How To Prevent Workpiece In Circular Step Conveyor From Shifting During Turning or Stepping?

What is Circular Step Conveyor ?

How To Prevent Workpiece In Circular Step Conveyor From Shifting During Turning or Stepping?

Here in this blog, we are goint to share with your an inquiry story with a client from USA: 

First, let’s discuss what is Circular Step Conveyor? Circular Step Conveyor is an automated manufacturing system where parts or products are mounted on a circular platform. The platform rotates in a precise, stop-start motion to move items between multiple workstations arranged around its circumference. At each “step,” the table pauses, allowing robots or operators to perform specific tasks like assembly, testing, or packaging simultaneously on different parts. This intermittent motion ensures high accuracy and efficiency, making it ideal for high-speed, repetitive production cycles.

It is an interesting stories of exchanging emails discussing technical details, order confirmation, and payment about this set of Chain Circular Conveyor.

On 15th,Dec 2025, we got an inquiry from US as follows:

Hello, my name is XX of XX Innovative, a sustainable construction materials tech developer and manufacturer in the US. We are hoping to make circular step conveyor belts and wanted to see if our design requirements were valid and within a reasonable price range.
We are looking for a 25~35m circular step conveyor with around 7 inch wide steps that move 7 inch per step, and 6~8 seconds per step. Please let us know if this would be possible or if we can have an online meeting to discuss details. Thank you and I look forward to your response!

Thank you for your message.
Can you fill this form with basic data so that our engineering department can study and design accordingly?

Client: On 3rd Jan 2026,

Hello Jack,
Thank you very much for your email and the technical data form. We are completing some calculations for our processing procedures and filling out the form and will ask any questions that come up!

TallMan Robotics: On 24th Jan 2026

Thank you very much for reaching out! We have finalized our design and will be filling out the forms you sent in the next 2~3 days and send it over so we can begin discussions. Have a good day!

Client: On 26th,Jan 2026

Here is our filled technical data collection form with some questions. Could we schedule a meeting to discuss details and specifics?

Client’s reply about this Chain Circular Conveyor: On 27th,Jan 2026.

Here is my response with the proper answers and a question.
I want to compare quotes for elliptical and horizontal rectangular (technical data in the attached file).
Also, for the positioning accuracy, is the 0.05mm for belt drive & 0.03mm for chain drive the absolute maximum error? Depending on whether it is a belt drive or chain drive, can the error get worse over time?

TallMan Robotics:On 28th,Jan2026 for this Chain Circular Conveyor

We studied the basic data, and Engineering department has feedback, and gave a rough drawing as follows.
圆弧直径，我们的标准是612，他客户写的是636。
300的中心距移动一个工位的时间1.2秒，客户需求是0.2秒。
高速，有轻微灰尘的结构，建议用链条。
建议用椭圆的方案， 矩形的成本高。
1. The arc diameter, our standard is 612, while the customer specified 636.then arc dia has to be 612.
2. The time to move a workstation at a center distance of 300 is 1.2 seconds, while the customer requirement is 0.2 seconds. High-speed, slightly dusty structure,
Thus it is recommended to use a chain.
3. It is recommended to use the oval design, as the rectangular one has higher costs.

Client: On 29th, Jan 2026

Thank you very much for the information.

1. We are fine with Arc diameter being 612 mm, as long as distance between the 10 steps can be 300mm.
2. We are fine with using a chain. Will using chain allow 0.2 seconds to move workstation at a center distance of 300mm or will the time still be 1.2 seconds? 1.2 seconds to move is fine, I just wanted to make sure. Our priority is position accuracy of workstation and costs, so it would be great if you could recommend based on that.
3.We are fine with using an oval design.

The STP 3D design looks good to me, Can you share a quote including shipping and import duty fees?

I also had two more questions

1. Are we able to control how long (0~60 seconds) the workstation remains in each position?
2. Will the positioning accuracy error compile over time or remain within 0.03mm for chain drive?

Client: On 29th,Jan 2026

Thank you very much for the response. It is pretty clear now.

As for your response

‘But usually, we only provide circular system, servomotors, etc, would you need us to provide controller, HMI ? ‘

We can assemble the circular system and servomotors as long as there is a good instruction manual. Will the system come with instructions to assemble the system? If not our engineers can probably figure out something too.

It would be great if you can provide a controller too and include that in the quote.

However, would the controller be configurable in english?

If not, can you tell us what kind of controller HMI you recommend?

TallMan Robotics: On 29th,Jan 2026.

1.I checked just now, The circular system is not long, we’ll pack it in a strong plywood box for protection, Then when you receive the goods, you can just connect motor and gear reducer to it, that’s simple.
yes, we have manual instruction for maintainence, there is no worry.
2.Yes, this conroller and HMI is in multiple languages including English language, About controller, and HMI, please check this page, or you can check data sheet as attached too.3. Then, i will send quotation and prepare PI for this order.

TallMan Robotics for this Chain Circular Conveyor: On 30th,Jan 2026

Now, engineering department has found a problem, for 10 workstation to position, there are 4pcs (in red X) ,which can not be positioned, as these 4pcs are located at the arc area.
We assume 6 positions are ok too.
Besides, the centre is 427mm with our standard arc diameter by 612 mm, IS this ok to your application? Also, attached please find PI and updated 3D too.

Client: 2nd,Feb 2026

Thank you very much for the confirmation. If we place the order and receive the package, will we have to assemble the parts with our engineers? Will there be an instruction manual or video we can follow?
At the same day, we replied:
We checked, this circular system is not long, generally, we pack in one plywood box as follows, You can just connnect with gear reducer, servo motor, etc. The circular system is in a complete one packing, not in components.

Client: 6th,Feb 2026

Our engineering team seems happy with the current design and was asking if they can get the CAD file for the image in STEP file format? Our engineering team wants to prepare our manufacturing equipment to integrate with your circular step conveyor based on the designs.

Also, for the workstation size, will the workstation size be 8in x 8in or will the dimensions shown in the website (300mm) be the size and we can custom attach our platform to it? Our engineering team is asking so they can prepare those parts & designs too.

Thank you and I look forward to your response!

At the same day, we replied:
1. About CAD file.
yes, please check attachment with updated 3D, 2D,and CAD, you can delete the previous drawings, this one is the final one.
2. About workstation size, in our drawing, it is a standard slide(L108*W85*H18), usually, the end customers can fix their working platform to the slides.
Of course, you can send your 200*200mm drawing(with your designed holes, for example) to us, we can make for you too with our CNC machine.

Client: 14th,Feb 2026

Can you include this CNC platform design (attached design) for all 6 workstations? If you can share the final quote based on these platform designs, I will proceed with the order as soon as possible. Thank you and I look forward to completing the ordering process!

TallMan Robotics: 24th Feb 2026

Some staff are coming back to work.
1. Attached please find updated 3D and CAD, which imports your 3D of working station plates in the Chain Circular Conveyor?
2. Stainless steel 304 working plates are available,please check updated PI.

Client: 25th Feb, 2026

Oh just one question. Can we control the time between placement rod (highlighted in screenshot) moving out for the circular step conveyor to move to the next step?

We want to know if we can control the time after the rod (highlighted in screenshot) pulls out and before circular step conveyor starts moving to next step.
At the same day, we replied
Yes, the time/speed(speed to move a distance between the two adjacent centres between carriages) to move a station is controlled by controller via touch screen HMI.
There is no worry, this speed is not fixed, you can adjust it.

Client for this type of Chain Circular Conveyor: 26th Feb, 2026

We are having some issues with our bank (please check attached pdf) for the international wire transfer. They have declined the transaction for some reason. I have called them and it seems I cannot get it through at the moment, and may need to call the bank during office hours tomorrow (US est) to get some security check approved. If you know of any past experiences like this or find any mistake I made in the attached pdf, could you let me know?

In the meantime, could you share a photo of the device or similar device at your factory? I may be prompted to share this information for security check for our bank.

Thank you and I look forward to getting the payment completed promptly so we can get the product shipped out as soon as possible.
Hello Jack,

Here is the signed version. Just wanted to let you know we actually want the steps seconds to be significantly longer at around 45-60s. I do believe you said we can control that to be any length of time we want. Could you just give instructions on how we can control the step time so we can share that with our engineering team?</p>

TallMan Robotics for Chain Circular Conveyor: 28th, Feb 2026

Thank you for your signed file,
1.2S is the mas speed, so long as it is lower than this speed, there is no problem.
You can set speed data in HMI, please check attached files of controller and HMI maual instruction for your reference.

Client: 1st, Mar 2026

Hello Jack,Thank you very much for this information. I look forward to getting the order finalized. Is there anything else to di on our end?
At the same day, we replied
I suppose there is no questions now, PMC has arrange this order for production in queue.
I will take photos, videos of test of the finished machine to you once all is ready.

Client:

Hello Jack,Yes, we are happy with this and look forward to the finished product,
And one more question: An important concern for our users is how to prevent the workpiece in workstation from shifting during turning or stepping?

We replied as follows for this set of Chain Circular Conveyor:

The key is to ensure that the slider remains stable, rigid, and has no sudden gaps during the turning process, thereby avoiding displacement of the workpiece due to vibration or displacement Based on our years of production and debugging experience, we share the following technical measures with numerous users:

Core: Anti design for such circular step conveyor

Symmetric layout of rollers,Transition section precision grinding treatment,Pre tightening force control,Optional steering structure

Auxiliary measures: Process and system

Drive system adaptation: using synchronous belt+servo motor or gear ring gear meshing drive to ensure smooth power transmission during turning, avoiding slipping or instantaneous stall
Workpiece fixing method: Install fixtures, zero point quick change interfaces, or pneumatic/mechanical locking devices on the slider to rigidly position the workpiece, especially in high-speed turning sections to strengthen fixation
Lubrication and maintenance: Regularly lubricate the contact surface between the roller and the guide rail to reduce friction and wear, and maintain smooth operation; Sealed design is required in dust-free or high-precision environments

Matching use of controller and HMI:

Our company recommends using TRIO’s motion controller and TRIO touch screen HMI device in combination.TRIO motion controller is a device designed specifically for industrial automation. The advantages of TRIO touch screen HMI device: Seamless integration,Real time monitoring and operation.Please click on the link page to view the specific parameter selection models for the controller and HMI. 

Overall, structural design is fundamental, while drive control and workpiece clamping are guarantees. It is recommended to prioritize mature circular guide rail systems (such as TallMan Robotics, Rollon, etc.) with the aforementioned geometric optimization and transition processing, and match corresponding drive and positioning modules according to actual load and rhythm requirements.

In next post, we are going to share photos, test videos, packing details of this finished Circular Step Conveyor with your! You are welcome back!

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