Motor Applications in Cross-Belt Sorters

1. Component Overview

Cross-belt sorters, as essential systems in modern logistics, include the following subsystems:

Main Track System: Provides the path for shuttles, coordinating multi-vehicle routing and ensuring smooth logistics flow via traction motors.

Shuttle and Cross-Belt Unit: Each shuttle has a lateral belt driven by compact motors, enabling fast and precise bi-directional parcel transfer.

Drive System: Includes servo traction motors, BLDC motors for belts, encoders, and reducers to ensure power and control accuracy.

Control System: PLC or embedded controllers handle routing logic, sort timing, and multi-shuttle coordination.

Power & Communication: Power is delivered via sliding contacts or inductive coupling; data via wireless or bus systems for central communication.

Frame & Sensor Modules: Structural elements, rollers, and item sensors maintain physical integrity and enable real-time parcel detection.

2. Working Principle

Cross-belt sorters operate through coordinated mechanical and control processes:

First, WMS or order systems assign tasks to the controller, which sends path commands to the shuttle. The traction motor moves the shuttle while carrying the parcel.

Upon reaching the correct chute, the cross-belt motor activates and delivers the parcel laterally to the chute. This requires ultra-fast motor response and precise control.

Meanwhile, real-time position and object data are fed back via the communication bus, and closed-loop logic adjusts motor behavior dynamically to ensure continuous accuracy.

These sorters are widely used in express delivery, warehousing, and e-commerce to enable high-speed, around-the-clock sorting.

3. Motor Roles

Motors in cross-belt sorters serve critical roles across the following functions:

Core Drive Power: Servo motors enable shuttle traction with high torque and speed stability for continuous sorting tasks.

High-Frequency Switching: Belt motors must start/stop and reverse direction within milliseconds, requiring low inertia and fast response.

Accurate Position Control: Encoders maintain exact position control for precise parcel placement at high speeds.

Low Noise, Long Life: BLDC or premium servo motors reduce wear and noise, ideal for unmanned operations.

System Integration: CANopen and EtherCAT support coordinated motion and real-time feedback among multiple carts.

Thermal & Energy Optimization: Efficient winding and cooling design ensures reliability under continuous high-load conditions.

4. Custom Motor Solutions

For the high-speed and high-precision demands of cross-belt systems, we provide tailored motor solutions:

GPG-BL42N BLDC motors are ideal for individual cross-belts with high RPM, low inertia, and magnetic encoders supporting 0.2° accuracy.

GPG-G60 servo motors with high-precision reducers offer consistent torque and feedback for shuttle traction across complex paths.

We support both direct-drive and reduction-integrated options, with communication protocols like CANopen or Modbus-RTU for multi-vehicle systems.

For reliable power, we offer low-EMI brush systems or inductive power transfer for continuous uptime in demanding logistics environments.

Customizations such as IP54/IP65 protection, wide temperature operation, and structural dimensions ensure long-term high-performance deployment.