Perspectives on Material Handling Practice THE BASICS OF CONVEYOR ENGINEERING (BELT, ROLLER AND GRAVITY) BY RICK GARRITY MANAGER. SYSTEMS ENGINEERING INTERLAKE CONVEYORS. INC. 300 HWY 44 EAST ‘SHEPHERDSVILLE, KENTUCKY 40165 ABSTRACT Technology should not be applied asa goal but used as a mcnas to reach a goal INTRODUCTION Prior tothe selection of any conveyor equipment, we must first have an in-depth understanding of the problem we need to solve The understanding showld ideally be tinderstood by all areas thar may be involved in the problem or solution These areas my include operations, distibution, mamtenance, msskenng. MIS and msnagement ‘When the problem has been defined. a team with representatives (especially those who will dperate the system) from all involved areas should be assigied to begin to explore solutions. (Quue often these teams can recommend simple procedural changes that can save thousands of dollaes in material handling purchases TOMI 220 hus ox samara sua 201 Pasouves on i rin Pace GRSTHIOTE Chto Nort Caine 28217-3002 Pag of26We nnist have a basic understanding of what any given technology's capabilites are before we ccan apply it to solve our problem. This is why a basic understanding of couveyar engineering is required. Aga, technology of any lund should never be applied just Because at exsts, It must ‘improve your ability to meet your goals. ‘Any system design should have a planned design hfe, sometimes referred to as the “design year" ‘Thus as the projected capacity required, usually 2 minimum of 5 years from the current yea Unlize marketing mput and manufacturing or processing ability to match the design year rate with the system capacity. As an example, it would not be a good business decision to put in a systema that can run L 20 cartons per minute at design year if your facility cannot physically accommodate the aumuber of production machines, storage ot tuck docks that would be required for this rate To assist our team in the proper application of conveyor technology. we will be diseussang the basic construction and technical capabilities for some of the most common types of conveyors utilized in conveyor systems. ‘The ypes of conveyors we will discuss are ‘+ Non-Powered Conveyor (commonly referred to as gravity conveyer) + Powered Conveyor © Belt © Roller (© Lineshaft (refer to separate paper by Mike Coleman, Interlake Conveyors, Tne ‘The Basics of Lineshaft Conveyor Engineoring”)GRAVITY CONVEYOR provce “erantle oo Doriom surtage. rey sn be fed in beth pormenont and Schnemical manne ot mowing porate eppievone, Droduct. Gravity corwoyore can Quick rreve large quartiies ot To seseet the oraper ecuipment ifoms in italy ary destin with or reaurad appleaten, the minimum of ater! a3 ewpanse. tani stats rust by conmloered Gravity conveyors move product jaune 1. Lond Charactraien 1 ptoh.utising he natural? Gonellons snd Bearing Mow et gro. or " Selection 5 3. Raller Center Spacing 2. on level tne where 4 Rater Capacity Seccrpchod by pushing 6. Frame Reauirement 7. Support Capacity ‘rast, oF non-sowered, olor 8: Conveyor Pitch convayers tra eal fr moring &. Supper Helga ene frost ont loads which have a Hem, vem LOAD CHARACTERISTICS ‘The shgie, most imporiam consigeraton w MeuIe Your sytem rotetty |e mown a8 the Footprint the betlem aurace of the loa whic Ie to be Cormosee. Te loed bottom must be frm and feo of orowetona which could prevent smcath travel over rele. & sip shee! coud areca the necessary Figiity. "at the sto, at load charaotersios are not iavorabie, do nat Dreceed: Consider power conveyor cwoeoes Ssoeee ‘atest tt ram te oak orreares ect tection of yu pte one tarda fale prerung WF lop our eee. AAAAAA 4/20 Hod Usk Loulovrd Suto 201 ‘Perspecuves on water ena Practice GSiiivTE Chrlote North Carola 28217-3092 Pago 30f26CONDITIONS AND BEARING SELECTION unt Boag an or GresoeabeGuarra BEARINGS OPEN ORY BEARING [Open ory Besrngs offer the West res'stance to tung ofall Gearing oes. ‘Thay are consiructec win 9” Outer shold, whee Fixed fo Ihe etaonary Inner race of tie bearing snd dows not touch ary rotang part Manulactured min’ ight el breant, the open ary bearing ges Salstactory resus in ost normaly lean, dry, indoor appteatons. DUST PROTECTED BEARINGS Dust protected deerings, non-hbricated, heve the same easy rollng action fas a ninn bearing Because tha Gust shel ‘sa non-contact "ype sani The Sric which i Mt the statoney Inner rece Jews not toucr ay roletng paris of the bearing. Ina reasonably molalre {tea envrenment, excelent Fosute ere achieved with absolutely no lubrcaton FACTORY LUBRICATED BEARINGS “he bericated beetnga erates In conaucion to the dit protected iccrrprating fe some Gt shad rangement wh an weston Tae OTe factory lubricated bearings are recommended for all powered roller agpteatone, toh for ne role and bot conveyor eppcalena, Cauten ‘fou be teed In spphing te constuction m aess utero ovoseave get ‘cat soit 88 thara ara no mesna provided for greasing ‘hese bearings {5 hare are nih pressure Ubrictod conan PRESSURE LUBRICATED SEARINGS: The praxsie hovicted bearings are simi in construction te the factory ‘however. requing in appeation the necessity of driling {0 itera lubreated boa ng the hex ave for grease fttnga for detvery Of boring. Grea forces out 21d grease, thereby produchg # new ellecive sea! The fecvantagas of the re-ofaasnbe feature ara covious when eonsisering appeation in extremely Gity environments, vai Practice Dage Sof 6DETERMINE ROLLER CENTER SPACING [A MINIMUM OF THREE ROLLERS MUST SUPPORT THE SMALLEST UNIT Loao. Divide the minimum package length you anticipate conveying in your system by three (or ine number of rolers needed) to ave at the roller ‘enter 19 ‘center disance. Croose a role: Secton win ole Centers the Same oF loss than thie figure Package Length Maximum Roller Spacing = Te tong Pactare ae 6" Roller Centers Nee: Resorsmanded mdm role spas 12 bes, note {Raters poet Package DETERMINE ROLLER CAPACITY ta capac eterna yang a waht of reread ty the rintruen Macinum Package Weight pininuan Copaciy Rammer of Rollers Under trad Reauired Per Rote varie 108 the S64 IHS. 566 Ib. Capacliy Required Per Roller ep or shook aang anttatecrtere Tyke! al camry are Wa" 3° 4 inch note gamete rtyceregwonse 1m '8 came AMBALA 2720 Rod Oak Bowers Suto 201 Perspectives on Heil Handing Practice GsgHTUTE Chita North Carina 28217-3092 Pago 6f26DETERMINE WIDTH & SETTINGS STRAIGHT SECTIONS 1 your spect corso of rach conveyor sectens the recemmanted conenor ‘Overhang Load eet se Soca sso meray ‘orca, CURVE UNITS: \ oars ae required. the canveye with (de ram) mest bo Dave ete eg tw pachage recare (ey wan te Ferman Fo stemnng Dance Baben Frame 4 Package length IF lds fr LF afe Oe OT - R- 2) En St CURVE TYPES DIFFERENTIAL DEPERENTIAL | ‘TAPERED ROLLER CURVES ‘STRAIGHT FACE AVESDETERMINE FRAME REQUIREMENT To extend the ile of tne conveyor oF 10 avoid damage from overioading, it 4s bos to be cn the sale side In colcuating Irma capacty. Alow for extra Yooding. in many cases conveyors ero subjected to greaier abuse and loads than they ware intended for. Frame requirements should be cereluly ‘cacultes. Locating supporis on closer contors is one way to increase tame cepaciies In doing this. comeare the cost of an increased frame to the number of ‘exra suppats to see wevch method fa most econemicely Tessie. When {igutirg eapaeties, incluce the worgm af me cowveyor section and be swe to check the capecites of each type cf fame agama the tote Toad, FORMULA Lve_Lomdi Mutiny Number of Losde In 107-0" Long Section x Weight of Each Loa Bead Load Mutely Number of Rollers in 10'-0" Long Section | sWeignt on E20 Roller = Total Lod DETERMINE SUPPORT CAPACITY ‘The suppers to be selectec rust nave a fond carrying capanty equal te fr greater han tho masimum loacing condition and Weight of wacion eat Fe eo ened cured 50. pO TOTAL Los ren syetOnr + TOTAL19A0 poe «Tata SBPORT = rota Loan pen SiR ~ Nera secton No, TOTAL LOAD PER suroee = SW satin IVTERMEOIATE (TOTAL Lono PER surpont “ala sesrost reine Page of 25DETERMINE CONVEYOR PITCH Two Condens affect the determination of the comeyor ph to be ured, ‘Generally speching, tne smocther and herder the loac bottom, and greeter the weight. the lesa pion needed. For more uneven, softer (corrugated) bottom toad, and igiter weight. more pitch it requres. Corsizer these deitona factors *# Bows with cords. straps or uneven dotioms ‘8 The mote rallare under he loed. the more plich needed. # Rolers with ubcstes bearngs requre more piten and ars usualy Deiter suited fer powsred conveyor ‘© Palot condiions ~ badly caled, barded or ndented gallste requre moro pitch, ‘he folowing chart con De 8 siartng pont fo estmete oWten under norma: room temperatures and condtons. Variances roted above should be considered. Advise your conveyor representative of the type of loads 10 be conveyed. 6 aan mak suggestions 45 t the pitch required. The final pitch ‘ust be determined at time of installation or prior testing wah your produc. DETERMINE SUPPORT HEIGHTS AND QUANTITIES SUPPORT HEIGHTS: Conveyor height are generally consiceted to be the dlstance (rom the 09 ‘ofthe rollers to the foer. To caleuate suoport heights, (8), subtract the distance from the top of the roller to the bottom ofthe fame. (A), trom the ‘etal conveyor height. (C), atthe point the support wil be located. The balance is he suppor height at mat poi Use your conveyor layout (or make one) to determine the quansty (by helt) of conveyor supports necessary. Both top and full run side views are roqutres to determine (ne number of Secvions, plot tho cn and caleute the height of each suppor. Anmmme 4/20 Koo Lak kowora cule 2% urspecives on maa runing Practice Reivivae Chante Wort Carina 28217-3902 Pogo 10o£26POWERED CONVEYOR Belt Conveyors — Types and Applications Being the most versatile of poner conveyor, belt conveyors are the most equentiy used. One ronson for the versatty ie the “work aurfece™ belt which can hands loads of almos! ary shape and over a moving plate for Process 0° production work. Galt conveyors re alto one of the loast ‘expensive Power comveyOrs. ‘Slider Bed The bat sides over @ continuous metal bed which Is atlached vetween the tops of te conveyor channel frames. Becaute support fer the entre Bok surface provided, the bel Fiction (30% trlction coeticient) ie increase, thus Ieiing lotds to 82 be. per eq. ft lees, Operation fs quiet and the bed offers a no sag. no bump surface. ‘Sidor bac conveyors are excolint fer production work where srrall ons ‘of varying sizes end shapes mus: be carried or assembled. The surtace remains constant at Roller Bod The belt rolls over rallare rather than & mo bec. Ficton ie preety ‘reduced thus emaliot moters ane aves ean be Used. For light loads, ono) Toller is suicient under each Iona tt for heavier loace and incines. two | ‘F more rolers should be used. (See your conveyer supple’ for specie toler capacities.) BAT REMAN cam Practice anestavew agp 2 026Inclines and Declines \Wnen elevcion mus: be changed, cine or denne elt conveyors are ed of @ mimimur 30° gt, This rule Cen only be used for evenly weighted loeds! A vertical the ‘cropped from the exact carter of the load (center of gravy) shou fa sith the Senter oe thes of the Botiom of tha loas. Outside of the arae the load would be unstable. the weight within the carton is off center 0 ‘novery detibvted, do not use this rue! Testing may be necesEarY To otermine the cantar of gravity and exact inline. example A package ts 25° Lx 207 Hx 12" W HANDY INCLINE TABLE Se] (EEL ‘This chart is also 10 be used eniy ee with eveniy weighted loads. Diide we | an carton longth by carton height 19 ws | a od go [ton zm ian (On tho tle the degree of inctine next to your value of "X" wil be he maximum indine guideline you should use. ta Practice pistsBOOSTER CONVEYOR This 1 a term sppted 10 8 belt conveyor used fo “boost” loads up at a sight elevation (rot more than 15°). Boosters are gone FEED CONVEYORS A ncine, oF dacine, conveys ovr 15° ange reaure a loeder= cowevo ERR, to prover the tops of covey spnced RM — tows tom pring orenaiing. Foedora are gonerahy shor {bat ot est tice the with ‘of the bolt, or longer if loede are oe er as FED CONTR 1 Yoece feecng onto an icine must be sat sown then the spac of he incine conveyor. leeing removing hace from # cine conveyor must be set fst than tho docine ut. (See Hetar Specirg Elis.) WETER OR SPACER BELTS: ‘Maver or space els are used to separate Toads wah & ‘isionce between esch lord ‘To determine the conveyor speed (hr feat per mute FPM) required 10 ace unit loads at « epeciied stance, ‘ollow this formula FEM » (LL4S) x LPM Ft = Feet par minut. LL Lond length inf S = Space between 1080s (feet). LPM = Loads per mirute being fed 19 spacer bet ‘Spsce” belt speed Int. per min. = (Loed length + epace desired between toacs) x tne number of lords per minute being fed to spacer batt. Example: Shou 3 ft. long 10nd be fed to the spacer belt atthe rate of 20 toads per minute end the desred soece between loads Is 18°, then the FM rate o! the spacer belt sould be vet at 0 FF, (QO FPM = co 18) 420 peated space BRAKE BELTS Generaly. brake belt Conveyors are used @t the encs oF gravy OF powered accumwiation conveyors" 19 “brake,” slow the Ine or reduce pace between packages, ‘rake Bote are vaualy sider bad bet conveyors wih a roughtop belt 10 -nchiewn nmaimum amount of ton. Tha gener Formula foe Racing Row long a trake belt conveyor should be & to divide the total length of the ‘raximum accumdleted load” to be braked by 6. NOTE: Tis formula applies to “MR” conveyor ony. Total fength aed Brake Bolt Length Example: suppese you have a proposed maximum accumulated toad length of 78 toot. Oni by. TE 43 You would nand a 13 ft Brake Bat dine Practice e pot o825oseovens aoe ger renee Soaks Soares eennes ite ee sce tae “sor me ro Seas eae praesent Sone smatate clemes: tance rate Se el ects a eta Te ROLLER CONVEYOR Belt Driven Live Roller Conveyor ~Types and Applications Bolt divan lve roller Conveyor is widely used for cartons. boxes oF tote pans. Live role offers easier adeptablty to ransiering or dvering lacs than doea batt conveyor ‘ive roller conveyors must be Kept 8 herizontal a8 possible for etfectve tronaport of prodest ‘Adjustable Pressure Belt Driven Live Roller Conveyor Use roller conveyort that are belt driven are a versatile conveyor offering ‘any berefis. Loads rice directly onthe stool carrar roles that provide f2nsy movornen: with a minimum ot power. Loads are easily merged getecied oF vensterrd. Convayeble loads rust have fat, smooth, har, Dottoms (ono type of BOLA iiizas numbered the ahalt of the presevre roller, ‘These rolers can be adhusted un or down in stages. This 3 Jacre9ses, ‘ospectvaly, the amount of cving foroe tranamitted from the batt to ‘Ae rosut, the bet chivan ive roller ‘conveyer is excellent for both general norizantal vansporting ané mod: ‘AgusIabie pressure rolers can be S610 Use WSs force On 8 stralgne-eway ‘oF more force at & waneter of dering post. Lees pressure extends bth the erve Bet ond ror ito sncana Praciee Page 5 086Zoned Zero Pressure Accumulation B. Conveyor 22PA Is a Det driven ve raller ccnveyor wth air contrclled zones to ‘accomplish a *zero-deving” force of the conveyed product at the accumulation port The product introduced ento the conveyor wil travel uninterrupted atthe {en spaed to the ext end of the conveyor wher it wil either continue on to the next conveyor or stop i eccurulation mode, cepending on the Ldenignes mode 0! operation, Once the intial product stopped on the ZZPA conveyor. © box Mung he fst verwor rol UosteaM of eroduet ‘nil cause the desing force under that box to cago in that zn. This is ‘sovompiehes By sroppng the tenon ros away. When the senaor rol eprensed, i lac pres the next 2008 upstream 80 1 wil goo “20/0 rive" when depressed ‘and 80 cn unté the cD conveyor ine completely full, A END STOP 220A conveyor tong fed tom 2 ‘on-eccumvieting MODE | (NO RELEASE) cornet aaa ie Carey comin BRAKE BELT ZZPA ip full, otherwise, CONVEYOR oe se Catena. Oreo tet ir pane Lares Sanetaone ‘upstream becomes MODE |i (BRAKE BELT RELEASE) torte, ea Decora 8 oaeg oe ioe a cine pom eTees, ANY OTHER MODE Ill (AIR STOP RELEASE) TOO a720 p00 sca sae 201 Perec oni a Price Renae Chance ho Coobe 200 S02 i 180028Minimum Pressure Accumulation B.D.L.R. Convayor ME conveyor f a minimum pressure accumulaton coweyor. The MA peviorms two key package accumelion funciors: “Training oF Sug Discharge Package Singulaton ‘One dosigh Is as folows: The “HE conveyor operates a8 a noimel belt divon live roller conveyer Ihe dference isin © pressure rolowng feature consisting of each cerning ‘all aves in'a busting ing In 8 specialy designed ramp type slot. The ‘aller rice the lower portion of the sot when ihe conveyer Is Used as Straight ansport conveyor, (see deta A"). As soon as @ oad mows an Sbatruction. such e 8 slepped o Blocked load, an opposite reaction causes the cerryng rol bushina to rol up the ramp sot. (see dela “B"). thus Telieving some of the pressure between the belt and carrying cols. When the Dbstructon is removed the carrying falls wil return back {> the vigil lower postion. thus re-engaging withthe crva Dat, (89 Geral "C"). The ‘Wa convevor accumulates packages vith ‘# Misimur pressure Moimum systems wear 1 Maximum efficiency Packages move Wrely and immedistey when they aro relatsed ‘The MA conveyor, witout ery addtional controls or mechenical har da provides. slug sischarge — forward packages and to end. l can alto ‘perat In conjuntion with a trake-metering bet to perform package. Singuiatin ~ forwarding Inchvidual packages et evonly-epaced Inorvals. The MR cenveyor raqures no rrore maiterance than 2 stendard belt riven IVE Taller conajor. Adjustable dai cam facture citer the moat sfesen! maihod fvalabie to achieve variable pressure conto forthe criong action. Tho MA can operate at slower rates than other tyoes of acoumulation conveyors because the MA can be used lo perform 8 sig release function. The MA requires less footege 10 absorD # given degree of surge. Tis sto of conveyor fequise rnimal ease 829 weigh varanon wn Lnilonn ands. Neo, cerone shaud be selumnized Yo minmize canon jame fine shasing RESTRAINING PACKAGE veralL “A” DETAIL “c* | mf CONVEYOR BRAKE OELT, || METER UELT, ‘nana Practice PACKAGE SINGULATION Page 17 26Photoeye Sensors vs. Sensor Rollers Sensor rolers are compattie with product whic wil convey on lnesha ‘conveyor and welgns § peunds or mare. Phetoeye sensing anculd be used ‘my 21 the folowng condlions are encountered “Tapered tote Tote pans wit tapered sides crane & void between loads \whion a sensor ro wll no dotect. The conveyor wil not ‘F0p into socumulaton ‘Property i the sensor rf s ‘no depresses ~ Protomyes can be skewed up to 15° off perpendicular to prevent “seeing through the gees.” = Upm packages: cases, envelopes, pt. loss than § pounds sre prime ceanaiotee for photoeye soncors. — Non-marring suriaces: Product which cannot be marred sometimes raqulees coated rolls. The secsor role Is sluminum ard cannot be coated. ~ Uneven bettom surtaces: The sensor rotor wil project 1/8 ‘2bove the carrying suiace; cases with roundec bettoms may not press the senscr, = Loads pusnes on. trrown on, or conveyed en from the side of a Tineshalt 2° conveys may damage the senor rllor ‘Some applications require that the photosye be adjusted down to look st ® retiector uncer the carrying surtace. As long as the eye can soe sny part ‘ot te refinctor, the eye wil Not be “blackad.” The crestes a brs area on tie conveyor surface. This is not @ good apolcation # small cases can pass by the eye without being sensed and the operators the cases across the conveyor 10 the pnotocel sis. oerntvane Coane mat Cavin coe eee rage 18 of 25Belt Driven Live Roller Curves Bett civen cures are used win ve roler conveyor, However. their use oes have some imitatons, such as can be uses for Yensporiion only land camot accuTuiate. Pressure rollers are not used In cues. In heir piece, sheaves along the inner Fame (amaller rack) a6 Used to Gude © \V-Balt and apply bot gresoure to the carrying rollers. The carrying role da the curve are tapered to beep loads properly algned. There is & maximum 400 B. tt of dstriouted load por curve. Powered curves ooneraly operate fester than straight conveyors to keen loads separated and from “humping” ‘each other, CHAIN DRIVEN LIVE ROLLER CONVEYOR Chain driven ive roller conveyors utilize roller bec for the carrying space. They provide controlled mavemen' of a great variety of commodities from the lightest to the heaviest loads. Unit loads travel directly on the roller surface, The posiwve arve atforoea oy chan on sprockets makes chan crven We Faller conveyor the choice for Reavy leads (pales, et) and for conveyors Used in epplcations where heal, it, ol, gremse oF otter Conterinants my conueo bolt damage. Two eprockate ere welded to wach roller and indhicual loope of chain connect roters in 8 staggered patton. The . TURNING WHEEL POWERED TRANSFERS — 90° In casos where trnstorlorces are desired otter then detectors, powered transiers a avalabie. Those ere elther wheel, bet or chain tanslars that ‘aise oF lower win he transfer intersection 10 change toes fiom one Son eyo to arotier. Fer complete welght and speed speciteators on these Unis, consult your conveyor supate UNIT RAISES TO LIFT AND TRANSPORT LOAD, TT LOWERS TO PLACE LOAD ON ROLLERS MOVING AT 90 DEG. ‘TRAFFIC COP ‘Trae cop" Is the rama eppled to © mechanics! erm wrich i used :0 stop lonas and contol the load tow at a merging of twa carvayor lings. Pr ‘ling arms eparare Independentiy to stop oF release the comect 1080s rte the merging Stuetion, and operete on a "Fikst come-Fist served” Desls ‘RAT COPS CAN OF USED [AT MERGNG PARALLEL CORVEYORS 30, 45 end 90 DEG. MERGNG CONVEYORS CoP" saa Practice ge 2 of 8ACCESSORIES: FIXED OR MOVABLE DEFLECTORS. i ie eure to dallact Ibads onto murs, from cn conveyor ina fo ral corvayors ito one. deflectors are yn bo either maruaty or automaticaly operated. When ‘erated, timng, 820 and weight of load and the speed cf the conveyor are factors to be considered. EMER Ge PUSHERSSUMMARY To insure a cost effective solution to material handling problems, we aust: © Obtain an in-depth understanding of the problem, ‘© Assemble a team of all involved parties to work toward an efficient organizationally agreeable solurion tothe problem, + Obtain enough understanding of proposed technological solution capabalities to apply the technology ns needed to reach a cost effective solution. Apply technology only when itis required.