A rugged roller-chain conveyor (slat/strap or twin-strand) with an electronic overload sensor to protect the drive and avoid jams. The system monitors motor current/torque and shaft speed, auto-stops (or short reverse-jogs) on blockage, and logs faults. Great for teaching power transmission, sensing, and safety interlocks.

Parts Used:

1. Frame & Bed – Welded/channel frame with UHMW wear strips and side guards.
2. Chains & Sprockets – Duplex #40–#80 (08B–16B) chain; drive sprocket + idler/take-up with tensioning.
3. Drive Unit – AC gearmotor + VFD (or 24 V DC gearmotor), torque limiter/shear pin (mechanical).
4. Guides & Supports – Return rollers, chain guides, product stops, drip tray.
5. Sensors (Overload & Health)
6. Motor current sensor (Hall/CT) → torque proxy.
7. Shaft encoder on drive to verify motion.
8. Photoeye at choke points for jam detect.
9. (Optional) Load cell at take-up (chain tension), motor temp (NTC).
10. Controls – PLC/Arduino/ESP32, relay/MOSFET outputs, E-stop, start/stop, fault reset, speed knob/HMI.
11. Electrical & Pneumatics (opt.) – 230 VAC/24 VDC supply, MCB/fuse, VFD, FRL if using air-lift stops.