Glossary · Packaging and intralogistics
Merge conveyor
Also known as: Merge, Merge unit
German: Zusammenführförderer
In intralogistics, a merge conveyor is a conveyor section that combines items from two or more incoming lines onto one outgoing line, controlling gaps and priorities so items don't collide.
- Intralogistics
In one sentence
A merge conveyor combines items from several incoming lines onto one line and controls gaps and priorities to prevent collisions.
Example
Before the sorter induction, a merge conveyor combines cartons from four picking zones and creates the gaps the sorter needs.
How it applies
- Engineering: Merges use sensors, accumulation zones and speed changes to insert items into gaps on the main line. Merge logic can be first-come, priority-based or round-robin.
- Operation: Merges are frequent Bottlenecks: when the combined incoming flow exceeds the outgoing capacity, lines back up. Line balancing and merge priorities determine overall Throughput.
- Commissioning: Merge rates are tuned during commissioning with real products; parameters such as gap length and release times should be recorded as part of the configuration.
- Documentation: Document merge priorities and parameters as configuration data, and explain on the HMI and in the manual how operators can change priorities and what effect it has upstream.
Merge conveyor vs. diverter
A merge combines flows; a Diverter splits them. Both need precise item tracking in the Conveyor control.