Plug. Play. Convey.
Modern conveyor systems in intralogistics are increasingly modular, data-driven and scalable. The right cabling architecture - whether centralised or decentralised - determines the installation effort, flexibility and long-term efficiency. LAPP offers end-to-end solutions for power and data distribution in modular conveyor systems - from classic control cabinet concepts to decentralised architecture along the conveyor line.
Whether centralised or decentralised - connectivity determines performance. Discover how LAPP enables scalable, efficient and future-proof conveyor systems.
Intralogistics in transition: Why cabling is becoming a key technology
Conveyor technology is the backbone of modern intralogistics systems. Whether a distribution center, automated warehouse or airport - modular conveyor systems must be reliable, flexible and economical.
With increasing modularisation, the requirements for intralogistics cabling are also changing:
- Higher cycle times
- Flexible layout customisation
- Faster project runtimes
- 24/7 availability
- Increasing data communication
LAPP connects everything that moves your conveyor technology - from energy to sensors.
Central cabling in conveyor systems
With centralised cabling, the control system, frequency converter and power distribution are mainly located in the control cabinet or directly on the conveyor system. Motors, sensors and actuators are supplied from there.
Typical features of centralised architectures
- Centralised energy supply
- Clear system structure
- Proven architecture for standardised systems
Limits for modular conveyor systems
With increasing system complexity:
- Long cable runs
- High installation costs
- Limited flexibility for enlargers
Centralised cabling remains sensible for clearly structured, less dynamic system concepts.
Decentralised cabling: The architecture for modular conveyor technology
The decentralised conveyor system architecture integrates power distribution, drive systems and communication directly along the conveyor line. Components such as I/O modules or frequency converters are located close to the process.
This structure is particularly suitable for modular conveyor systems with spatially distributed axes and flexible layouts.
Advantages of decentralised cabling
- Reduced cable lengths
- Faster installation thanks to plug-and-play
- Improved EMC due to short motor cables
- High scalability
- Clear zone structure along the line
Decentralised concepts create the basis for economically scalable intralogistics systems.
The future needs flexibility: smart concepts for decentralised cabling.
Line topology
With the line topology, energy and communication are passed from module to module. Each conveyor segment is part of a continuous structure, without a separate return to a central control cabinet. This architecture reduces the number of parallel wiring harnesses and minimises the interfaces between the energy and control levels. The line topology is particularly economical for modular conveyor systems with high change dynamics.
- Reduced installation complexity: The sequential connection of the modules eliminates the need for complex star cabling and centralised collection points.
- Faster commissioning: Pre-assembled connections enable a clear structure and shorten installation times.
- High scalability: New conveyor modules can be integrated into existing lines without having to fundamentally adapt the overall architecture.
- Optimized use of materials and space: Fewer cable bundles and reduced cable routes simplify system planning.
Ring topology
The ring topology enables segmented energy and signal distribution along the conveyor line. Modules are connected via defined transfer points, creating a clean separation of individual conveyor sections. In contrast to the pure linear structure, the ring architecture allows a clearer segmentation of energy paths and maintenance zones. The ring topology is particularly suitable for systems with high maintenance frequency and clearly demarcated conveying zones.
Benefits
- Targeted maintenance of individual segments: Sections can be inspected or maintained in isolation without affecting the entire conveyor line.
- Reduced failure propagation: Failures in one module do not have an immediate effect on the entire structure.
- Improved system transparency: Clear transfer points facilitate troubleshooting and diagnostics.
- Structured energy distribution: The ring structure supports a clean load distribution along the system.
Drive motor rollers (MDR)
Motorised drive rollers (MDR) integrate the electric drive directly into the conveyor roller. This eliminates the need for centralised drive trains, gearboxes or mechanical couplings. Each conveying zone is electrically controlled separately. This reduces mechanical complexity and increases control precision.
- Zone-by-zone energy efficiency: Only active conveyor segments are operated - this reduces energy consumption and thermal load.
- Reduced mechanical wear parts: Fewer external drive components mean less maintenance.
- High modularity: Conveyor segments can be integrated or replaced independently.
- Improved EMC conditions: Short motor cables and decentralised drivers reduce electromagnetic interference.
Industrial data communication
Modern conveyor systems are highly networked. Sensors, drives, safety components and control systems communicate continuously via industrial networks. An unstable data infrastructure leads directly to downtime or process interruptions. A well thought-out industrial network infrastructure increases system availability, improves diagnostic options and supports predictive maintenance concepts.
- High interference immunity (EMC): Motors, frequency converters and power cables generate electromagnetic interference fields. Data cables must be shielded accordingly.
- Mechanical load capacity: Movement, vibration and industrial ambient conditions require robust cable constructions.
- Future-proof data rates: Modular systems must transmit increasing data volumes reliably.
- Standard compatibility: Support for industrial Ethernet and fieldbus protocols such as PROFINET.
Connection technology for scalable conveyor systems
LAPP supports manufacturers and operators in the implementation of centralised and decentralised cabling concepts in intralogistics.
Our portfolio includes:
- Power and control cables
- Industrial data cables
- Industrial connectors
- Pre-assembled plug-and-play systems
- Cable protection and marking systems
Integrated system solutions reduce installation times, increase system availability and enable long-term scalability.
Things to know about the cabling architecture in conveyor systems
The difference between centralised and decentralised cabling lies in the structure of the power and data distribution within the conveyor system.
With centralised cabling, the control system, frequency converter and power distribution are mainly located in the control cabinet. Motors, sensors and actuators are supplied from there via longer cable routes.
With decentralised cabling, power distributors, I/O modules and drive components are integrated directly along the conveyor line. Energy and data distribution is segmented into individual modules or zones.
Decentralised architectures are particularly suitable for modular conveyor systems with high scalability and flexible layout adaptations.
Decentralized cabling is particularly useful when conveyor systems have a modular design and are regularly expanded or adapted.
Typical areas of application are
- General cargo and parcel conveyor technology
- Distribution centers
- Automated warehouse
- Systems with zone-based control
Decentralized cabling reduces cable lengths, simplifies installation and enables clear segmentation of the system. This allows enlargers to be implemented more efficiently and maintenance work to be carried out in a targeted manner.
The line topology is a cabling structure in which conveyor modules are connected from unit to unit. Energy and data will be continued along the funding line.
In contrast to star-shaped structures, there is no central main line. Instead, a modular chain structure is created.
The line topology is particularly suitable for:
- MDR-based conveyor modules
- Zone controls
- Expandable system layouts
It reduces the installation effort and supports a clear segment structure within the conveyor system.
The ring topology enables a structured distribution of energy and signals with defined transfer points between individual conveyor modules.
It is often used when:
- Modules should be interchangeable
- Ease of maintenance takes center stage
- the cabling complexity is to be reduced
Thanks to the clear separation of modules, individual segments can be serviced or replaced without affecting the entire system.
Motor Driven Rollers (MDR), also known as drive motor rollers, are conveyor rollers with an integrated electric motor. The drive is located directly in the roller, eliminating the need for external gears or central drive units.
MDR systems:
- Zone-based control
- Energy-efficient operation
- Reduced mechanical complexity
- Modular enlarger
In modular conveyor systems, MDR systems are often combined with decentralised cabling, as each zone can be supplied and controlled separately.
The cabling of MDR-based conveyor systems must fulfill several technical requirements:
- Compact design with limited installation space
- EMC-stable motor cables
- Segmented power supply
- Robust plug connections
- Secure data communication for zone-based control
Short, shielded motor cables improve electromagnetic compatibility and increase the operational safety of the system.
Modern conveyor systems are data-driven. Sensors, drives and controllers communicate continuously via industrial networks.
Industrial data communication must:
- Be real-time capable
- EMC-stable operation
- withstand mechanical loads
- be compatible with common standards such as PROFINET
A robust Ethernet or Fieldbus infrastructure is crucial for system availability and process reliability in intralogistics systems.
The choice between centralised and decentralised cabling depends on several factors:
- Degree of modularisation of the system
- Planned enlargers
- Maintenance strategy
- EMC requirements
- Installation time
- Energy requirement of the drives
A holistic view of energy and data distribution is crucial for the long-term efficiency and scalability of a conveyor system.