a conveyor system is a common piece of mechanical handling equipment that moves materials from one...

8/3/2019 A Conveyor System is a Common Piece of Mechanical Handling Equipment That Moves Materials From One Locatio

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A conveyor system is a common piece of mechanical handling equipment that moves materials

from one location to another. Conveyors are especially useful in applications involving thetransportation of heavy or bulky materials. Conveyor systems allow quick and efficient

transportation for a wide variety of materials, which make them very popular in the material

handlingandpackagingindustries[1]

. Many kinds of conveying systems are available, and are

used according to the various needs of different industries. There are chain conveyors (floor andoverhead)[2]as well. Chain conveyors consist of enclosed tracks, I-Beam, towline, power & free,

and hand pushed trolleys.[3]

Contents

[hide]

1 Industries that use conveyor systems 2 Care and maintenance of conveyor systems 3 Types of conveyor systems

o 3.1 Pneumatic conveyor systemso 3.2 Vibrating conveyor systemso 3.3 Flexible conveyor systemso 3.4 Vertical conveyor systems and spiral conveyorso 3.5 Heavy duty roller conveyors

4 See also 5 References

[edit] Industries that use conveyor systems

A lineshaft roller conveyor conveys boxed produce at a distribution center
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AConveyor beltconveys papers at a newspaper print plant

Roller conveyorfor carton transport in the apparel industry

Conveyor systems are used widespread across a range of industries due to the numerous benefitsthey provide.

Conveyors are able to safely transport materials from one level to another, which whendone by human labor would be strenuous and expensive.

They can be installed almost anywhere, and are much safer than using a forklift or othermachine to move materials.

They can move loads of all shapes, sizes and weights. Also, many have advanced safetyfeatures that help prevent accidents.

There are a variety of options available for running conveying systems, including thehydraulic, mechanical and fully automated systems, which are equipped to fit individual

needs.

Conveyor systems are commonly used in many industries, including theautomotive,agricultural,

computer, electronic,food processing,aerospace,pharmaceutical,chemical,bottlingandcanning, print finishing andpackaging. Although a wide variety of materials can be conveyed,

some of the most common include food items such as beans and nuts, bottles and cans,automotive components, scrap metal, pills and powders, wood and furniture and grain and

animal feed. Many factors are important in the accurate selection of a conveyor system. It isimportant to know how the conveyor system will be used beforehand. Some individual areas that

are helpful to consider are the required conveyor operations, such as transportation, accumulation

and sorting, the material sizes, weights and shapes and where the loading and pickup points needto be.
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[edit] Care and maintenance of conveyor systems

A conveyor system is often the lifeline to a companys ability to effectively move its product in atimely fashion. The steps that a company can take to ensure that it performs at peak capacity,

include regular inspections, close monitoring of motors and reducers, keeping key parts in stock,

and proper training of personnel.

Increasing the service life of your conveyor system involves: choosing the right conveyor type,the right system design and paying attention to regular maintenance practices.

A conveyor system that is designed properly will last a long time with proper maintenance. Hereare six of the biggest problems to watch for in overhead type conveyor systems including I-beam

monorails, enclosed track conveyors and power and free conveyors.

Poor take-up adjustment: This is a simple adjustment on most systems yet it is oftenoverlooked. The chain take-up device ensures that the chain is pulled tight as it leaves the drive

unit. As wear occurs and the chain lengthens, the take-up extends under the force of its springs.As they extend, the spring force becomes less and the take-up has less effect. Simply compressthe take-up springs and your problem goes away. Failure to do this can result in chain surging,

jamming, and extreme wear on the track and chain. Take-up adjustment is also important for any

conveyor using belts as a means to power rollers, or belts themselves being the mover. Withpoor-take up on belt-driven rollers, the belt may twist into the drive unit and cause damage, or at

the least a noticeable decrease or complete loss of performance may occur. In the case of belt

conveyors, a poor take-up may cause drive unit damage or may let the belt slip off of the side of

the chassis.

Lack of lubrication: Chain bearings require lubrication in order to reduce friction. The chain

pull that the drive experiences can double if the bearings are not lubricated. This can cause thesystem to overload by either its mechanical or electrical overload protection. On conveyors that

go through hot ovens, lubricators can be left on constantly or set to turn on every few cycles.

Contamination: Paint, powder, acid or alkaline fluids, abrasives, glass bead, steel shot, etc. can

all lead to rapid deterioration of track and chain. Ask any bearing company about the leading

cause of bearing failure and they will point to contamination. Once a foreign substance lands onthe raceway of a bearing or on the track, pitting of the surface will occur, and once the surface is

compromised, wear will accelerate. Building shrouds around your conveyors can help prevent

the ingress of contaminants. Or, pressurize the contained area using a simple fan and duct

arrangement. Contamination can also apply to belts (causing slippage, or in the case of some

materials premature wear), and of the motors themselves. Since the motors can generate aconsiderable amount of heat, keeping the surface clean is an almost-free maintenance procedure

that can keep heat from getting trapped by dust and grime, which may lead to motor burnout.

Product Handling: In conveyor systems that may be suited for a wide variety of products, suchas those in distribution centers, it is important that each new product be deemed acceptable for

conveying before being run through the materials handling equipment. Boxes that are too small,

too large, too heavy, too light, or too awkwardly shaped may not convey, or may cause many
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problems including jams, excess wear on conveying equipment, motor overloads, belt breakage,

or other damage, and may also consume extra man-hours in terms of picking up cases thatslipped between rollers, or damaged product that was not meant for materials handling. If a

product such as this manages to make it through most of the system, the sortation system will

most likely be the affected, causing jams and failing to properly place items where they are

assigned. It should also be noted that any and all cartons handled on any conveyor should be ingood shape or spills, jams, downtime, and possible accidents and injuries may result.

Drive Train: Notwithstanding the above, involving take-up adjustment, other parts of the drive

train should be kept in proper shape. Broken O-rings on a Lineshaft, pneumatic parts in disrepair,

and motor reducers should also be inspected. Loss of power to even one or a few rollers on aconveyor can mean the difference between effective and timely delivery, and repetitive nuances

that can continually cost downtime.

Bad Belt Tracking or Timing: In a system that uses precisely controlled belts, such as a sortersystem, regular inspections should be made that all belts are traveling at the proper speeds at all

times. While usually a computer controls this with Pulse Position Indicators, any belt notcontrolled must be monitored to ensure accuracy and reduce the likelihood of problems. Timingis also important for any equipment that is instructed to precisely meter out items, such as a

merge where one box pulls from all lines at one time. If one were to be mistimed, product would

collide and disrupt operation. Timing is also important wherever a conveyor must "keep track" ofwhere a box is, or improper operation will result.

Since a conveyor system is a critical link in a companys ability to move its products in a timely

fashion, any disruption of its operation can be costly. Most downtime can be avoided by takingsteps to ensure a system operates at peak performance, including regular inspections, close

monitoring of motors and reducers, keeping key parts in stock, and proper training of personnel.

[edit] Types of conveyor systems

Belt driven roller conveyor for cartons and totes.
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Flexible conveyor

Gravity roller conveyor Gravity skatewheel conveyor Belt conveyor Wire mesh conveyors Plastic belt conveyors Bucket conveyors Flexible conveyors Vertical conveyors Spiral conveyors Vibrating conveyors Pneumatic conveyors Belt driven live roller conveyors Lineshaft roller conveyor Chain conveyor Screw conveyor Chain driven live roller conveyor Overhead conveyors Dust proof conveyors Pharmaceutical conveyors Automotive conveyors

[edit] Pneumatic conveyor systems

Every pneumatic system, makes use of pipes or ducts called transportation lines that carrymixture of materials and a stream of air. These materials are such as dry pulverised or free

flowing or light powdery materials like cement,fly ashetc. These materials can be transported

conveniently to various destinations by means of a stream of high velocity air through pipe lines.Products are moved through various tubes viaair pressure, allowing for extra vertical versatility.

Pneumatic conveyors are either carrier systems or dilute-phase systems; carrier systems simply

push items from one entry point to one exit point, such as the money exchanging tubes used at abankdrive-thruwindow. Dillute-phase systems use push/pull pressure to guide materials throughvarious entry and/or exit points. Three basic systems that are used to generate high velocity air

stream: 1. Suction or Vacuum systems: utilizing a vacuum created in the pipeline to draw the

material with the surrounding air.The system operated at a low pressure, which is practically 0.4-

0.5 atm below atmosphere, and is utilized mainly in conveying light free flowing materials. 2.Pressure Type systems: in which apositive pressureis used to push material from one point to

the next. The system is ideal for conveying material from one loading point to a number of
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unloading points. It operates at a pressure of 6 atm and upwards. 3. Combination systems: in

which a suction system is used to convey material from a number of loading points and apressure system is employed to deliver it to a number of unloading points.

[edit] Vibrating conveyor systems

A Vibrating Conveyor is a machine with a solid conveying surface which is turned up on the side

to form a trough. They are used extensively in food grade applications where sanitation,washdown, and low maintenance are essential. Vibrating conveyors are also suitable for harsh,

very hot, dirty, or corrosive environments. They can be used to convey newly cast metal parts

which may reach upwards of 1,500 F (820 C). Due to the fixed nature of the conveying pans

vibrating conveyors can also perform tasks such as sorting, screening, classifying and orientingparts. Vibrating conveyors have been built to convey material at angles exceeding 45 from

horizontal using special pan shapes. Flat pans will convey most materials at a 5 Incline from

horizontal line.

[edit] Flexible conveyor systems

The flexible conveyor is based on a conveyor beam inaluminiumorstainless steel, with lowfriction slide rails guiding a plastic multi-flexing chain. Products to be conveyed travel directly

on the conveyor, or on pallets/carriers. These conveyors can be worked around obstacles and

keep production lines flowing. They are made at varying levels and can work in multipleenvironments. They are used in food packaging, case packing, and pharmaceutical industries but

also in retail stores such asWal-MartandKmart.[4]

[edit] Vertical conveyor systems and spiral conveyors
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Vertical Spiral Conveyor

Vertical conveyor- also commonly referred to as freight lifts and material lifts - are conveyorsystems used to raise or lower materials to different levels of a facility during the handling

process. Examples of these conveyors applied in the industrial assembly process include

transporting materials to different floors. While similar in look to freight elevators, verticalconveyors are not equipped to transport people, only materials.

Vertical lift conveyors contain two adjacent, parallel conveyors for simultaneous upwardmovement of adjacent surfaces of the parallel conveyors. One of the conveyors normally has

spaced apart flites for transporting bulk food items. The dual conveyors rotate in opposite

directions, but are operated from one gear box to insure equal belt speed. One of the conveyors is

pivotally hinged to the other conveyor for swinging the pivotally attached conveyor away from

the remaining conveyor for access to the facing surfaces of the parallel conveyors .[5]Vertical liftconveyors can be manually or automatically loaded and controlled.

[6]Almost all vertical

conveyors can be systematically integrated with horizontal conveyors, since both of theseconveyor systems work in tandem to create a cohesive material handling assembly line.

In similarity to vertical conveyors, spiral conveyors raise and lower materials to different levels

of a facility. In contrast, spiral conveyors are able to transport material loads in a continuous

flow. Industries that require a higher output of materials - food and beverage, retail case
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packaging, pharmaceuticals - typically incorporate these conveyors into their systems over

standard vertical conveyors due to their ability to facilitate high throughput. Most spiralconveyors also have a lower angle of incline or decline (11 degrees or less) to prevent sliding

and tumbling during operation.

Vertical conveyor with forks

Just like spiral conveyors also avertical conveyorthat use forks are able to transport materialloads in a continuous flow. With these forks the load can be taken from one horizontal conveyor

and put down on another horizontal conveyor on a different level. By adding more forks more

products can be lifted at the same time. Conventional vertical conveyors have the restriction that

the input and output of material loads must have the same direction. By using forks many

combinations of different input- and outputlevels in different directions are possible. A verticalconveyor with forks can even be used as a vertical sorter. Compared to a spiral conveyor a

vertical conveyor - with or without forks - takes up less space.

[edit] Heavy duty roller conveyors

Heavy Duty roller conveyors are used for moving items that are at least 500 lbs. This type ofconveyor makes the handling of such heavy equipment/products easier and more time effective.

Many of the heavy duty roller conveyors can move as fast as 75 feet/minute.

Other types of heavy duty roller conveyors are gravity roller conveyor, chain driven live roller

conveyor, pallet accumulation conveyor, multi-strand chain conveyor, and chain & rollertransfers.

Gravity roller conveyors are extremly easy to use and are used in many different types of

industries such as automotive and retail.

Chain driven live roller conveyors are used for single or bi-directional material handling. Large

heavy loads are moved by chain driven live roller conveyors.
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Pallet accumulation conveyors are powered through a mechanical clutch. This is used instead of

individually powered and controlled sections of conveyors.

Multi-strand chain conveyors are used for double pitch roller chains. Products that can not be

moved on traditional roller conveyors can be moved by a multi-strand chain conveyor.

Chain & roller conveyors are short runs of two or more strands of double pitch chain conveyorbuilt into a chain driven line roller conveyor. These pop up under the load and move the load off

of the conveyor.

[edit] See also

Manufacturing Moving bed heat exchanger Material handling Belt conveyor Chain conveyor Checkweigher Lineshaft roller conveyor Moving walkway Treadmill
http://en.wikipedia.org/w/index.php?title=Conveyor_system&action=edit&section=9http://en.wikipedia.org/w/index.php?title=Conveyor_system&action=edit&section=9http://en.wikipedia.org/wiki/Manufacturinghttp://en.wikipedia.org/wiki/Manufacturinghttp://en.wikipedia.org/wiki/Moving_bed_heat_exchangerhttp://en.wikipedia.org/wiki/Moving_bed_heat_exchangerhttp://en.wikipedia.org/wiki/Material_handlinghttp://en.wikipedia.org/wiki/Material_handlinghttp://en.wikipedia.org/wiki/Belt_conveyorhttp://en.wikipedia.org/wiki/Belt_conveyorhttp://en.wikipedia.org/wiki/Chain_conveyorhttp://en.wikipedia.org/wiki/Chain_conveyorhttp://en.wikipedia.org/wiki/Checkweigherhttp://en.wikipedia.org/wiki/Checkweigherhttp://en.wikipedia.org/wiki/Lineshaft_roller_conveyorhttp://en.wikipedia.org/wiki/Lineshaft_roller_conveyorhttp://en.wikipedia.org/wiki/Moving_walkwayhttp://en.wikipedia.org/wiki/Moving_walkwayhttp://en.wikipedia.org/wiki/Treadmillhttp://en.wikipedia.org/wiki/Treadmillhttp://en.wikipedia.org/wiki/Treadmillhttp://en.wikipedia.org/wiki/Moving_walkwayhttp://en.wikipedia.org/wiki/Lineshaft_roller_conveyorhttp://en.wikipedia.org/wiki/Checkweigherhttp://en.wikipedia.org/wiki/Chain_conveyorhttp://en.wikipedia.org/wiki/Belt_conveyorhttp://en.wikipedia.org/wiki/Material_handlinghttp://en.wikipedia.org/wiki/Moving_bed_heat_exchangerhttp://en.wikipedia.org/wiki/Manufacturinghttp://en.wikipedia.org/w/index.php?title=Conveyor_system&action=edit&section=9

a conveyor system is a common piece of mechanical handling equipment that moves materials from one...

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