Conveyor
What is Conveyor
A conveyor is a fast and efficient mechanical handling apparatus for automatically transporting loads and materials within an area. This system minimizes human error, lowers workplace risks and reduces labor costs - among other benefits. They are useful in helping to move bulky or heavy items from one point to another. A conveyor system may use a belt, wheels, rollers, or a chain to transport objects.
Advantages of Conveyor
They are very useful
Any time you need a product moved, a conveyor makes the job much faster and easier for you. A heavy-duty conveyor can keep moving heavy, jagged objects in even harsh conditions. You can have peace of mind knowing that your manufacturing process won't come to a halt. Plus, you won't have to worry about logistics. Placing a product on a conveyor is a lot more simple than having one person separate the items. Then, someone has to carry the individual item and assemble it correctly. Then another person inspects it, packages it, stages it, and places it aside for shipping.
They can help reduce your costs
When you have a conveyor in place, you won't need as much labor, helping you save money in the long run. And conveyors do quick work, helping to cut back on your production hours. The faster you move the products down the assembly line, the fewer hours you have to keep the lights on. Across many different kinds of industries, conveyors consistently increase efficiency by 15%.
Downtime is reduced
Another benefit of a conveyor system is that it reduces downtime. Even if your factory has a truck or forklift, you still need manpower to load and unload the vehicle and then drive it. With the flick of a switch, you can keep a conveyor working consistently, providing continuous loading and offloading - as long as it doesn't break down. When you go with a top-of-the-line conveyor system, you won't have to repair it quite as often.
Conveyors are safe
A safer workplace is a happier workplace. With the help of a conveyor, you significantly reduce your chances of operator injury from a worker that is pushing, pulling, or lifting a heavy load. Whether you've been carrying products by hand or by forklift - a conveyor system eliminates collisions. Now, all of your products will move straight down a fixed pathway. Without human error, you'll have fewer breaks, spills, and drops to deal with. Thus, you won't have to replace as many items, allowing you to meet the needs of your clients.
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One-stop solution
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Customization services
They provide customization services to meet specific customer requirements, ensuring that clients receive products that exactly fit their needs.
Innovation
We are dedicated to improving our systems continually, ensuring that the technology we offer is always cutting edge.
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Types of Conveyor
Sometime our customers call these “Conveyor belts”. This is actually the belting material. A belt system is one of the simplest conveyor types. It moves parts from one end to the other. Speed can be variable with a variable speed drive. Don't use belt systems as a working surface. They also can't be used to present parts to a robot, or buffer or sequence parts. But their simplicity makes them one of the most common conveyor types available.
Also one of the simplest types, they are very affordable. A series of rollers mounted on a side frame provides the rolling surface. When mounted on a decline angle, parts move by themselves. However if using gravity conveyors for parts of different size and weight it can be more difficult. you will need to control the speed and angle. Parts running into each other may cause damage. But compared with carrying parts from point A to point B, a gravity roller table is often a great starting point. It is a very simple productivity improvement.
Floor mounted chain conveyors are great for heavy items. They are especially useful for items that have an uneven lower surface. The conveyor chain provide two or three contact points on the bottom of the load. As the chain moves it carries the product forward. They're used to carry pallets and large industrial containers. If necessary, products are mounted on a fixture, or “skid” and the fixture is carried along the chains. This is a common application in auto plants. They are heavy duty, and generally move at slow speeds.
If we combine the rollers from a gravity conveyor with the chains of a chain driven system, we can link the rollers. Add a motor and gearbox and now we have a live roller conveyor or chain driven live roller system. Sometimes people in the industry use the acronym CDLR. They are members of the floor conveyor family, and they are heavy duty material handling systems. Use them to transport pallets, seats (on skids or pallets), tires and containers. If fitted with loose plastic sleeves over the rollers as shown in the photo below, they can accumulate or buffer product. The rollers can keep moving even though the product on top is not moving. Chains are linked together from one roller to the next on the side.
Working Principle of Conveyor System
A conveyor system has parts that are essential for it to operate just like any other mechanical or technical system. If these parts of the conveyor are not properly maintained it leads to increased chances that the conveyor system will no longer work properly which of course potentially increases risks, incurs costs, and causes higher delays on product output the longer a conveyor system is not maintained.
Depending on the conveyor system you have and what the conveyor system will be carrying will change how your conveyors will be designed. However, all conveyor systems will have the same essential parts for it to work and for the conveyor to do its job of moving what it's been bought for.
Structure of Conveyor System
Conveyor belt support
A conveyor belt system is supported by either rollers or a flat pan along its path so the system stays upright and has a structure to its movement. The structure of conveyors is relatively similar to each other in terms of construction with them consisting of a metal frame with rollers at each end of a flat metal bed or having rollers closely spaced on the system if it's a heavy use application. Rubber conveyor belts are commonly used for items that are oddly shaped and have irregular bottom surfaces or bags of product that would sag between rollers.
Pulley
Belt conveyor systems consist of two or more pulleys in order to operate and these are sometimes referred to as drums. They are what the conveyor belt(s) are wrapped around to give the conveyor belt system a structure and feed the belt back around the system. At least one of the pulleys will be powered so the belt on the conveyor system can move the items to the desired location. The powered pulley is called the drive pulley while the unpowered pulley is called the idler pulley.
Driving unit
This is the driving power or driving unit behind how conveyor systems work and are the mechanical units that allow the conveyor system to run smoothly. Similar to controls and electricals for automation projects, the driving unit is responsible for the conveyor system to run continuously and control the direction of the conveyor system. Essentially it's the part that provides the motion to the conveyor for it to either go one way or another.
Conveyor systems specifications to consider
When installing a conveyor into your business, either on its own or as part of a wider system, there are certain aspects you want to consider and factor in. Combining the answers to these questions will give you an idea of what sort of conveyor system you want for your business such as a spiral conveyor, inclined belt conveyor, slat and mesh conveyor, pallet handling conveyor, or plastic conveyor.
Load capacity
This is an important part of how any conveyor works and will be a fundamental decision as to what conveyor system you get and what functions you have. When companies like L-A-C are manufacturing valued customers conveyor systems, they will make sure the conveyor is built to the required and custom length which will determine the loading capacity or the loading margins of the conveyor system.
Conveyor system speed or rated speed
Belt conveyor speeds are typically rated in foot per minute while a powered roller conveyor speed is usually measured in terms of how much product, package, or volume of an item will be moving over the powered roller conveyor system. The speed a conveyor system works at varies depending on what's being moved and is a key part to how conveyor systems work due to controlling the speed which can affect other factors such as throughput of the conveyor system.
Throughput
Throughput is what measures the amount of product that goes through the conveyor system. The throughput capacity of a conveyor system is sometimes referred to as Cases Per Minute (CPM) and is dependent on the slowest speed mainline conveyor and the length of the product that's being transported. It's measured by volume per unit time such as cubic feet per minute.
Drive location
They need to be considered in terms of where it's placed on the conveyor system. Usually, a head or end drive is found on the discharge side of the conveyor and is the most common type. You can also get centre drives which are mounted underneath the system alongside the conveyor system. drives are used for reversing the direction of the conveyor.
Functions of Conveyor Systems
Automated and streamlined process: By automating material handling, conveyor systems enable higher efficiency, optimise the production process, and reduce downtime.
Consistent handling, sorting, and distribution: They precisely regulate the speed and motion of the objects, guaranteeing accurate and consistent handling.
Customised layouts: Conveyor systems are flexible and tailored to fit a variety of layouts and operational demands based on Industry needs.
Specialised functionality: To efficiently handle a variety of products or materials, conveyor systems include components like sensors, diverts, or sorting mechanisms. Conveyor systems designed for liquid material handling frequently use particular belt materials, such as those resistant to corrosion or able to take fluids without leaking.
Some Routine Maintenance Checkpoints
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Check Point |
Action |
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Motor |
Check Noise |
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Check Temperature |
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Check Mounting Bolts |
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Reducer |
Check Noise |
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Check Temperature |
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Check Oil Level |
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Drive Chain |
Check Tension |
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Lubricate |
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Check for Wear |
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Sprockets |
Check for Wear |
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Check Set Screws & Keys |
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Belt |
Check Tracking |
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Check Tension |
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Check Lacing |
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Bearings - pulleys and rollers |
Check Noise |
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Check Mounting Bolts |
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V-belts & O-rings |
Check Tension |
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Check for Wear |
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Check Sheave Alignment |
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Structural |
General: Check bolts for tightness |
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Safety |
Check machine guard placement (for belts, pulleys, sprockets and other pinch points) |
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Lockout/tagout before any maintenance |
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Check emergency stops functionality |
Design and Selection of Conveyors
Motor and Gearbox Selection
To aid the selection of the motor, one must first know what the effective pulling force required for the conveyor is.
For a simple horizontal conveyor, the effective pulling force is given by the formula below:
Fu=µR · g(m+ mb+ mR)
Where:
Fu=Effective pulling force
µR =Friction Coefficient when running over roller
g = Acceleration due to gravity
m =Mass of goods conveyed on the whole length of the conveyor
mb =Mass of Belt
mR =Mass of all rotating rollers minus mass of drive roller
For a system on an incline, the effective Pulling force is given as below:
Fu=µR · g · (m + mb+ mR) + g · m · sina
Where
Fu =Effective Pulling Force
µR =Friction Coefficient when running over roller
g = acceleration due to gravity
m = mass of goods conveyed on the whole length of the conveyor
mb =Mass of Belt
mR =Mass of all rotating rollers minus mass of drive roller
a =Angle of inclination
Once the pulling force is determined, it becomes easy to come up with the torque and hence the motor to use and the gearbox will follow after.
Speed of Conveyor
The speed of the conveyor will be the circumference of the drive pulley multiplied by the revolutions per unit time.
Vc=D · F
Vc =Speed of conveyor belt in ms-1
D =Diameter of drive pulley in meters.
F =Revolutions of drive pulley per second
Tension and Take-up of the Belt
Take-up is an important component in maintaining and achieving optimum belt tension. This will contribute greatly to the process and its mechanical stability.
A properly tensioned belt will wear evenly and will contain material evenly in the trough and run centrally when going over the idlers.
All conveyors will always experience some stretch in their length and width. Generally, it is acceptable that a new belt will stretch with an additional 2 percent of its original length. Since this fraction will add to the length of the belt, the entire belt will have a slack. This slack will have to be taken up in order to retain optimum tension.
The longer a conveyor is, the bigger the stretch will be. Using the 2 percent stretch, a 2-meter long conveyor can stretch 40mm, but a 200-meter long conveyor will slack 4 meters.
Take up is also profitable when the belt has to undergo maintenance. In such a case the take-up is simply let loose and the personnel will undertake maintenance with ease.
Benefits of Conveyor Systems in Modern Business
Conveyor systems are integral to streamlining operations across various industries, offering numerous advantages that significantly enhance business efficiency and productivity. Here are some key benefits:
Increased Efficiency and Productivity
Conveyor systems automate the movement of goods, leading to faster production times and increased throughput. This automation allows for consistent and continuous operation, minimising manual handling and reducing the time taken to move items.
01
Improved Workplace Safety
By reducing the need for manual lifting and carrying of heavy items, conveyor systems help in lowering the risk of workplace injuries. This not only ensures employee safety but also reduces the potential for compensation claims and downtime.Benchmarking machinery has great influence,covering 1,500 companies and 15 well-known enterprises across the country
02
Enhanced Product Handling
Conveyors provide smooth and controlled transportation of goods, which is crucial for handling fragile or sensitive items. This reduces the risk of damage during transit, ensuring product integrity.
03
Scalability and Flexibility
Modern conveyor systems can be customised and scaled to meet the specific needs of a business. Whether it's adapting to different product sizes or integrating with existing production lines, conveyors offer the flexibility to grow with your business.
04
Cost-Effectiveness
Over time, the investment in a conveyor system pays off through improved efficiency, reduced labour costs, and lower risk of product damage.
05
Application of Conveyor
Manufacturing and Assembly Lines
They facilitate the smooth movement of components and finished products within production facilities, enhancing efficiency and reducing manual handling.
Agriculture and Farming
Belt conveyors are employed in agricultural settings for tasks such as loading/unloading of crops, sorting, and packaging.
Warehousing and Distribution Centers
They play a pivotal role in the logistics industry for sorting, packing, unloading, and unloading, and transporting goods within warehouses and distribution centers.
Airports and Baggage Handling
Belt conveyors are instrumental in swiftly moving luggage and cargo between terminals, ensuring timely departures and arrivals.
Food Processing and Packaging
They are used for conveying ingredients, processing various food products, and packaging operations in the food industry.
Retail and E-Commerce
Belt conveyors are employed in retail settings for tasks like moving goods to and from storage areas and facilitating order fulfillment.