Arrestors: Beyond electrical brakes, Gradin deploys robust mechanical anti-fall cams that engage the guide rails instantly if an overspeed condition is detected (ISO 13849-1 / CE / OSHA).
Para essa série para serviços pesados, podemos projetar capacidades de carga de até [300] toneladas, com dimensões de plataforma e alturas de elevação personalizadas de acordo com seu envelope operacional. Os requisitos que excederem nossa matriz de engenharia padrão serão submetidos a uma análise de elementos finitos (FEA) por nossa equipe de engenharia para garantir a viabilidade estrutural antes de propor uma solução.
Para iniciar a proposta de engenharia, forneça os seguintes dados de linha de base:
Capacidade de carga nominal
Altura máxima de elevação e altura fechada
Dimensões da plataforma (C x L)
Ciclo de trabalho (por exemplo, ciclos operacionais por hora/dia)
Condições ambientais (por exemplo, interno/externo, lavagem, à prova de explosão)
Restrições de profundidade do poço ou de espaço aéreo
Sim. Os sistemas de controle podem ser equipados com protocolos de comunicação padrão (por exemplo, Profinet, Modbus, Ethernet/IP) utilizando [Siemens / Allen-Bradley / Omron]. PLCs. Isso garante uma sincronização perfeita do sinal de E/S com transportadores upstream/downstream, unidades AGV/AMR e sua sala de controle central.
Toda unidade personalizada passa por um teste obrigatório de aceitação de fábrica (FAT) antes do envio. Isso inclui testes operacionais contínuos com carga nominal de 100%, testes de sobrecarga estática com [120% / 125%] e o acionamento físico de todas as travas de segurança mecânicas antiqueda e hidráulicas. A documentação FAT e a prova de vídeo estão incluídas em seu pacote de engenharia.
Após a aprovação final dos desenhos de arranjo geral (GA), o prazo de fabricação normalmente é de 4 a 8 semanas. Os componentes estruturais de grandes dimensões são projetados com um design modular para caber em contêineres de transporte padrão (20FT/40HQ). A montagem no local utiliza conexões de flange aparafusadas pré-projetadas e plugues de aviação para serviços pesados, eliminando rigorosamente a necessidade de soldagem em campo.
Fornecemos um padrão [12/24]-A garantia de um mês cobre a estrutura e os principais componentes hidráulicos/elétricos. Para minimizar o tempo de inatividade operacional, um conjunto abrangente de consumíveis padrão (por exemplo, kits de vedação de cilindros, interruptores de deslocamento, relés) é enviado junto com o equipamento. Durante o período de garantia, as peças de reposição para falhas não induzidas por humanos são enviadas por frete aéreo prioritário (DHL/FedEx) em 48 horas.
Além da garantia, garantimos suporte de engenharia vitalício. Os desenhos CAD, os esquemas elétricos e a lista de materiais (BOM) do seu equipamento personalizado são arquivados permanentemente em nosso sistema. Isso garante que você receba solução remota ininterrupta de problemas, orientação de manutenção e correspondência exata de peças de reposição durante todo o ciclo de vida do equipamento.
Seguro e confidencial: Sua proposta técnica e seu projeto 3D estarão prontos em 2 horas.
A Gradin Machinery é um fabricante líder especializado em plataformas de trabalho aéreo e soluções de elevação hidráulica. Com certificações ISO e CE, fornecemos equipamentos seguros, confiáveis e personalizados para as necessidades industriais globais
Direitos autorais ©2026 GRADIN Maquinário. Todos os direitos reservados
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