CHAPTER 1 Chutes Definition 2 Design 2 Chute Types 4 Slide 4 Flat Bottom 5 Trough 5 Pie or Funnel 5 ~ Spiral 6 Application 7 LChutes Definition Chutes are used as an inexpensive way to move products without drive or control. Chutes are often referred to as “gravity chutes or slides” because gravity provides the force to carry the load down the chute. Through the years many different materials have been used for the surface of the chute to provide as little friction as possible, Some of these include wood, laminates, stainless steel and various plastics. But cost and wear characteristics have driven most suppliers to steel or fiberglass. ‘The chute concept is simple; a surface for product to slide on. The shapes can vary from a simple flat sheet to complex spirals. The final design for a chute is dictated by the shape, weight and material of the load, distance and angle of travel, and physical space available. Long chutes that cannot be made in one continuous piece or surface are sometimes needed. In these instances where two sections are joined, it is necessary to overlap (shingle) (below, left) and/or flair the sections (below, right)"to insure there are no catch points for the load Figure 1.1 Overlap Joint (left) and Flared Joint (right)Design Transitions are sometimes needed at the entry and exit of chutes. For example, if a horizontal roller conveyor is feeding a 25° chute, loads will tip into the chute, making, noise and potentially damaging the items. To reduce these concerns, a transition should be used that has a radius so the load is supported through the transition. The higher the speed of the load as it enters the chute the greater the radius needs to be. Figure 1.2 Chute Entry Transition Exit transitions are often needed to reduce the load speed and keep the product from damage. Ifa 30° chute is feeding a horizontal belt or roller conveyor, the front edge of the load will “dig into” the belt or “ive” between the rollers. This can be avoided with a transi- tioh section that brings the load to an angle that will minimize these problems before it reaches the next conveying surface. The transition can have a radius or a series of angles that achieve the same effect. The longer the load, the larger the radius needs to be. Another option on roller conveyors is to put the rollers on closer centers so loads cannot dive between the rollers. Figure 1.3 Chute Exit TransitionChutes When a chute causes the load to reach undesirable high speeds, a different surface can be used to reduce the speed. A piece of conveyor belting or other higher friction material can be added at various positions along the chute or at the end to slow the load to accept- able speeds. It is important that the carrying surface be overlapped (shingled) and the fastening method must be below the carrying surface to insure there are no catch points for the product. Also consider that a drastic change in speed may cause the load to begin to tumble or roll forward rather than sliding. BELT FOR SLOW DOWN re 1.4 Chute Slow Down Section Some manufacturers cut holes or slots in the bottom of the chute so that wheels or rollers can protrude above the chute surface to influence the speed and/or direction of the load. Chute Types Slide When several chutes are required in a row, a simple flat slide without sides may be used to reduce cost. This type works well for short runs where load control is not critical or the receiving device is wide enough to accept loads in various positions. (Figure 1.5 shows a primary slide chute (1) to carry the load away from the sorter and a secondary chute (2) to redirect loads into a container.) Figure 1.5. Simple Flat Slide with Secondary ChuteFlat Bottom Trough Pie or Funnel Chute Types ‘Typically made from a single formed sheet or three piece design made of a flat bottom with sides attached. (Figure 1.6 shows flat bottom chute feeding a horizontal trough with a fixed end stop.) Figure 1.6 Flat Bottom Chute ‘These chutes have a formed bottom (curved or multiple bends) to help orient the load and position it in the center of the chute. The trough can be consistent over the length or tapered to “funnel” the load. (Figure 1.7 shows a tapered trough chute with in-feed and discharge transitions.) Figure 1.7. Trough Chute ‘These chutes can have flat or trough bottoms that taper in width from the entry to the exit. These are often used when receiving load that is not fully controlled, so the wide end gives the load room to rotate and/or align. (Figure 1.8 shows a funnel chute with a wide flat bottom chute infeed section.) Figure 1.8 Funnel ChuteChutes Spiral At times a large elevation change must take place in a very short distance. Spiral chutes are used for this. They can be made of steel or fiberglass and are typically curved around, and mounted on, a center pole Spiral chutes, like straight chutes, utilize gravity to move product form one level to another. The key advantage is that spiral chutes use far less floor space. Spiral chutes are available in either fiberglass or steel (Figure 1.9). Both steel and fiberglass have advantages over each other and over straight chutes. Figure 1.9. Fiberglass Spiral Chute (Left) and Stee! Spiral Chute (Right) Properly designed spiral chutes control the speed of the load’s descent due to centrifu- gal force pushing the load outward to a longer, shallower path and pushing it against the outside rail, creating drag. Spiral chutes can be designed steep enough to allow accumulation of load and be self- starting as the loads below are cleared. Fiberglass chutes with low-friction gel-coatings are best suited for this type of application. Fiberglass chutes are not impacted by changes in environment such as humidity. Steel chutes, by their very nature, are not flammable, The gel-coat used in a fiberglass chute is typically flammable, although some manufacturers offer flame retardant grades of ‘gel-coat for their fiberglass chutes. Unlike straight chutes, spiral chutes are often designed with in-feeds on multiple levels This could be an advantage in a multi-level picking module or discharge from multiple sorters on different levels.Application Application Load Size, Shape and Weight Sizing the Chute Chute Angle Chutes are not sophisticated devices but there are many things to consider in the design The load being handled must be the first consideration. Loads that are short in length and tall in height can have difficulty negotiating chute transitions as they havea tendency to tip over. This can be minimized with good transitions and reduced angles. If the center of gravity is low, the height is less of a factor, but always design for the worst condition. If the loads have a wide variation in weights, be aware that heavy loads may damage light loads when accumulating. ‘The size and shape of the load, the distance to be traveled, and the elevation change are the main factors to consider when sizing chutes. When the load is presented to the chute in a controlled fashion, the chute can be narrower, maintaining the orientation. If there is the potential that the load will be skewed or spinning as it is presented to the chute, itis best to use a chute that is wider than the diagonal dimension of the largest load to be handled. FLOW > “\ SY Figure 1.10. Sizing a Chute ‘The angle of the chute is determined by load being handled, the speed of the load as it enters the chute, the material of the load, the material of the chute surface, and if the Joad will need to stop and restart in the chute. The general angles discussed here are based on steel chutes and corrugated card- board load surfaces. For each project, tests should be conducted to verify your design. During testing, remember that the chute surface may burnish or shine with time and will generally have a somewhat lower coefficient of friction (COF) after a period of use. When the load has significant speed as it enters the chute, the minimum angle should be 18°-20° below horizontal. This is for straight transportation-only (in other words, loads are not stopped or accumulated in the chute) If the load will be accumulated and/or stopped in the chute and will not have excessive contact with the side frames or guardrail, the angle should be at least 23°-25° below horizontal to allow the load to restart on its own.Chute Materials Environmental Considerations Controls When using guardrail to align or redirect loads, an angle of as much as 35° may be required to counteract drag and avoid sticking on the guardrail Caution: Do not angle the chute more than required to consistently move the load. The greater the angle, the faster the load will move. Large and/or heavy loads moving at excessive speeds can damage other loads or equipment, and may cause unsafe conditions. ‘Again these are general guidelines that need to be tested for each chute and product that you are designing for. For spiral chute angles that work best, please contact your spiral chute manufacturer. ‘* Unfinished mild steel— Provides a low COF, but will oxidize in areas where loads do not frequently travel. * Powder coated mild steel—An orange peel finish will have less friction than a smooth glossy finish. Teflon can be added to the powder-to reduce friction, * Stainless Steel —Preferced by some because there is no oxidation but is more costly than mild steel. « Fiberglass— Used extensively on spiral chutes because of the complexity of the chute shape, The fiberglass usually has a low-friction, wear-resistant coating, + Hard Maple —Was used in the past for its low COF and lack of splinters. Gener- ally cost prohibitive now. * Laminate— Has low COF but wears poorly over time. Tn non-ait-conditioned facilities or where chutes are located near dock doors, the characteristics of a load’s travel can change dramatically in a matter of a couple hours. ‘When humidity is high and air temperature rises quickly, chutes can “sweat” or collect condensation on their surface, This can slow some loads significantly, particularly cor- rugated materials, In testing, be sure to simulate such conditions to avoid problems later Tn some cases, sensors are required to detect the presence of product in chutes. If holes are put in a chute, they should be dimpled or bent so that the upstream side of the hole is further into the chute than the downstream side of the hole (Figure 1.1). This will minimize the potential of loads getting caught on the hole.Application Installation PHOTOEVE FLOW PHOTOEYE Figure 1.11 Dimpled Hole (top) and Bent Edges (bottom) When a chute s installed, itis important to verify that there is nothing that can impede the load’s travel. The chute should be level side-to-side unless load alignment to one side is desired. In some applications, itis necessary to polish the chute for a short period until the chute burnishes or shines to its lowest COR, Common furniture polish (such as Pledge’) can be used for this purpose. Maintenance Considerations Chutes should be inspected regularly. Inspections should verify that supports are rigid, fasteners are tight, welds are intact and there is nothing to interfere with load travel. Safety Considerations Chutes that have no moving elements (the vast majority) pose few safety hazards, One safety issue to be concerned with is that of the potential for loads to leave the chute and strike personnel at lower levels due to jams. Adequate guarding and netting must be designed into the application to avoid this possibility. Another concern is that of packages striking and injuring hands if personnel are operating at or near a chute discharge with a solid load stop. This relatively minor potential can be mitigated by education and posted warnings if deceleration means are not an option. By far the most difficult to avoid potential for personnel injury is the tendency for the uninitiated to attempt to climb or ‘walk on chutes. By definition, chutes are slippery and pitched so such behavior is very likely to result in a fall and injury, Reducing or avoiding this possibility where chutes are accessible is often accomplished by adding a low barrier making it difficult for personnel to enter the chute from the bottom area, Warnings and emphasis on the safety materials provided with the equipment are the keys to success (no accidents) in this area.CHAPTER 2 Non-Powered (Gravity) Conveyors Defi Design 12 Non-Powered Roller Conveyors #2 Carrying Rollers 13 Side Frames 14 Cross Ties (Bed Spacers) 14 Couplings 14 Non-Powered Skatewheel Conveyors 14 Skatewheels 15 Skatewheel Axles 15 Skatewheel Spacers 16 Side Frames 16 Cross Ties (Bed Spacers) 16 Couplings 16 Application. 1 Conveyability of the Product 16 System Layout 17 Determining Conveyor Width 12 Pitch Requirements for Gravity Flow 12 Other Considerations 19 Accessories 79 Technical Data 20 Maintenance Considerations 20 Safety Considerations 20Definition Non-powered conveyors are an economical choice for unit handling. Loads are con- veyed on rollers or skatewheels mounted in frames so that they are free to rotate. They are usually mounted so that the elevation of the conveyor decreases from the begin- ning of the conveyor to the end of the conveyor, and power to move loads along the conveyor is provided by the Earth’ gravity. Because of this, these types of conveyors are often referred to as “gravity conveyors’. Non-powered “gravity” conveyors may be used to move boxes, cartons, and totes with firm rigid bottoms. They may be used to convey loads for long distances using the above-mentioned “gravity” power. They may also be mounted in a horizontal position. In these cases, power to move loads is provided by an outside source, such as a human operator who pushes them along as required. Figure 2.1 Non-Powered Roller Conveyor System Design Non-Powered Roller Conveyors There are two basic forms of Non-powered conveyors—Non-powered Roller and Non-powered Skatewheel. ‘These are very simple in construction. The conveyors typically consist of sections that are connected together to achieve the required length, Unlike their powered counter- parts, straight non-powered roller conveyor sections are normally very similar except for variations in length. Curve sections are also used when it is necessary to alter the direction of the conveyor. 12Design Carrying Rollers A typical non-powered roller conveyor section will include the following components: * Carrying rollers * Side frames * Cross ties (bed spacers) « Butt couplings, splice plates, or other methods to connect sections to one another Carrying rollers vary in diameter from %” to 3%" or larger. Common sizes are 1%", 1.9”, and 2%” diameters. Smaller diameter rollers are lighter and usually less expen- sive, while larger diameter rollers can support heavier unit loads. Since the rollers do not turn constantly, the bearings used in the rollers can often be the less exper commercial-type bearings. Figure 2.2 Non-Powered Roller Conveyor Section Carrying rollers are evenly spaced along the length of the conveyor sections. The spacing used depends on product characteristics like size and weight. Itis good practice to have at least three rollers in contact with a unit at all times during transport to ensure stability of the unit. It is also important that the minimum number of rollers under the load can support the weight of the heaviest load being conveyed. Common roller spacing increments are 3”, 4”, and 6", Figure 2.3 Non-Powered Roller Curve with Tapered Rollers 13Side Frames Cross Ties (Bed Spacers) Couplings Non-powered Skatewheel Conveyors Curve sections may be supplied with “straight face” rollers (the same rollers used in straight sections) or tapered rollers, which are rollers made with tapered tubes. Tapered rollers provide a differential action to help keep unit loads oriented properly as they travel through the curve. Please see the roller chapter of this book for more detailed information about conveyor rollers. Side frames, also known as frame rails or side channels, provide the structural support for the carrying rollers. Side frames for non-powered roller conveyors usually have a channel shape (a “C-shaped” cross section). Angle type side frames, or frames with an angular cross section, are also common. They are typically formed from sheet metal, but some heavy-duty versions are made of structural channel or angle. SS ES Figure 2.4 Cross Section, Figure 2.5 Cross Section, Rollers Set High Rollers Set Low The rollers may be mounted in the frame in such a way that the upper-most por- tions of the rollers extend above the side frames. This is known as the “rollers set high” position. This position makes it possible for wider unit loads to extend past the frame width, and also makes it easy to load and/or unload the conveyor from the side. The rollers may also be mounted so that the side frames extend above the rollers. This is known as the “rollers set low” position, In this position the side frames can act as guide rails to help keep unit loads from falling off of the side of the conveyor. Gross ties hold the side frames apart at the proper distance to hold the carrying rollers. ‘They complete the structure of the conveyor frame, Cross ties may be made of formed steel or structural steel, and may be an angular, channel, or square cross section. They may be welded or bolted to the side frames, A minimum of two cross ties are used per conveyor section, with as many as 4 or 5 in a longer section. Couplings provide a way to connect the conveyor sections together into one complete conveyor. Coupling methods vary from manufacturer to manufacturer, as well as by purpose. Many light-to-medium duty conveyors use a hook-type coupling, which provides the advantage of easy setup and teardown. Other methods include bolt-in or welded-in “butt couplings,’ which allow the conveyor to be bolted together along it’s length, and splice plates, which help keep the side frames aligned. These conveyors are also simple in construction. Instead of using rollers to support and convey loads, this conveyor uses skatewheels mounted on axles. 4Skatewheels ‘Skatewheel Axles Design ‘A typical non-powered skatewheel conveyor section will include the following components, * Skatewheels * Skatewheel axles * Skatewheel spacers ‘* Side frames '* Cross ties (bed spacers) + Butt couplings or connecting hooks Figure 2.6 Skatewheel Conveyor Section ‘Skatewheels vary in diameter with typically the most popular being I"%o” in diameter. ‘The skatewheels are placed on axles mounted in the side frames and are separated on the axles by tubular spacers. Spacing between axles and horizontal spacing between skatewheels vary depending on the type and weight of loads being conveyed. This spacing is typically measured in the number of skatewheels per square foot of conveyor. There are many different types of materials used in the construction of the skatewheels, Some of the most popular materials include galvanized steel, aluminum, and various types of plastic. uy ia Figure 2.7 Cross Sec Mn of a Skatewheel Conveyor Skatewheel Axles are typically steel rods spanning across the conveyors on which the skatewheels are placed. One common size of skatewheel axle is "diameter,Skatewheel Spacers Skatewheel Spacers are generally tubular components located on the skatewheel axles Side Frames Cross Ties (Bed Spacers) Couplings and between the skatewheels. The length and quantity of spacers used is determined by the number of skatewheels required per square foot of conveyor. Just as side frames for roller conveyor provide the structural support for carrying rollers, the side frames for skatewheel conveyor provide the structural support for the skate- wheels and the skatewheel axles. Side frames for skatewheel conveyors usually have a channel shape (a “C-shaped” cross section). Angle type side frames, or frames with an angular cross section, are also common. They are typically formed from sheet metal or aluminum for light weight conveyors, Skatewheels may be mounted in the frame in such a way that the upper-most portions of the rollers extend above the side frames. This is known as the “set high” position. This position makes it possible for wider unit loads to extend past the frame width, and also makes it easy to load and/or unload the conveyor from the side. The skatewheels may also be mounted so that the side frames extend above the rollers. This is knownas the “set low” position. In this position the side frames can act as guide rails to help keep unit loads from falling off of the side of the conveyor. Cross ties hold the side frames apart at the proper distance tg hold the skatewheels. ‘They complete the structure of the conveyor frame, Cross ties may be made of formed steel or aluminum, and may be an angular, channel, or square cross section. They may be welded or bolted to the side frames. A minimum of two cross ties are used per conveyor section, with as many as 4 or 5 in a longer section. Couplings provide a way to connect the conveyor sections together into one com- plete conveyor. Coupling methods vary from manufacturer to manufacturer, as well as by purpose. Many light-to-medium duty conveyors use a hook-type coupling, which provides the advantage of easy setup and teardown, Other methods include bolt-in or wwelded-in “butt couplings,’ which allow the conveyor to be bolted together along its length, and splice plates, which help keep the side frames aligned. Application Conveyability of the Product Non-powered roller conveyors and non-powered skatewheel conveyors are popular choices for unit handling systems because of their low initial cost and low mainte- nance costs, simplicity, and relative ease of application. The following items should be considered when applying these conveyors. There are several factors that must be considered that relate to the actual product to be conveyed. 16Application * Weight: The weight of the unit loads being conveyed must be considered when choosing the rollers and frames to use. ‘The frames and rollers must be able to support the maximum weight that may be on the conveyor at one time. In the case of skatewheel conveyors, there must be a sufficient number of skatewheels per square foot of conveyor to support the load being conveyed. Product weight is also a primary factor in determining the ability to move and stop the unit load. Very light loads may require more “pitch,” or decline, to overcome the rolling resistance of the roller bearings when the conveyor is gravity-powered. Heavy loads, on the other hand, can accelerate rapidly if more pitch is used, requiring the use of speed control devices such as hysteresis brakes to reduce unit momentum. Skatewheel type conveyors are often chosen over rollers because there is less inertia to overcome. Therefore loads often may convey with less pitch or less force. * Condition of “bottom” surface: Generally, a unit load is conveyable ifthe bottom surface (the surface in contact with the conveyor rollers) is firm, flat, and long enough to span at least three rollers. Uneven surfaces, “feet,” chimes (ridges) or soft surfaces that tend to conform to the shape of the rollers or skatewheels are examples of non-conveyable bottom surfaces. + Other factors: Other qualities of unit loads being conveyed may affect the ap- plication. For example, ifthe loads are cartons containing fragile items, the pitch of the conveyor must be carefully selected to prevent inertia of the items within the container from damaging them. Another example is loads that might receive unwanted damage if they impact other loads. In some cases, factors such as these may eliminate gravity powered conveyors as a choice for the application. System Layout. _Asmentioned earlier, non-powered conveyors are typically used in two types of systems: + Level installations, where the loads are pushed by hand along the conveyor. This type of installation is often used in order picking, in-process assembly, testing, and packing areas. + Gravity flow installations, where the loads are moved along the conveyor by gravity. The conveyors are mounted at a downward pitch to allow this gravity flow to occur. Figure 2.8 Level Installation Figure 2.9 Gravity Flow Installation 7Determining The dimensional data of the unit loads to be conveyed are used to determine the Conveyor Width conveyor width required. Usually, a conveyor width is chosen that is slightly wider than .the widest unit load, In other applications it may be permissible to allow the load to overhang the sides of the conveyor slightly. (Of course, this may only be done when the rollers are set high in the frame.) In applications where curves are required, the width requirements of the curves generally determine the conveyor width used in the system. Between Rail Width (BRW) Formula BRW = (Inside Radius+ Package Width) «(Seow ~ Inside Radius +2” re 2.10 Formula for Determining Width Between Frame Rails (or Guard Rails) for Curves Pitch Requirements When designing the system layout care must be taken to determine the required angle for Gravity Flow of pitch for adequate flow. The degree of pitch needed depends on several factors, including: + The weight of the load. * The quality or firmness of the load’s bottom surface. + Type of lubrication in the rollers bearings. Grease packed bearings roll slower than lightly oiled bearings. * Other factors, such as the fragility of the load’s contents, ete. The elevations of critical points must be established when laying out the system. Ifa direct run of conveyor from the beginning elevation to the final elevation would result in too much pitch, a “loop” of extra conveyor may be needed to allow the pitch to be reduced to acceptable levels. 18Application <7 Figure 2.11 Complete Non-Powered Roller Conveyor System Other It is not uncommon for unit loads to stop due to friction on guard rails or for other Considerations _reasons. For this reason it is a good idea to provide access to the conveyor system so personnel can clear jams. Accessories ‘As with other conveyor types, there are accessories available for non-powered roller and skatewheel conveyors that enhance its functionality. These include the following: * Guard rails to guide the unit loads and prevent them from falling from the conveyor. * End stops to stop the loads when they reach the end of the conveyor system. © Retarding plates, hysteresis brakes, etc. to reduce the momentum of the loads. * Gates, to allow equipment and personnel to cross the conveyor system. + The rollers or skatewheels may be coated with a plastisol of*polyurethane coating to prevent marking or scratching of fragile items. * Other accessories, some unique to the application, may be used to provide the user with the optimum conveyor system. 19Technical Data Further detail on Non-Powered Roller Conveyor technical specifications can be found in the current version of CEMA Standard 401. The 401 standard includes detailed information on calculating roller bearing capacity and service life, roller shaft deflection calculations, and other important design parameters. Other CEMA standards that provide useful information include: * CEMA 102 —Terms and Definitions * CEMA 201 —Safety Label Brochure Maintenance Considerations Maintenance on non-powered/gravity conveyors is relatively simple compared to powered conveyors, In general the frames and rollers/skatewheels must be kept free of damage which could prevent free turning of rollers or wheels, Also the rollers must be kept free of foreign materials such as tape and labels that could adhere to the rollers thus preventing them from rotating freely. Safety Considerations Safety is as important with non-powered conveyors as it is with powered conveyor. Keep in mind that product located on declining gravity conveyors contain various amounts of stored energy depending on the degree of decline and load weight. Unit loads located anywhere on the conveyor, whether moving or not, contain stored amounts of energy; therefore, all loads should be removed or securely blocked from moving prior to performing any type of maintenance. All areas where non-powered conveyors interface with either powered conveyors or other machinery must be free of nip or pinch points. At no time should gravity type conveyors or other conveyors be used as seating surfaces, platforms, tables or as a means of climbing from one elevation to another. Please refer to the safety page of the CEMA website and the CEMA Safety Video for additional informatioy 20CHAPTER 3 Belt Conveyors Definition 22 Design 22 Intermediates 22 Drives 24 End Idlers 24 Powered Feeder 25 Nose-Over 26 «Carrying Belts 2s Take-Ups 26 Complete Conveyors 28 Application 29 Accessories 36 Technical Data 36 Maintenance Considerations 36 Daily Checks 37 Weekly Checks 37 Six Month Checks 37 Safety Considerations 37Definition Design Intermediates Belt conveyors are the most commonly used unit handling conveyor because they are usually the least expensive and simplest option to move a unit load from one point to another. They are used to convey unit loads in varying sizes, shapes, and weights. Since the conveying medium is a flat belt, these conveyors are capable of moving everything from well formed boxes, cartons, and totes to very flimsy bags and bundles. ‘Typically, belt conveyors are used to carry unit loads over long distances with a single drive motor, or to safely move them from one elevation to another. These are often referred to as incline belt conveyors when going from a lower elevation to a higher elevation, and as decline belt conveyors when going from a higher elevation to a lower elevation, Complete belt conveyors are typically built by attaching a series of pre-manufactured sections together to achieve long runs. In industry, these sections are called the following: * Intermediates * Drives id Idlers * Power Feeders » Nose-overs + Take-ups Power feeders and nose-overs are used only when a belt conveyor is used to move unit loads from one elevation to another. In its simplest form, a belt conveyor must have an end idler, a drive, and some form of intermediate sections. Intermediate sections are the simplest of the pre-manufactured belt conveyor sections. ‘They are the most common and make up the majority of the finished operable convey- or. Typical maximum section lengths are ten or twelve feet. Belt conveyors are gener- ally available in two different carrying surface designs, rollers and slider pans. Rollers as a belt carrying surface are often referred to as “roller bed” belt conveyor (Figure 3.1). The carrying rollers are evenly spaced along the length of the section. ‘The exact spacing of the rollers depends on product characteristics like size and weight; however, increments such as 3”, 4”, 6”, and 9” are frequently used. Intermediates with slider pans as a belt carrying surface are known as “slider bed” belt conveyors, The slider pans are typically formed steel pans that are either unpainted or made from a low friction material like galvanized steel. However, other low friction 22Design materials such as composite wood can also be used. The formed pans simply drop in between the frames and bolt into place (Figure 3.2). ———aaew ' ' ———O————— Figure 3.1 Roller Bed Cross Section Figure 3.2 Slider Bed Cross Section. Another variation of the slider bed belt conveyor is known as the “box bed” type of slider bed conveyor. The box bed is simply a steel sheet that is formed into the shape of the conveyor cross section (Figure 3.3). This design is typically very eco- nomical because there are fewer parts and the labor to assemble a conveyor section is minimized. It is also commonly used for carrying lighter unit loads such as empty corrugate and is often marketed as a light duty belt conveyor or a “trash” conveyor because itis frequently used to carry empty boxes to bailers for recycling. Figure 3.3 Box Bed Cross Section The roller bed and slider bed designs are made of two steel side rails with a cross tie welded or bolted between them to hold the required conveyor width. Both designs also have a lower roller, known as a return roller, under the carrying row of rollers or pans that is used to support the return run of conveyor belt. Figure 3.4 and Figure 3.5 show roller and slider bed assemblies without belt for clarity. The return rollers are typically adjustable in the direction of travel on both side rails. ‘This allows the rollers to be “skewed” (not square to the side rails) slightly to assist with belt tracking. Please see the chapter on conveyor belts for more detailed information about tracking belts, ~ ®&. Figure 3.4 Roller Bed Assembly Figure 3.5. Slider Bed AssemblyDrives End Idlers 24 ‘There are two basic styles of drives for belt conveyor known as end drives and center drives, End drives use a coated or “lagged” drive pulley that is usually located on the discharge end of the belt conveyor (Figure 3.6). Center drives (Figure 3.7) use the same drive pulley but are located on the underneath of the conveyor anywhere along the conveyor’ length, but typically near the discharge end The pulley is driven to a specified RPM (revolutions per minute) which translates belt movement into: linear feet per minute (FPM) movement. sure 3.6 Belt Center Di Figure 3.7 Belt Center Ds End drives and center drives each have unique features that make them ideal for certain situations. For example, end drives are typically less costly since they are smaller and directly contribute to the overall length of a conveyor. However, they cannot carry the load that a center drive can if internal components are similar, and often times the gap between the end drive and the next downstream conveyor can be so large that the minimum unit length conveyed must be increased so unit loads can transition between them without toppling or getting damaged, Drives consist of the main drive pulley and additional non coated pulleys that aid in directing the belt path through the drive assembly. Directing the belt path is required to ensure proper belt wrap around the drive pulley for optimum performance. The belt take-up is an adjustable pulley that can be moved to properly tension and “take-up” the belt as it stretches over time. Drive pulleys are driven toa design RPM through the use of motors, reducers, and sprockets or belt and pulleys. Another common type of drive is a motorized pulley that has a motor and gear reduction built inside the pulley. There are other devices some- times used along with motors and reducers that offer other benefits. Some of these are brakes, clutches, variable frequency drives (vfds), and soft starts/stops, Please see the chapter on conveyor powered motors for more information, End idlers in belt conveyors are often referred to as terminal ends because they are the section at the beginning and end of every belt conveyor where the belt moves from theDesign Powered Feeder carrying side to the return side (discharge end), or from the return side to the carrying side (infeed end). The main component in all end idlers is the end pulley. This pulley is usually not lagged; however, itis usually “crowned” in some fashion to help aid in belt tracking. Please see the chapter on pulleys for more details about pulley design. Some end idlers incorporate take-up pulleys similar to those found in a drive, while others allow the end pulley to move many inches parallel to the direction of travel to accom- plish this. Other end idlers, where added belt take-up is not required, are simply an end pulley with a snub roller (Figure 3.8) to assure optimum wrap around the end pulley. Figure 3.8 Belt End Idler Drive Powered feeder sections are used in most incline and decline conveyors as the section that transitions unit loads from level to incline or from decline to level. They are generally required when the slope exceeds 10°. It is usually adjustable in angle from about 0° to 25°, The powered feeder is typically very short combining a transition and an end idler in one sub-assembly (Figure 3.9), The level portion of the powered feeder often has its own belt and gets its power through a power take-off (PTO) arrangement from the adjacent incline/decline portion. Often the PTO is sprockets and chain, but belts and pulleys can also be used. ‘The two pulleys in the PTO are crowned in shape, often lagged with a high friction material, and purposely designed with a smaller outside diameter to minimize the gap between them thus allowing smaller unit loads to suc- cessfully make the transition from level to incline or from decline to level. Some ‘manufacturers use a fill device between the two pulleys near the carrying surface in an effort to allow very small unit loads to navigate through the transition. The PTO arrangement also uses different sized sprockets or pulleys to incorporate a speed change and build a small gap between two unit loads and minimize the likelihood of them touching as they move through the transition portion. Some powered feeders do not require a PTO arrangement and actually share a belt with the incline or decline portion. These are known as integral power feeders.Nose-Over Carrying Belts Take-Ups Figure 3.9 Belt Powered Feeder Figure 3.10 Belt Nose-Over Nose-over sections are used in most incline and decline conveyors as the section that transitions units from incline to level or from level to decline, It’s usually adjustable in angle from about 0° to 25° or 30°. The nose-over is typically very short consisting of two or three side frames per side fastened together in an overlapping fashion with a pivot bolt for the angle adjustment (Figure 3.10). The sole purpose of this section is to gradually transition unit loads into or out of steeply angled belt conveyor sections thereby minimizing the chances of tumbling. Unlike the powered feeder used at the lower end of belt conveyor assemblies that sometimes have their own contained belt, nose-overs are used at the upper end of belt conveyor assemblies and do not have their own belt. Rather, they share a common belt with the incline or decline portion of the belt conveyor as well as the drive and terminal ends. It is this belt that provides the power to the PTO on the powered feeder discussed earlier, ‘The conveyor belt is the carrying medium for all unit loads on belt conveyor. There are several different types of belts used in industry to accomplish a wide variety of objectives. Conveyor belts often have a different material and/or different construction on the underside than they do on the conveying side. Belt manufacturers commonly publish coefficients of friction of both sides of their belts on various materials such as bare steel, galvanized steel, and painted steel, The belts are usually cut to a width that is 31’ to 4” less than the width between the frames of the designed conveyor to allow for belt tracking, There are many factors that go into finding the right conveyor belt for a given application, but generally belt conveyors with changes in elevation use a rough top belt and level belt conveyors can use a less expensive smooth top belt. The rough top belt has a thick rubber like “spiked” or “ribbed” surface that holds unit loads while they traverse changes in elevation. Please see the chapter on conveyor belts for more detailed information. “Take-ups are required on all belt conveyors to account for belt stretch and keep a conveyor belt taught enough for it to move product and not slip on the drive pulley. ‘Take-ups are often built into drive assemblies on the low tension (return) side of the drive pulley. They can, however, be separate assemblies that attach anywhere along the return side of the belt (non carrying side or bottom) 26Design igure 3.11 Belt Take-Up ‘Take-ups are simply pulleys that have mechanical means of adjustment along the conveyor path. The belt is usually wrapped 180° around a take-up pulley, to gain max- imum belt take-up, 180° of belt wrap means that every 1” of take-up pulley movement takes up 2” of belt take-up (Figure 3.11). Different types of conveyor belts will stretch different amounts. A good rule of thumb for designers to follow is to allow for all belts to stretch 1%. In this case, a 100’ Jong conveyor would have approximately 200 of belt plus some extra to route through a drive and mechanical take-up. If we allow for 1% of 215' of belt, we would require a take-up pulley with approximately 13” of movement: 215" x 0.01 = 25.8" 25.8" + = 12.9" of pulley movement. Take-ups can be adjusted to remove the slack in the belt manually (usually with screws or threaded rod) on each side of the conveyor or some can be automatic. It is not uncommon to use air or springs connected to the take-up pulley to automatically take-up the slack in the belt as it stretches. Each side of the take-up pulley must be adjusted equally to keep it square to the frame which keeps the belt properly tracked. Different manufacturers employ different means to ensure both sides of take-up pulleys are adjusted equally. Very long belt conveyors may need more than one mechanical take-up to account for all the belt stretch. However, this may be cost prohibitive. In this case, designers can elect to install a “dutchman” in the belt. A dutchman is simply a short piece of belt around 3! to 5 in length that can be removed after all the take-ups are fully extended and can be adjusted no more. Then the two ends can be spliced together without having to cut and re-lace a belt end.Complete Conveyors Figure 3.12 Complete Belt Conveyor ‘Complete conveyors are simply made up of some or all of the aforementioned components bolted together to form a complete belt conveyor. The length and change in elevation of each design is limited largely by the capacity of the internal components, the motor and reducer combination, the weight of the moving parts, and of course the weight of the load being carried. All of these factors contribute to the overall load carrying capacity of every belt conveyor design. Figure 312 shows one example of what a complete belt conveyor incline or decline could look like. Notice it contains a center drive, a powered feeder, a nose-over, a pair of end idlers, and of course some intermediate sections indicating a roller bed design. ‘There are two other basic types of complete conveyors frequently used. They are brake belts and brake meter belts. Brake Belts are basically a short complete conveyor usually around five feet long, The length can vary, but its purpose is common regardless of length, Brake belts are used to hold product back from advancing or moving forward. Often times in system design it is necessary to accumulate units, hold them from release, and then discharge them at a specified speed or rate. The use of a brake belt provides more positive control of unit loads. “The brake meter belt (Figure 3.13) is really two short sections of complete conveyor next to each other with different speeds. They share one power unit and the slower belt feeds the faster belt. The slower belt is the brake portion, and the faster belt is the meter portion, The brake meter belt is designed to hold unit loads back and then pull a gap between them as they are released over the meter portion. The brake meter works in the same manner as the powered feeder except there is no change in slope. The speed change forces a gap between unit loads that traverse the conveyor. ‘This again provides for more positive control of unit loads and is often necessary when 28Design trying to intentionally build a gap between unit loads for equipment downstream, like sortation equipment for example. Figure 3.13 Brake Meter Belt Application — As previously mentioned, belt conveyors are a very economical method of conveying unit loads from one location to another. When the simplest form of transportation will do the job, belt conveyors fill the need. A few good rules of thumb for choosing belt conveyor are as follows: © When a unit load must be conveyed a long distance while utilizing few power units and accumulation of the product is not required. * When a unit load must change elevations quickly and/or remain stable and not topple. * When positive unit load tracking is needed. Meaning that a conveyor's control system needs to know the unit load’s location on the conveyor, + When unit load gapping is required to help with conveyor control. Figure 3.18 through Figure 3.25 show typical arrangements of belt conveyors. You will note Figure 3.18 and Figure 3.19 show arrangements without nose-over and/or powered feeder. They are also shown pitched at an angle of incline or decline. These figures show the most basic of belt conveyors, and the angle of incline or decline be from 0° (level) to approximately 20° depending on the characteristics of the unit load being conveyed. You will also notice that the only difference between the two figures is Figure 3.18 has a center drive, and Figure 3.19 has an end drive. So, if they both do the same things, how does a designer choose one versus the other in their application? It really all comes down to the following three questions: an 2930 1. Which drive unit will cost less? 2, Which drive unit can effectively convey the product? 3. Which drive unit will physically “fit” in my application? ‘An end drive assembly is usually less expensive than a center’ drive assembly. However, due to their design, a center drive that has the same pulley as an end drive can take more conveyor load. Therefore, longer runs of conveyor can be achieved on a single drive. In short, depending on the application, a center drive may be the most cost effective option. Table 3.1 shows some of the factors that come into play when making this decision, Table 3.1 Center Drive versus End Drive Design Decisions Center End Design Factor Drive Drive Most cost effective option for identical applications and footprint ey Large pulley load carrying capacity for long runs of conveyor “ on a single drive Short conveyables require a minimum gap from idlers to e adjacent conveyors Applications that require maximum clearance under an elevated conveyor @ Applications that require very low elevations v Applications where physical restrictions disallow a drive tobe located on, the exit end idischarge) of the conveyor Applications that require bi-directional travel Fa Also notice that all the applications in these figures showing the use of an end drive also show load travel in one direction, always toward the end drive. End drives are usually located on the very discharge end of the conveyor so they can pull the load along the conveying surface, They can, however, be located on the infeed end of the conveyor in very short conveyors. This is nota recommended practice because the belt will be pulled across the return rollers underneath the carrying surface and therefore pushed across the carrying surface itself Take note of the use of the powered feeders and nose-overs as well. Generally, powered feeders and nose-overs are required anytime the angle of incline or decline exceeds 10°, The nose-overs use the same belt as the incline or decline portion of the conveyor and simply allow a gentler transition, The powered feeders often have a much bigger role in unit handling since they can be used to induce gaps between products, Figure 3.14 for example shows how a powered feeder used in a decline arrangement pulls gaps between units as they transition from the decline portion toApplication the horizontal powered feeder portion, This is done through a speed change. The decline portion of the conveyor runs at a slower speed than the powered feeder portion. Thus when the unit load reaches the powered feeder, the belt pulls it away from the decline portion and induces a gap between itself and the unit load behind it. The amount of gap pulled depends on the speed differential between the decline belt and the powered feeder. Ideally, the speed difference should be large enough to keep the unit loads from touching one another as they make the transition. Decline Belt pulling gap Incline Belt pulling gap with powered feeder away from powered feeder oO Figure 3.14 Decline Powered Feeder Figure 3.15 Incline Powered Feeder In the case of an incline belt (Figure 3.15), the powered feeder would be running at a slower speed than the incline portion. The gap pulled between the units will then be on the incline portion, Another factor in designing a belt conveyor is determining the best angle of incline or decline. When designing inclines and declines it is important not to make the angle steeper than the product can accommodate. A maximum slope of 25° has been proven to be a good practice for handling most unit loads. The rela- tionship of height to length of a unit load is important in determining the maximum slope it can traverse without toppling. ‘The safe rule is to make the slope such that a perpendicular line drawn through the center of gravity of the unit load will fall within the middle % of its length (Figure 3.16). \ ay, Figure 3.16 Calculating Safe Incline/Decline Angle Designers must also choose between a roller or slider belt supporting surface. Slider pans are made of low friction materials such as galvanized steel, but it still takes more horsepower to pull a belt across slider pans than it does to roll it across carrying rollers. Generally, slider pans are used for decline belts and rollers are used for incline belts. The additional friction between the belt and the slider pans adds resistance to 3help keep unit loaded belts from moving in decline units since unit load weight will often make it harder to hold a belt in place. In these applications it is very common to use a brake motor to stop and hold the decline belt in place. Brake motors are simply an ordinary electric motor with brake pads attached that automatically engage on the rotating motor shaft when power is removed. It's a good idea to make certain that loads are not allowed to move without power to the motor for safety sake and to allow programmers to accurately control the conveyor: Brake motors are also very commonly used for incline conveyors as well to keep loads from moving backwards down the incline, In addition to electric brake motors, air clutches and/or brakes may be used to achieve the same effect. They work in the same manner, only they use air for their energy source rather than electric. Design considerations for roller bed versus slider bed carrying surfaces are shown. in Table 3.2 below. Table 3.2 Roller Bed versus Slider Bed Design Decisions Roller Slider Design Factor Bed __Bed Most cost effective option for identical applications and footprint v Large load carrying capacity for long runs of conveyor on a single drive e Minimize horsepower requirements, especially for incline conveyors ae Most decline conveyors a Applications where unit load stability is very important— y, scanning, labeling, et. Applications where heavy unit loads will be placed on e the carrying surface Applications where unit loads can be very small and fall between ? rollers or get damaged Another common application for brake motors is use in brake meter belts. As mentioned earlier, these conveyors are used to separate unit loads and put a predeter- mined amount of gap between them, Most sortation conveyors and transfers require unit loads to be gapped toa minimum distance in order to sucessfully divert or transfer. ‘The brake meter belt does this with good accuracy. The length of the gap is dependent upon the speeds of each of the belts and the length of the unit load. 32Application Resulting Gap Figure 3.17 Gapping a For the example in Figure 3.17 let’s say the customer requires 30 UPM (units per minute) to be delivered through the brake meter belt and get gapped to a minimum of 9”, We have unit load characteristics as follows: ‘Average Load Length = 24" Minimum Load Length = 12" Maximum Load Length = 30” To calculate the minimum speed of the brake belt or Belt “A” to meet the required rate of 30 UPM, we use the average unit length. Avg Load Length (inches) Speed Belt A= et Tin /fexupm 24 Speed Belt A=— 4 ai 12x30 ‘Speed Belt A=60 fpm To calculate the speed ratio of the meter belt and acquire the speed of Belt “B, ‘we use the minimum unit length, the required gap, and the speed of Belt “A”. Minimum Load Length+ Gap Ratio= LN ee Speed Ratio=2*9) Speed Ratio=1.75 Speed Belt B( fm) = Ratio Speed Belt A Speed Belt B( fpm)=1.75%60 fpm Speed Belt B( fpm)=105 fpm ‘The speeds designed will always ensure that there is at least a°9" gap between all loads. Longer loads will have a larger gap when running across a brake meter belt with 1.75 speed ratio, but the required rate of the average load length will be met. Itis obvi- ous that it is critical to get actual load length data when designing a system. 33Belt Conveyors END IDLER CENTER DRIVE WITH TAKE-UP Figure 3.18 Simple Belt Conveyor with Center Drive END DRIVE WITH TAKE-UP END IDLER, ep eve UiTW ake-uP eo UE —< center ceive yin TaxeoU ep 10LER POWERED FLEDES, Figure 3.21 Belt Conveyor with Center Drive and Power FeederApplication nose-over END IDLER CENTER DRIVE WITH TAKE-UP Figure 3.22 Belt Conveyor with Center Drive and Nose Over 0 pelve mice PONERED FECEER rose-over _ SOC ‘cevter senve 8 Cine rater 3 sims rowerey Feng a ; 5 Figure 3.24 Belt Conveyor with Center Drive, Power Feeder and Nose Over Figure 3.25 Belt Conveyor with Power Feeder, Nose Over and end Drive 35Accessories ‘There are some accessories that designers have used in conjunction with belt conveyor that have proven to be very helpful in certain applications. ‘Turning posts, wheels, or rollers are very common and help safely guide loads around corners onto or off of a belt conveyor: Fixed or swing arm deflectors are also used to guide product off of or onto a belt conveyor. These types of accessories are used to maintain control of unit Toads and safely and effectively move them from one conveyor to another. It is also very common to see installation personnel use channel type or rail type le guides to “funnel” product or steer it to the middle of or one side of a belt conveyor, When trying to move a load on a belt conveyor it is critical to consider the fric- tion of the belt to the unit load. For example, when trying to divert a load off of a belt conveyor using a fixed deflector, a designer should consider belts that allow the unit load to slide freely enough so they can slide on the belt without affecting the tracking of the belt. A tacky belt in this type of application will often make a belt very hard to keep tracked, and could very easily cause damage to the belt and/or unit loads. Technical Data Further detail on Belt Conveyor technical specifications can be found in the current yersion of CEMA Standard 402. The 402 standard includes detailed information on calculating horsepower for belt conveyors and some additional design parameters to be aware of, There are also other CEMA Standards that will help in further under- standing belt conveyor. These include: * CEMA B105.1—Welded Steel Conveyor Pulleys. * CEMA 102 — Terms and Definitions * CEMA 201 —Safety Label Brochure Maintenance Considerations ‘There are many items to consider for the safe operation and continued maintenance of belt conveyors. Some of these are belt tracking, belt condition, belt lacing, loose debris, unusual noises, etc, The following is a good guide often used in an end users preventive maintenance program to assure a safe operating belt conveyor. Most original equipment manufacturers (OEM’s) include recommended maintenance schedules, procedures and resources for documentation with all equipment they manufacture and ship. ‘Always follow these recommendations and directions. In the absence of specific manufacturer's maintenance information, use the following schedule. 36Maintenance Considerations Daily Checks ii Weekly Checks L 2, Six Month Checks 1 While conveyor is running listen for abnormal noises that could indicate worn bearings in rollers, motors, reducers, ete. With conveyor shut down and locked out, look for and remove foreign material wrapped around rollers, bearings, and shafts. With conveyor shut down and locked out, look for metal shavings or belt dust under the conveyor. This typically indicates misaligned or damaged components. With conveyor shut down and locked out, look for oil leaks near the reducer and near every roller axle. With conveyor shut down and locked out, visually inspect belts and rollers for ‘wear, improper alignment, or buildup of foreign materials and repair and/or clean as required. While conveyor is running watch all belts for several revolutions to make certain they are tracking between the frames correctly. Track belts according to the manufacturers recommendations. While conveyor is running, visually inspect all motors. Take temperature readings with an infrared thermometer if available. Motors and reducers run- ning at higher than normal temperatures often indicate a failing component in some part of the conveyor. With conveyor shut down and locked out, clean and lubricate all drive chains according the manufacturers recommendations. With conveyor shut down and locked out, check all set screws and tighten as necessary as these may work loose during normal operation. With conveyor shut down and locked out, check all bolted connections and tighten as necessary as these may work loose during normal operation. With conveyor shut down and locked out, check belt tension and adjust per the manufacturers recommendations. Safety Considerations Installation and Maintenance shall be performed only by qualified and trained personnel. When ‘a conveyor is stopped during installation or for maintenance, starting devices or powered accessories shall be locked or tagged out in accordance with a formal proce- dure designed to protect people against an unexpected start. Personnel,should be alerted to the hazard of stored energy, which may exist after the power source is locked. out. Refer to: 37* ANSI 2244.1 1982, American National Standard for Personnel Protection — Lockout/Tagout of Energy Sources — Minimum Safety Requirements, and OSHA Standard 29 CER 1910.147, “The Control of Hazardous Energy (Lockout/ ‘Tagout).” CEMA provides industry adopted safety labels used by most OEMS and are typically applied to the equipment before it ships from the OEM's factory. Refer to the safety page on the CEMA website (www.cemanet.org) for the CEMA safety labels link for an all inclusive list of available safety labels. The website also contains a label place- ment guideline which identifies where labels are typically applied by product type End users can also call theit OEM or contact CEMA for a CEMA safety poster which is to be displayed in operator areas where unit handling equipment is commonly used. 38CHAPTER 4 Belt Curve Conveyors a ts 48 Determine Incline for Helix Curves e Accessories 49 Technical Data 50 Maintenance Considerations soDefinition Belt conveyors are the most commonly used unit handling conveyor, but basic belt conveyors only move loads in a straight line, When a change in direction to the left or to the right is required, a Belt Curve conveyor can be used. Like straight belt conveyors they are used to convey loads in varying sizes, shapes, and weights. Since the conveying medium is a flat belt, these conveyors are capable of moving everything from well formed boxes, cartons, and totes to very flimsy bags and bundles. Belt Curves, however, are not recommended for bulk material applications. Belt curve conveyors are typically flat, operating at a single elevation and can be supplied in almost any arc depending on system layout constraints. Typically all flat turns have a single drive, When elevation change is required, whether up or down, a helix or spiral belt curve is used. Typically, each belt curve has a single drive for up to 180°, Ifa larger turn is required it is broken into multiple units, For some Spiral belt curves, depending on outside conveying radius (discussed below) and product loading, arcs as high as 450° have been achieved. Design Frame Construction Belt curve conveyors are typically shipped as complete units. Due to logistical reasons belt curves can be made in multiple sections. The rarity of this does not require a distinction be made between drive and intermediate sections. Therefore, this chapter will be discussing complete curves units. Belt curve conveyors are categorized into several size groups based on the outside radius of the conveying surface. A up to47” (up to 1,200 mm) B >47” to 59” (1,20. mm to 1,500 mm) Gi 59" to 87” (1,501 mm to 2,200 mm) DorS over 87" (over 2,200 mm) Some manufacturers offer only a limited number of outside radii coupled with choices of belt widths. For instance; they may offer a 1,500 mm outside raclius with 600 mm, 800 mm, or 1,000 mm belt widths. Other manufacturers offer virtually any radius and belt width combination, Depending on the manufacturer virtually any radius and belt width combination is available. There are some geometric limitations such as pulley diameter that will be discussed later. While straight belt conveyors are available as either slider bed or roller bed; belt curves almost always utilize a slider bed concept, The sliding surface is typically a low-friction surface, unpainted steel, galvanized steel or phenolic-impregnated wood composite. 40Drives Design In instances where reduced friction in heavy load applications is desirable, rollers are used in conjunction with the slider bed. There are several prominent frame design types. The first and most common is, a welded steel frame. The majority of manufacturers use this type because it is the easiest to manufacture. With the inside and outside frame members welded to the top plate to create three sides of a box frame (Figure 4.1). This type of frame also lends itself well to stainless steel wash-down applications due to the sealed box structure, Stainl ss Steel is the material of choice in these applications, Figure 4.1. Welded Steel Frame The next frame design is the open frame (Figure 4.2). The open frame can be cither welded steel or extruded aluminum. The open design allows for easier visual inspection and access to some service parts. Peas Figure 4.2 Open Frame ‘The primary drive types available on belt curves are friction drive, pinch drive and the chain drive. The friction drive directly drives the belt the same way a straight belt conveyor drives the belt. Conveyors that utilize a friction drive are engineered with pulleys tapered to exacting tolerances to ensure good belt traction. Friction drives can operate reliably at high speeds, such as 600 FPM (feet per minute) or higher. The belt ofa friction drive typically has a guiding element added to the outside periphery. This guiding element can be a series of bearings or a guide bead. The guide bead is typically sewn on aBelts and provides much quieter operation than that of the bearings. Although not recom- mended, friction drives can be used to push the belt rather than the typical arrangement _of pulling the belt through the curve, The pinch drive squeezes the belt between two rotating wheels. This drive allows for looser tolerances on the tapered pulleys because they are simply used to track the belt. Pinch drives typically have the lowest driving capacity of the three types. Like the friction drive the belt typically has a guiding element added to the outside periphery. ‘An advantage of the pinch drive is that it can be reversed without modification to the conveyor. Pinch drives are typically located at the center of the outside arc so when the travel direction is reversed it is never pushing the belt through the curve. ‘The chain drive pulls a chain or other transmission device that is attached to the belt and pulls the belt along with it (Figure 4.3). Chain drives are more forgiving of the tolerances of the tapered pulley. Chain drive can pull heavier loads that either the fric- tion or pinch drive, and can operate reliably at high speeds such as 600 FPM or higher. Chain drives that utilize side-bow chains as the driving force require that the chain, drive sprockets and/or the chain guide be lubricated regularly to maintain optimum operation and minimize wear, Chain drive can be used to push a belt depending on speed and loading requirements. Figure 4.3 Side Bow Chain On straight running belt conveyors itis preferable that the belt be stiff across the width of the conveyor to keep product from getting under the edges of the belt. These belts utilize a mono-filament weft and multi-filament warp (Figure 4.4), Curved belts, however, require what is referred to as a balanced weave. When a curved belt is cut from a roll of belting the resulting piece has the warp and weft pointing in different orientations throughout the arc of the belt (Figure 4.5). Because the mono-filament weft stretches differently than the multi-filament warp, a balanced weave typically employs a multi- filament construction for both the warp and the weft. (see the chapter on belting in the Components section of this book) 42,Design Beading Figure 4.4 Straight Conveyor Figure 4.5 Curved Conveyor The belt design is closely tied to the frame design and drive type. Due to the basic principles behind a belt curve, the belt has a natural tendency to pull toward the center. ‘An integral part of the belt design is how the belt is held in place. The primary belt design options include three primary choices: beading, chain, or bearings. This design utilizes a urethane bead that is sewn onto the outer perimeter of the belt (Figure 4.6). This is typically used with friction or pinch drive designs. The beading is held.to the outside through a series of bearing holders. With this design there is a close relationship between the beading and the belt. It is important that the belt be of a design that has a balanced weave and tracks well through the curve. 43Chain As shown in Figure 4.7 the chain drive design has the chain attached to the belt through a series of rivets, The chain travels through a guide track that holds it out at the proper radius. Figure 4.7 Chain Bearings Finally, the third popular variation is a series of bearings attached to the belt around the outer periphery (Figure 4.8). The bearings are generally bolted on either side of the chain through a hollow rivet or grommet. As with the beading design, this is typically used with the friction or pinch drive designs. Figure 4.8 Bearings aPulleys Design The beading design, while offering the quietest operation does have limitations when handling particularly heavy loads. The chain design, along with the bearing version, offers the highest load handling capacity, but may not be as quiet as the beading design at higher speeds. Because the chain and bearing designs actually hold the belt in place and have little dependence on belt tracking, it is important that the chain or bearing guidance system be robust. Belts can be either endless with a vulcanized splice or can utilize a lacing, The lacing method simplifies belt replacement, while the endless belt ensures a continuous surface with no catch points. Pulleys on belt turns are typically tapered to match the radius of the curve. The taper is designed to ensure proper belt tracking. The pulley can be made in a variety of ways and from a variety of materials, Below is alist of various pulley constructions + Roll-formed tapered steel * Cold-formed steel © Cast urethane * Machined urethane In the case of the steel pulleys a rubber or urethane lagging may be added for drive pulleys for additional traction on friction driven turns (Figure 4.9). eeu Lagging Figure 4.9 Lagging Added to Pulley Chain drives require that a sprocket be added to the same shaft as the pulley to drive the attached chain or other power transmission device (Figure 4.10). 45Figure 4.10 Chain Drive Application Determine Curve Radius and Belt Width ‘The width and radius are selected based on the longest and widest unit load to be handled. Below is a formula to determine the spacing required between the sideguards or the belt width (Figure 4.11), BF =, |(Radius+ Package Width) + ) (Radius +1) LENGTH 1” CLEARANCE ] | PACKAGE wioTH DISTANCE BETWEEN SIDEGUARDS = BF RADIUS NY Figure 4.11 Curve Radius and Belt Width 46Determine Drive Type and Location Application Drives can be either shaft-mounted or base-mounted, Shaft-mounted drives are less expensive and are lower maintenance than base mounted drives. The primary drawback is that speed changes require a gearbox change, not just the sheaves and drive belt. The speed of conveyors with shaft-mounted drives is limited by the available output RPM (revolutions per minute) of the gearbox. More recently end users have begun using variable frequency drives to control motor RPM. Thisallows using the simplicity of the shaft mount drive in wider applications Base-mounted drives are available in a variety of configurations; under slung, under hung, and side-mounted (Figure 4.12). The primary difference between under slung and under hung is that with under hun gs from the mounting plate and with the under slung drives the drive rests on top of the mounting plate. The drives the drive ha side-mounted drive is useful when space under the curve is limited. Side Mounted Drive Figure 4.12 Drive Mounts 47Determine Horsepower Requirements Determine In for Helix Curves Drive location is typically referred to by a two-letter designation (Eigure 4.13): * L1= Belt travel to the left, drive on the inside * LO = Belt travel to the left, drive on the outside * RI-= Belt travel to the right, drive on the inside * RO = Belt travel to the right, drive on the outside LO LOCATION RO LOCATION LILOCATION RILOCATION Figure 4.13 Drive Location Each manufacturer has their own proprietary horsepower calculation. ‘This is due to the fact that the drive type as well as whether the curve is a flat or helix greatly affects the calculation. Just like straight belt conveyors there are limitations to how steep a helix belt curve can be. A good rule of thumb is that the angle of incline at the inside radius should not exceed 18°, This may increase or decrease depending on the type of belt used, the radius of the curve as well as the physical characteristics of the unit load itself. ‘The angle is always steepest at the inside radius. Use the formula below (Figure 4.14) to determine the angle of incline: Below is an illustration that shows how to determine the maximum angle of in- cline that a unit load can handle without toppling, The relationship of height to length of a unit load is important in determining the maximum slope it can. The safe rule is to make the slope such that a vertical line drawn through the center of gravity of the unit load will fall within the middle ¥ of its length (Figure 4.15) 48Application a@=arctan| —HD _ =arel axnixA 360 \ Figure 4.14. Angle of Incline Length Height —T Treline/ Decline Angle Figure 4.15 Maximum Angle of Incli ‘Typically Belt curves are used for transportation. Therefore, the accessories available are primarily concerned with improving unit load handling. Transfer brushes and pop-out rollers are two accessories that help support unit load as it transitions from ‘one conveyor to the next. Side guards are very common and are most frequently made from formed and rolled sheet metal. Channel type and extruded UHMW (Ultra High Molecular Weight Polyethylene) have also been used to guide unit loads on belt curves. Under guarding is used when personnel need to be protected from coming into contact with moving parts. The materials most often used are: expanded metal, plastic mesh or solid sheet steel 49Technical Data ‘Although there are no CEMA Standards that apply strictly to Belt curves there are other CEMA Standards that will help in further understanding belt curves. These include: * CEMA 102— Terms and Definitions + CEMA 201 —Safety Label Brochure Maintenance Considerations Preventive Maintenance must be performed only by qualified individuals who are trained in the operation of the conveyor and who are knowledgeable of all safety devices, their locations, and functions. The safety information section should be reviewed before performing any maintenance tasks. Recommended service checks and equipment maintenance presented by the man- ufacturer are usually general in nature and more specific tasks should be developed for your particular use of the equipment, All newly installed equipment should be closely observed during the first period of operation; thereafter, an appropriate maintenance program should be established and followed. ‘Maintaining separate service log sheets on each type of conveyor is recommended, particularly for plants operating more than one shift. Each log sheet should show dates, detailed inspection service information, and name or initials of person performing the inspection o rvice. PENS Before performing maintenance on a conveyor, verify that the conveyor’s power disconnect is locked in the OFF position to prevent accidental or unexpected application of power. Do not perform maintenance while the conveyor is running unless specifically instructed to do so in the manufacturer’s manual. It is recommended that a regular PM inspection schedule is established to monitor Maintenance (PM) the condition and operation of the conveyor to ensure proper performance, reduce downtime, and promote long component life.CHAPTER 5 Plastic Belt and Chain Conveyors Definition 52 Design 54 Intermediates 54 Drives 55 End Idlers 57 Take-Ups 57 Transitions 57 Application se Length and Width Requirements 59 Belt or Chain Selection «o Drive Type 60 Transition Requirements 60 Accessories 61 Technical Data 61 Maintenance Considerations 63 Safety Considerations 63Definition Plastic belt and chain conveyor, like traditional Belt and Chain conveyor, transports product directly on a continuously moving closed loop surface, The basic conveyor consists of a drive (usually located at the discharge end), intermediate section(s), and infeed idler section. Plastic chain is used primarily for handling narrow products but can also handle wider products when multiple strands are employed. These chains are constructed similar to steel chains where individual links are connected by pins to allow the chain to flex around the end idlers and form a closed loop. A single sprocket is employed at each end of the conveyor to guide each strand of chain to and from the return side, The conveying surface consists of wings or flights that are typically molded to the top of the chain links. The flights are supported by guides or tracks, which straddle the chain in the center. Most plastic chains are side flexing which allows them to go around curved sections of conveyor. Hold down tabs are typically molded to the bottom of the chain links to prevent them from coming out of a curved track under tension (see Figure 5.1). Plastic belt has @ uniform cross section similar to a traditional belt and can be purchased in a wide variety of widths. Narrow belts are typically molded to width (see Figure 5.2) while wide belts are constructed from modular pieces that are inter~ woven in a brick like pattern, Pivot rods are threaded through each segment of belt to connect them together. A wide variety of conveying surfaces are available in plastic belt. Some belts havea smooth solid surface (see Figure 5.3) while others have an open grid (see Figure 5.4) to allow dirt and debris to fall through. Some have a low friction surface and some have high friction rubber pads (see Figure 5.5) or cleats molded into the surface for inclines, declines, and brake belt applications (see chapter on Belt Conveyor for more details). Belts with small plastic rollers imbedded or attached to the conveying surface are also available in a variety of configurations. The most common configuration employs in-line rollers (see Figure 5.6), which allow product to back up or accumulate on the conveyor with minimal line pressure. This is sometimes referred to as low pressure accumulation. Another configuration employs transverse rollers (see Figure 5.7), which allow product to be easily transferred on or off the belt from the side of the conveyor. This type of belt is commonly used for right angle transfer applications using a pusher or puller, It can also be used for merge or divert applications that employ a swing arm or fixed deflector. Belts with rollers mounted at a 30° and 45° angle to the direction of travel are a recent development in plastic belt technology (see Figures 5.8 and 5.9), Unlike in-line and transverse rollers, which are passive or non-powered, angle rollers protrude below the bottom surface of the belt and are activated by the conveyor bed. Angle roller belts can be used for a wide variety of applications such as product justification (i.e. skew and herringbone sections), merging, diverting, so and singulation 52,Definition Figure 5.1 Plastic Chain (side flex) Figure 5.2 Plastic Belt (molded to width) Figure 5.3 Plastic Belt (smooth top) Figure 5.4 Plastic Belt (open grid) eve 4 2.2818) t (O'S) nny aaa E 12 21S) Figure 5.8 Plastic Belt (30° angled roller) Figure 5.9 Plastic Belt (45° ape roller) 33Most plastic belts are straight running, however some side flexing belts (see Figure 5,10) for curved sections are available. Recent design improvements have increased sthe belt pull capacity for some side flexing belts allowing them to gain popularity over plastic chains. Design Intermediates Most plastic belt and chain conveyors used for package handling are assembled at the job site with the following components: « Intermediates (straights and curves) * Drives (end or center) * End idlers + Take-ups * Transitions * Plastic belt or chain Straight sections can be constructed in a similar fashion to traditional belt conveyor. "The side frames are typically made in 10’ or 12’ lengths and are joined together with slider bed pans and/or crossties to obtain a desired width. In most cases, wear strips made from polyethylene (UHMW) or nylon are fastened to the top of the slider pan to reduce friction and wear on the chain. A polyester belting material is used in place of wear strips for belts with angled rollers, which also require side guide wear strips. Slider pans with wear strips can also be used to carry the return belt, but return rollers with rubber or urethane sleeves are generally preferred (see Figure 5.11). Since most plastic belt and chain manufacturers publish specific guidelines for wear strip and return roller configurations it is always best to follow their recommendations. 54Drives Figure 5.11 Return Roller with Rubber Sleeves Curved sections are constructed by forming an inside and outside side frame to a desired radius and degree and joining them together with crossties to obtain a desired width: Curved tracks made from polyethylene (UHMW) or nylon are generally used. for the carryway and returnway of the curve to support, guide, and retain the side flexing belt or chain. 'The tracks can be attached directly to the crossties (typical for chain) or to the side frames (typical for belt). Special consideration must be given to high speed or heavy load applications to avoid exceeding the pressure-velocity (PV) limit for the belt/chain or track material. Exceeding the PV limit causes heat buildup and accelerated wear. Generally, an Acetal belt/chain with a Molybdenum-filled nylon (ie. Nylatron) track works best for curve applications. End drives are generally preferred over center drives for plastic belt and chain conveyors. ‘They usually are more economical since they also serve as an end idler. The typical end drive section consists of a short frame with a carry way for the belt or chain, a drive shaft assembly (see Figure 5.12), and a return roller or guide. The drive shaft is supported by bearings and extends out on one side of the frame to attach the drive. ‘The drive can be a roller chain or timing belt from a gearmotor (see Figure 5.13) ora shaft-mounted gearmotor. Sprockets specifically designed to work with the plastic belt or chain are assembled to the drive shaft. Refer to the manufacturer's guidelines for the type and number of sprockets required. Sprockets are typically available in both round (see Figure 5.14) and square bores (see Figure 5.15). Square bore sprockets have the advantage of not requiring a key but must be held in position with special square bore shaft collars or retaining clips, For belts requiring multiple sprockets, usually only the centermost sprocket is locked in place and the 55Plastic Belt and Chain ConveyorsEnd Idlers Take-Ups Transitions Design others are allowed to float on the shaft. Wearstrips or chain track should extend out near the centerline of the drive shaft to prevent the chain from sagging as it enters the sprocket(s). Refer to the manufacturer's guidelines for the correct location of the return roller or guide. Figure 5.16 Center Driven Conveyor Center drives (see Figure 5.16) are generally reserved for applications requiring small end idlers or bi-directional travel, They usually are designed to attach to the bottom of an intermediate section allowing them to be located down and away from the ends of the conveyor. The typical center drive section consists of a frame, a drive shaft assembly, and two heavy-duty snub rollers capable of withstanding the drive sid¢ tension of the belt or chain, The drive shaft assembly and the drive are the same as that for an end drive. End idler sections are usually constructed in a similar fashion to end drive sections. The drive shatt is replaced with an idler shaft, which does not extend out to one side of the frame unless a slave drive will be attached to the upstream conveyor. A round idler shaft is recommended, particularly if more than one strand of belt or chain will be employed. Only the sprocket(s) for one strand should be keyed to the shaft. This allows the other sprocket(s) to adjust to slight differences in pitch length between each strand. The floating sprockets are axially held in place by set collars. Like traditional chain conveyors, a catenary take-up is preferred for plastic belt and chain conveyors. This type of take-up simply uses the weight of the unsupported belt or chain between the return rollers or guides to create back tension. In addition to its simplicity, a catenary take-up is less likely to cause over-tensioning and will automati- cally adjust for stretch. To function properly, the catenary take-up should be located on the slack side of the drive shaft assembly, usually between the first and second return roller or guide. The design requirements for the catenary take-up will depend on the length of the conveyor and the type of belt or chain that will be employed. Refer to manufacturer's guidelines for additional information. Most plastic belts and chains used for unit handling require relatively large end idler sprockets to minimize chordal action. The resulting gap between conveyors may be too great for small cartons to transition. ‘Transition plates (also called gap, filler, or dead plates) are commonly used to fill this void, ‘They are relatively inexpensive to produce and when properly designed, will not create pinch point hazard with the belt 37Plastic Belt and Chain Conveyors or chain. ‘Typically, gap plates are positioned slightly below the conveying surface to minimize contact with the product. A low friction material such as UHMW is also cused to reduce drag. ‘Transition rollers (also called gap or filler rollers) are generally preferred for short, heavy, or unstable cartons to minimize drag. They can be powered or non-powered and must be designed to pop-out of the frame to alleviate the pinch point hazard with the belt or chain, Additionally, they must be leashed to the frame on overhead applica- tions to prevent them from falling on someone below. Application ‘As mentioned in the Definition section, plastic belt and chain conveyors can be used in a wide variety of applications. Some of the most common applications are listed below: * Transportation — straights and curves (belt or chain) # Inclines/declines (belt or chain —high friction) + Brake/meter belts (belt or chain —high friction) + Accumulation (belt— in-line roller) «Transfers (belt— transverse roller) + Skews/herringbones (belt—angled roller) (see Figure 5.17 and 5.18) Figure 5.17 Skew Section (Case Alignment) Figure 5.18 Herringbone Section (Case Centering) * Wide merges (belt— transverse or angled roller) * Diyerters (belt — transverse or angled roller) * Sorters (belt —angled roller) * Singulators (belt—angled roller) (see Figures 5.19, 5.20, and 5.21) 58Application Many factors must be considered when selecting a design configuration for a plastic belt or chain conveyor. Proper selection must be based on the product or products being handled, Some important items to consider are as follows ‘+ Length and width requirements * Belt or chain selection * Drive type * Transition requirements Figure 5.19 Singulator (Case Induction) _Figure 5.20 Singulator (Case Separation) Figure 5.21. Singulator (Case Alignment) Length and Width When physical space is not a factor, the length of a plastic chain conveyor is generally Requirements limited by the allowable chain pull capacity or the slip-stick effect. This phenomenon, also known as chain surge, is somewhat unique to plastic belt and chain conveyors. It occurs when the initial tension of the belt or chain is insufficient to overcome the static friction with the conveyor bed or carryway. Like a spring, the elasticity of the belt or chain allows tension to build up until it breaks free and surges forward, This in turn relaxes it causing the cycle to repeat itself. Allowing the belt or chain to:surge in this manner can cause problems such as product instability, sprocket disengagement, and wear. Long, slow-moving conveyors are the most likely to experience the slip-stick effect. To avoid this problem, some plastic belt and chain manufacturers will specify a maximum allowable length for a conveyor. 59Plastic Belt and Chain Conveyors Conveyor width is normally determined by the widest product to be handled, however, additional width may be needed to negotiate curved sections (refer to chapter __ on Powered Roller Curves for additional information). Special consideration must be given to singulators so that side by side cartons will have sufficient space to rotate freely on the angled roller belts. Belt or Chain The type of plastic belt or chain best suited for a conveyor will depend on the application, Selection product, and environment, Some of items to consider when making a selection are listed below: * Belt or chain width * Belt or chain strength, * Minimum sprocket size © Erict al characteristics with product + Operating temperature * Straight running or side flexing * Solid surface or open grid © With or without rollers A choice of materials is usually available for most plastic belts and chains, The type of material will generally affect the strength, frictional characteristics, and operating temperature. Some of the most commonly used materials for plastic belts and chains are polypropylene, polyethylene, and acetal. Polypropylene is the most economical and has good strength characteristics, but is not recommended for cold temperature ap- plications (below freezing). Polyethylene works well in cold temperatures, but is not as strong as polypropylene. Acetal also works well in cold temperatures, but has superior strength and lower frictional characteristics than both polyethylene and polypropylene. In addition, Acetal has a higher pressure velocity (PV) limit making it a better choice for curve applications. When selecting a material for a plastic belt or chain never use a similar material for the wearstrip or track. Like materials tend to bond together increasing friction and accelerating wear. Drive Type An End drive should be adequate for most applications. However, if the conveyor needs to be bi-directional, a center drive should be employed. Transition Transition plates should be adequate for case lengths greater than twice the center Requirements distance between end idlers. Transition rollers are recommended for shorter case lengths, 60Accessories Accessories Divert arms or deflectors (fixed or swing type), case stops (lixed or gate type), pushers, pullers, and bump turners are accessories commonly used with plastic belt and chain conveyors. Divert arms should be equipped with alow friction surface such as UMW, skate wheels, or bead rail to reduce carton drag, A low friction guide rail is also recom- mended for skew sections with angled roller belts, Bump turners are used to rotate cases 90 degrees as they travel down the conveyor. Typically, cases are skewed to one side of the conveyor where they encounter an obstruction device that catches one corner of the case. As the conveyor continues to push forward, the back end of the case swings out and around the obstruction. Other accessories associated with plastic belt and chain conveyor are guide rails (fixed or adjustable), supports (floor or ceiling hung), and slave drives (infeed end). Technical Data Most manufacturers of plastic belt and chain have computer programs for calculating belt/chain pull, shaft deflection, and horsepower requirements, These programs are relatively simple to use and most can be downloaded directly from the manufacturer's website. They should be used whenever possible to obtain the most accurate results, ‘The following formulas from one manufacturer's catalog are listed here for reference only: BP = ((M + 2W) x Fw + Mp) x L + (Mx H) BP =bdelt pull (Ibs/ft of width) M = live load (Ibs/sq ft) W = belt weight (Ibsisq ft) Fw = friction factor between belt/chain and wear strip/track Mp = accumulated product back pressure (Ibs/sq ft) — see formula below L = conveyor length (ft) H = elevation change (ft) Mp = (M x Fp x Lp) + L Mp = accumulated product back pressure (Ibs/sq fi) ive load (Ibs/sq ft) iction factor between belt and product accumulated product length (f) conveyor length (fi) Stee aPlastic Belt and Chain Conveyors ABP = BP x SF ABP = adjusted belt pull (Ibs/ft of width) BP = belt pull (Ibs/ft of width) SF = service factor = 14 for frequent starts under load and speeds over 100 FPM ABS = BSx Tx S ABS = allowable belt strength (Ibs/ft of width) BS = belt strength (Ibs/ft of width) T = temperature factor (decreases from L.0 when temperature increases) $= strength factor (decreases from 1.0 when speed/length ratio increases) Ws = (ABP + Q)xB Ws = total load on drive shatt (Ibs) ABP = adjusted belt pull (Ibs/ft of width) Q= shaft weight (Ibs/ft) B = belt width (ft) D=(5x Ws x Ls’) = (384 x Ex I) D = drive shaft deflection (inches) Ws = total load on drive shaft (Ibs) Ls = shaft length between bearing centers (inches) E = modulus of elasticity (Ibs/sq inch) = 30 x 10° for carbon steel 1= moment of inertia (inches') = 0.049 x diameter’ for round shaft or 0.083 x width' for square shaft HP = (ABP x Bx V) + 33,000 HP = horsepower required at drive shaft ABP = adjusted belt pull (Ibs/ft of width) B = belt width (ft) V = belt speed (FPM) Other useful formulas and selection charts can be found in the manufacturer's catalog. 62tenance Considerations Maintenance Considerations In comparison to other conveyor types, plastic belt and chain conveyors require only a minimal amount of maintenance to ensure their proper operation and long life. Dirt can be a problem for any conveyor so periodic cleaning is always recommended. Insufficient lubrication is another problem that should be avoided, Some manufacturers employ re-greasable bearings in their design that need to be greased at certain intervals. Other manufacturers may use sealed for life bearings that should be replaced after a certain period of time. Most manufacturers use oil lubricated gearboxes to drive the conveyor. The oil level should be checked and maintained at the proper level to ensure adequate lubrication. The oil should also be drained and replaced on regular intervals to remove contaminants and extend the life of the gearbox. Refer to the manufacturer's Maintenance section for recommended intervals and lubricants. Plastic belts and chains tend to stretch over time so they must be shortened peri- odically to maintain proper tension, Insufficient tension can cause the belt or chain to skip teeth and damage the drive sprocket(s). Likewise, if roller chain is being used to drive the conveyor, it should be checked for proper tension and adjusted as required. Asa rule of thumb, roller chain that has stretched more than 3% of its original length should be replaced. Periodic lubrication is critical to extending the life of roller chain, Light oil is generally recommended and applied with a brush or spray to penetrate down to the pin and bushing. All sprockets (both plastic and roller chain) should be checked periodically for misalignment and unusual wear, Worn sprockets should be replaced immediately. Plastic belts and chains also need to be checked for unusual ‘wear patterns or damage, Damaged components should be replaced immediately. Set screws commonly used to retain bearings and sprockets can occasionally get loose resulting in costly damage to drive and idler shafts. They should be checked after the initial break-in period for the conveyor and periodically thereafter. Refer to the manufacturer's maintenance section for recommended intervals and torque values. Safety Considerations Like other powered equipment, plastic belt and chain conveyors contain inherent hazards to personnel that need to be safe guarded. One of the more obvious hazards is the roller chain or timing belt on the drive. Another is the nip point between the plastic belt or chain and the drive/idler sprockets. Since wide plastic belts tend to weigh and sag more than traditional case handling belts, the nip point at each return roller should also be safe guarded, Finally, the transition between conveyors must not create a pinch point hazard. If transition plates are employed, the clearance between the plate and the upstream belt or chain must be kept to a minimum, If transition rollers are used, they must be able to pop out of the frame and should be restrained from falling‘on personnel below. Please refer to the safety page of the CEMA website and the CEMA Safety Video for additional information 63CHAPTER 6 Slat Conveyors 66 Design 66 Infeed Tail Section 66 Intermediate Sections 67 Drive Section 67 Chain/Slat Assembly 6a Complete Slat Conveyor 69 Application 69 65Slat Conveyors Definition A conveyor employing one or more endless chains to which non-overlapping, non- interlocking spaced slats are attached. Often this isa slow running, horizontal conveyor used to convey items that are not typically conveyable on rollers or belts due to the shape or condition of the item, Slat conveyors may also be used for conveying items being assembled while in motion, More recently, specialized slat conveyors have been used as high speed sorters of unit loads. Design ‘A slat conveyor is made up of several modular components that are assembled to create a conveyor of the desired length. The main components are as follows: * Infeed tail section * Intermediate sections © Drive section * Chain/slat assembly Figure 6.1 Infeed Tail Section Infeed Tail Section ‘The infeed tail section consists of: * Frame structure * Infeed shaft 66Design * Infeed shaft bearings * Infeed sprockets * Chain take-up ‘The infeed tail frame structure consists of side frames spaced a set distance apart with frame spacers. A bearing is then mounted to each of the side frames to hold the infeed shaft. A sprocket is mounted on each end of the shaft just inside the side frames. ‘These sprockets will serve to rotate the chain/slat assembly from the lower return side to the top for conveying. The infeed shaft also is mounted so as to allow some movement along the length of the conveyor for chain take-up, Figure 6.2 Intermediate Section Intermediate Intermediate sections are located between the infeed tail section and the drive section. Sections ‘The number and length of intermediate sections are determined by the desired overall length of the conveyor, Intermediate sections are relatively simple consisting of side frames separated by spacers or cross members. Attached to the side frames are chain support tracks that support the chain/slat assembly. Drive Section The drive section consists of: * Frame structure * Drive shaft * Drive shaft bearings © Drive sprockets * Drive The drive frame structure is made up of side frames spaced a set distance apart, with frame spacers very similar to the infeed tail section. The drive shatt is supported by bearings that are mounted on each of the side frames. The chain/slat assembly drive sprockets are mounted to the drive shaft inboard of the side frames. ‘They employ either orSlat Conveyors Chain/Slat Assembly shaft keys or keyless type bushings to transmit torque from the drive shaft to the chain/slat assembly. Figure 6.3 Drive Section The power for drive section is provided by a drive train that consists of a motor and gear reducer. ‘These are coupled to the drive shaft using a chain and sprockets, y-belts and pulleys, timing belts and sprockets, or directly using a “hollow shaft” gear reducer mounted directly onto the drive shaft. The conveyor speed is determined by selecting the proper reducer ratio, sprocket ratio, or by using a variable frequency drive (VED), There are many other devices used with motors that offer speed control, start up control, and other benefits. Please see the chapter on motors for more infor- mation on this topic. Figure 6.4 Chain/Slat Detai ‘The chain/slat assembly is powered by the drive sprockets and carries the conveyed product. The chain is typically a heavy conveyor chain with oversized rollers that sup- port the load and reduce the friction by rolling on the chain tracks that are mounted in 68Design the frames. A loop of chain is located on each side of the conveyor. The slats are then. mounted across the conveyor with ends attached to each chain. Slats vary greatly depending on actual application. Slats may be steel channels, aluminum channels or even wood boards. In assembly operations, the slats often have fixtures attached to them to support the conveyed product while being assembled. Complete Slat __A complete slat conveyor is made up of one or more intermediate sections, an infeed Conveyor tail section, a drive section and the chain/slat assembly. Figure 6.5 Complete Slat Conveyor Slat conveyors are a reliable and cost effective way to convey unit loads that may not be conveyable on rollers or belts. They may be used to traverse short distances as well as very long runs. A slat conveyor may be the right choice when one or mote of the following statements are true: * When the unit must be moved along a substantially level path. * When the load is relatively heavy with no flat bottom to support the load for conveying, Examples include automobile seating, unboxed furniture, automobile drive train parts, etc, ‘+ When the conveyor may be loaded or unloaded in such as way that would tear ot puncture conventional conveyor belts. Examples include where loads are being dropped slightly onto the conveyor causing some impact, or where loads are being pushed onto the conveyor and would tear or cause tracking issues with belting. * When loads are dirty, oily, wet or otherwise would introduce contaminates to the conveyor that may be destructive to other conveyor types. Examples include mechanical components for automobiles, farm or construction equipment being returned for remanufacturing where parts are contaminiited with oil, dirt, sand, ete. ‘* When continuous assembly to the load is being preformed while being conveyed and the load needs to be firmly secured during assembly. The ability to attach fixtures to the slats by bolting or welding makes this conveyor ideal for this type 69Slat Conveyors of application. Examples include items such as automobile seating where fixtures are permanently attached to the slats for holding the seat frame. The seat frame is very slowly conveyed while seat springs, foam, fabric, ete. are assembled to the frame. In some cases the slat conveyors may even be mounted in the floor or have a platform built along side the conveyor, The slats then become an extension of, the floor where workers may stand during assembly. Accessories Accessories such as spurs, curves, transfers, etc are not available for slat conveyors. ‘Typically slat conveyors are limited to straight, horizontal runs. Due to the types of loads generally conveyed on the slower slat conveyors, loads are often introduced directly by hand, by hoists, lift trucks or robots, Higher speed applications usually employ other conveyor types to introduce and accept loads onto/from slat conveyors. Technical Data Further detail on the Slat Conveyor technical specifications can be found in the current version of CEMA Standard 405. The 405 standard includes detailed information on calculating horsepower and other important design parameters, Other CEMA standards that provide useful information include: * CEMA 102—Terms and Definitions * CEMA 201—Safety Label Brochure Maintenance Considerations As with any conveyor, proper maintenance is required to ensure proper operation and long life of a slat conveyor. Maintenance procedures will vary depending on manufac- turer's design and actual application conditions, Some maintenance considerations include keeping the conveyor chain and chain guides lubricated and in good condition. The conveyor slats must be kept in good condition and tight to the chain in order to prevent damage to the chainy/slat assembly and unnecessary downtime, The slat conveyor drive often contains either a mechanical torque limiter or electronic torque limiter in order to prevent damage to the conveyor in the event of a jam occurring on the conveyor. It is important to follow the manufacturer's recom- mendations on setting these torque limiting devices in order to prevent possible major damage and downtime that could result in the event of a jam. 70Maintenance Considerations Regular visual and audible inspections while following the manufacturer's recommended maintenance procedures will ensure the user of getting the optimum performance from the slat conveyor. Safety Considerations All powered equipment including slat conveyors contain inherent hazards to personnel that need to be safe guarded. Some hazards include the chain or belts on the drive. Also nip points between the slats and other equipment must be safe guarded. These areas are typically protected by guards that must be kept in place and in good condition, If personnel are likely to work on or near the conveyor they must be properly trained on the hazards that exist in the particular application, Please refer to the safety page of the CEMA website and the CEMA Safety Video for additional information. a”CHAPTER 7 Multi-Strand Chain Conveyors Definition 74 Design 74 Drive Section 74 Intermediate Sections 75 Transfers 75 Application”7s Load Information “76 Conveyor Width: 77 - Left Hand/Right Hand Configurations 77 Chain Spacing/Number of Chains 7z Conveyor Capacities 7 Frame Capac Drive Mounts 73 Speeds 79 Load Drift/Application of Motor Brakes 79 Environmental Factors 79 Load/Unload Stations 79 Blocked Load Condition 79 Accessories #0 Technical Data so Horsepower Calculations 20 Pallet Types 20 Chain Load Distribution 7 Weight Distribution on the Pallet «2 Maintenance Considerations #3 Preventive Maintenance 34 Safety Considerations 54 73Multi-Strand Chain Conveyor Definition Drive Section Multi-Strand Chain (MC) Conveyor consists of parallel strands of roller chain to con- vey unit loads, The chains are pulled along rails that support the chain. These convey- ors will carry loads where the base (pallet or slab) is strong enough to support the load between chains. Ifthe pallet is not strong enough, a third strand of chain or center lane of rollers will be required. MC conveyors are best suited when a minimum amount of starting and stopping is required. Figure 7.1. Two Strand Multi-Strand Chain Conveyor MC conveyors can be individually driven and controlled or, depending on load weight and configuration, two or more sections of MC conveyors can be linked together effectively making one longer conveyor section, MC conveyors are typically built by attaching a series of pre-manufactured sections together to achieve long runs. MC conveyors come in a variety of configurations consisting of the following: © Drive Section (drive unit included) * Intermediate (slave driven from drive section conveyor) ansfers Drive sections are commonly pre-manufactured MC conveyor sections. There will be one drive section per finished operable conveyor. MC conveyors are typically available in left/right hand configurations, varying widths, varying lengths, shaft mounted or 74Design Intermediate Sections chain driven drive packages, and varying conveying speeds. The parallel roller chains are the carrying surface. The carrying chains are spaced as needed across the width of the conveyor. The exact required spacing of the chains depends on product char- acteristics like pallet size, weight, and configuration; however, two and three strand conveyors are frequently used. End drives and center drives are common. Figure 7.2 Three Strand Multi-Strand Chain Drive Section Intermediate sections are the most common of the pre-manufactured MC conveyor sections. These sections are basically the same as the drive section conveyors minus any sortof drive package, The conveying chains are driven from the drive section conveyor. Drive Package Flange Bearing (2) Chain hain Track (4) Cha Side Frame (2) —~ Drive Sprocket (2) Figure 7.3 Typical Cross Section of a Multi-Strand Chain Drive Section Chain 2) ee igure 7.4 Typical Cross Section of a Multi-Strand Chain Intermediate Section 75Multi-Strand Chain Conveyor Transfers ‘Transfers provide a method for changing the direction of loads when necessary. They allow the ability to convey loads “straight through” or to change direction. Typically, the load is transferred to another conveyor. igure 7.5 Right Angle Transfer Application MC conveyors are a very economical method of conveying palletized unit loads from one location to another. MC conveyors are a simple form of pallet load transportation that have the capacity to convey heavy loads. Things to consider when choosing MC conveyor are * Pallet Loads when the bottom boards are perpendicular to the chains « Pallet Loads when the bottom boards are parallel to the chains + Unitized Loads (may require multiple chain strands) * Totes or slab pallets | * Loading/unloading * Aligning/squaring loads * Indexing accumulation of loads * Kegs or other products that are not conveyable by roller conveyor. | Load Information ‘To determine the correct MC conveyor configuration required for a particular appli- cation it is important to have a thorough knowledge of the load{(s) being carried. With that said, consider the following questions: + What is the type of load? (pallets, unit loads, containers, drums, fixtures, etc,) 76+ What surface(s) will the load present to the conveying chains? (pallets with bottom boards parallel/perpendicular to chains, unit loads on a slip sheet, slave pallet, etc.) Note: Loose or bagged material is generally unsuitable for conveyance on chains. + What is the heaviest load to be conveyed, including the weight of the pallet? * Do loads vary in size, shape and stability? * Does the load overhang the pallet? ‘+ How are the loads introduced to the conveyor? * Are loads conveyed from an adjacent conveyor/machine or are they manually placed on the conveyor? * At what rate are loads introduced to the conveyor? Generally, pallet/unit loads with interlocked patterns are relatively stable when the height does not exceed the load length. If the height is greater than the length, load stability and conveyor acceleration should be evaluated. Pallet/unit loads with column stacked patterns tend to be unstable, For these types of loads conveyor acceleration/ deceleration, speed and transitions should be evaluated. Pallet quality is an important factor in the successful performance of MC Conveyor. Pallets of poor quality (missing or warped boards, protruding nails, etc.) and/or incon- sistent construction will have a negative impact on the functionality of this conveyor. A thorough understanding of the load(s) being handled will help determine the correct configuration (number of chain strands) for the MC conveyor specified. Conveyor Width ‘The distance between the centers of the chains depends on both the width and con- struction of the unit load being handled. The distance between chain centers typically is 4” narrower than the width of the bottom surface of the unit load/pallet. If the unit load construction is adequate, the chain centers can be as narrow as half the load width. Left Hand/ Left hand/right hand configurations are a consideration based on space availabi Right Hand. and accessibility. For centerdrive MC conveyors, there are effectively no left hand/ Configurations —_ right hand configurations. Centerdriven MC conveyors are reversible in operation and can be rotated to place the drive unit in the desired locations (near side — far side). Chain Spacing/ As a general rule, two or three strands of chains suffice for the majority of loads Number of Chains conveyed on MC conveyor. Of course, there are many factors which determine the appropriate spacing/number of chains. They would include: + Heavier loads will require additional chains to support the weight. * Loads with soft or irregular bottoms will require closer chain spacing * Unit Loads (no pallet) will require multiple chains if conveyed on MC conveyor 7Multi-Strand Chain Conveyors Conveyor MC conveyor is generally capable of handling loads that weigh up to several thousand pounds. However, factors such as the load configuration/orientation, chain load bearing length, chain size, number of chains, and hours of operation can lower the maximum capacity of the conveyor. Frame Capa Frame capacity varies depending on factors such as frame depth, frame material thick- ness/strength, spacing of supports, and width of conveyor. Drive Mounts Typical drive mount configurations are depicted below, Drive Package Flange Bearing (2) ra ‘Chain ow Chain Track (a) —s* a WE Drive Shaft Pe Se [oie Sect) Figure 7.6 Shaft Mount Drive Configuration The shaft mount drive allows the MC conveyor to be installed at a lower elevation, but requires additional space at the drive side of the conveyor. Sufficient space to remove the reducer should also be allocated. Chain Track (4) chain Flange Bearing — Sprocket (2) ~~ side Frame (2) Drive Package — Dive Sprocket Figure 7.7 Under Mount Drive Configuration The under/top mounted drive requires less space on the drive side of the conveyor. Note: The under mount has a higher minimum elevation (Figure 7.7). 78Application Speeds Asa general rule, the minimum speed required is equal to the unit load length plus desired gap all multiplied by the desired delivery rate. As an example: (4' (load length) + 4’ (gap)) x 4’ (loads per minute) = 32 FPM. is isa basic rule and other operational factors will influence the requited speed. Speeds of adjacent conveyors should match. However, when speed changes are required, one of the conveyors must allow the unit load to slip during the speed transition. A variable frequency drive (VFD) is a system for controlling the rotational speed of an AC electric motor by controlling the frequency of the electrical power supplied. A VED provides the capability to adjust conveyor speeds in the field without replacing drive components, Load Drift/ Once a MC conveyor is turned off, some drifting of the load will occur, The amount Application of __of drift is dependent upon a number of factors including load weight, conveyor speed, Motor Brakes drive configuration, etc. If minimal drifting can be tolerated when the conveyor is turned off, depending on load stability, a motor brake may be applied. If precise posi- tioning is required when the conveyor is turned off, again depending on load stability, a mechanical stop (air or fixed) may be applied as an accessory. Environmental _Allof the application guidelines provided here have been based on an enclosed operating Factors environment which is reasonably clean and dry, with an ambient temperature between 40° and 120°E If an application is outside of these boundaries, i.e. wash down, significant airborne contaminants, and/or product spillage, below 40° B, ot above 120°R, exposed to the weather, etc., special considerations must be taken. Load/Unload Load/Unload Stations are MC conveyor where loads are manually loaded and/or Stations unloaded via a fork or clamp truck. Typically, this section of conveyor encounters additional stresses. As a result, a number of enhancements should be incorporated into the design to accommodate these stresses, These enhancements include: * added bracketry and gussets to reinforce the framework * separate framing or bollards to prevent fork trucks from striking the conveyor MC conveyors are typically loaded/unloaded from the end of the conveyor rather than the sides, Loading/unloading from the sides is discouraged because the chain can be pushed out of its guides. Blocked Load A blocked load condition occurs when the MC conveyor continues to run with the Condition Joad(s) remaining in place against a fixed stop. One example of this condition occurs when loads are driven against a fixed barrier for squaring and alignment. A blocked load condition adds significant stress to the conveyor sub-components which can lead to accelerated wear, damage, and ultimately equipment failure, The amount of time that a conveyor is allowed to “grind” under a blocked load should be kept to an ABSOLUTE MINIMUM. 79‘Multi-Strand Chain Conveyors Accesso} Technical Data Horsepower Calculations Pallet Types “There are some accessories that designers have used in conjunction with MC conveyor that have proven to be very helpful in certain applications. Air operated blade stops and fixed end stops provide a means of precisely positioning loads. Transition roller assemblies help support loads conveyed from one MC conveyor to the next. Transition Roller Assembly shown == ew Saf aerel etal eel ocsition arictariey Figure 7.8 Transition Roller Assembly ‘Accumulation lifts are used ina MC conveyor to allow multiple loads to accumulate on a single conveyor, usually for a processing application. When the load is in place, usually determined through the use of photo-eyes or other control methods, the lift raises the load off of the moving chains thus allowing additional loads to continue to move. Most OEMs (original equipment manufacturers) have their own customi power formulas based on their own experiences and particular designs. ‘There are two basic classes of pallets — Stringer Pallets and Block Pall of the classes of pallets are two types based on their handling characteristics — “Two-way Entry, and Four-way Entry, Two-way Entry type pallets will accept handling equipment from only two ends. Four-way Entry type pallets accept handling equip- ‘ment from both ends and sides. Beyond these four types of pallets, there are innumerable styles based on variations in the bottom and top deck configurations. MC conveyors are not recommended for handling single face pallets with the stringers parallel with the chains, Locating the pallet precisely on the chains is difficult and problematic. ‘Two general terms used to describe pallets are Reversible or Non-reversible. A re- versible pallet is a pallet with identical or similar top and bottom decks. A non-reversible pallet isa pallet with dissimilar top and bottom decks or without bottom deck. 80Technical Data Se S Se, S Se P Vie, GT w, SS <2 OL, A. % f » Figure 7.9 Stringer Pallets and Block Pallets Another consideration would be specialty pallets such as footed pallets and crates. ‘With the development of newer plastic pallets with special configurations, special attention must be paid to the pallet’ handling characteristics. A few examples are shown below. Figure 7.10 Footed Pallets and Crates Chain Load ‘The weight of each unit load that the MC conveyor can handle is limited by the allowable Distributi unit pressure between the chain and the track, The unit pressure is dependent on the pallet construction. In those instances where the loading on the chain is a concern, the unit pressure loading should be evaluated aIMulti-Strand Chain Conveyors Weight ‘The weight of the unit load on the pallet is distributed to general portions of the pallet. istribution on the Pallet 0.125 0.25 0.125 0.0625 0.125 0.0625 0.125 0.25 0.125 0.0625 0.125 + 0,0625) Figure 7.11 Pallet Load on 2 Strand Chain (left) and 3 Strand Chain These weight distributions apply independent of the pallet type. The loading to a given type of chain is determined by the center section of a pallet and the bearing length at that area, The bearing length is that portion of the pallet bottom board at the center or side center of the pallet that transmits its portion of the load directly to the chain. For two strand chain, as well as three strand, the determining factor generally is 25% of the load. Bearing Length Bearing Length Figure 7.12. Load Distribution For pallets with bottom boards oriented across the chains, the bearing length is the width of the bottom board, For pallets with multiple bottom boards at the center, the load is distributed evenly across the overall width of the boards. Bearing Length Figure 7.13 Load Distribution 82Technical Data For pallets without bottom boards and stringers oriented across the chains or block type, the bearing length is the width of the stringer or block. The unit pressure is determined by the bearing length Bearing Length Figure 7.14 Load Distribution For pallets with bottom boards oriented along the chains, the load bearing length is determined by the wiclth of the member transmitting the load to the bottom boards and the thickness of the bottom boards. The bearing length is the width of the member plus two times the bottom board thickness. Maintenance Considerations Maintenance must be performed only by qualified individuals who are trained in the operation of the conveyor and who are knowledgeable of all safety devices, their locations, and functions. The safety information section should be reviewed before perfor any maintenance tasks. Recommended service checks and equipment maintenance presented by manu- facturers are general in nature and modified inspection intervals should be determined for your particular use of the equipment. All newly installed equipment should be closely observed during the first period of operation; thereafter, an appropriate maintenance program should be established and followed. Maintaining separate service log sheets on each type of conveyor is recommended, particularly for plants operating more than one shift, Each log sheet should show dates, detailed inspection service information, and name or initials of person performing the inspection or servic 83Mul Preventive Maintenance trand Chain Conveyors & DANGER Before performing maintenance on a conveyor, verify that the conveyor’s energy sources are disabled per OSHA 29 CFR 1910.147 (Lockout/ Tagout) Do not perform maintenance while the conveyor is running unless specifically instructed to do so in the manufacturer's manual. It is recommended that a regular inspection schedule is established to monitor the condition and operation of the conveyor to ensure proper performance, reduce down time and promote long component life Safety Considerations 84 Properly designed MC conveyors typically are not intrinsically hazardous. The hazards evolve from the loads conveyed and misuse by operators. As discussed previously, load stability is a safety issue if falling items might injure workers. Another hazard presented by moving loads is the load/conveying media interface. Hands or other appendages caught under very heavy loads are very likely to suffer injury. Proper E-Stop placement in areas where personnel may routinely come in contact with or be near the equipment is recommended. Operators have a tendency to cross over and/or walk on MC conveyors. Consider- ation should be made to provide crossovers or walkplates to preclude operators from walking on the chains. It is not uncommon that operators will attempt to use the M conveying surface as a work platform, Regardless of the reasons, personnel must not be allowed to walk on the conveyor surface! Further detail on MC Conveyor safety can be found on the CEMA website and various other standards, These include: + ANSI/CEMA 102— Terms and Definitions + ANSI/CEMA 201 —Safety Label Brochure © ANSI/AS ME B20.1 Safety Standard for Conveyors and Related Equipment + CEMA Unit Conveying Safety Poster * CEMA Conveying Safety DVD.CHAPTER 8 Line-Shaft Conveyors Definition 86 Maintenance Considerations 97 F General 97 D ore Drive Belts 97 Application #9 Line-Shaft Bearings 97 Universal Joints 97 Coupler Sprockets/Chains 98 Air Systems 9@ Accessories 91 Timing Belts 92 Speedup Spools 92 » Coated Rollers 92 Safety Considerations 93 Line-Shaft Crossover 92 Line-Shaft-Driven ight Angle Transfer 92 Line-Shaft-Driven Diverter 93 Line-Shaft Herringbone Merge 93 Line-Shaft Curve 93 Line-Shaft Intersection 93 Line-Shaft-Driven Gate 92 Line-Shaft Brake 94 Drive Arrangement 95 Supports 95 Accumulation Conveyor 95 Technical Data 95 Drive Basics 95 Horsepower 95 Principles 96 Belt Break-In 96 85Line-Shaft Conveyors Figure 8.1 A Line-Shaft Drives this Live Roller Conveyor System Taking Full Advantage of Reducing Drives through Universal Joints in Curves, Inclines and Declines Definition 86 Line-shaft-driven live roller conveyors use a shaft (line-shaft) running longitudinally with the frame structure and perpendicular to the rollers to provide the power source to the rollers. The rollers are individually driven by pre-tensioned elastomeric belts which pull individual drive spools against the line-shaft. Each spool delivers a fixed amount of torque from the line-shatt to the rollers depending on the amount of belt tension. Ifthe torque requirement from the load on the rollers exceeds the fixed torque of the spool, the spool slips on the line-shatf like a clutch, Line-shaft conveyor allows unequaled versatility with high speed, complete revers- ibility and minimum pressure accumulation. The advantage of line-shaft conveyor is the ability to power straight sections and curves plus auxiliary devices from a single drive, Auxiliary devices include: transfers, spurs, adjoining parallel sections, merges, switches, sortation devices, powered guard rails, ete There are advantages to using line-shaft-driven live roller conveyor, not shared by other designs. By utilizing universal joints to change direction of the line-shaft both horizontally and vertically and the use of crossover jumps from one shaft to another, there is virtually no layout configuration that cannot be tied together into a single drive within the torque limitation of the components and the drive itself. The second unique difference is the ability to incline and decline line-shaft conveyor by utilizing the constant tension of the drive belt and the friction of the spool to control product movement within the limits of the roller drive capacity and friction considerations between the product and the carrying rollers, The third unique characteristic is theDefinition Versatility zero-pressure accumulation design which causes products to accumulate without contact between products. This can be a major advantage for very sensitive product and high value product that does not have a high throughput rate requirement. The greatest disadvantage to line-shaft-driven live roller with its non-contact accumulation is its inability to close-pack-accumulate multiple size products at higher rates. The non-contact advantage when carrying sensitive product becomes a disadvantage when high throughput is required. The zone length must be sized to the largest cases. Unique characteristics of line-shaft-driven live roller conveyor are listed below: * Add or subtract bed lengths easily * Skew rollers to direct product flow path without affecting the drive belt tracking * Drive multiple directions on same unit by reverse rollers * Incline/decline by applying universal-joint on line-shaft * Speedup/slowdown within same unit Economical * Fewer drives ‘+ No belts to track + No belt take-ups * No frame wear Clean * Open, simple design — objects fall through and spillage is not carried along by a flat belt Design Line-shaft conveyor consists of six major parts (see Figure 8.2): 1. product carrying rollers . elastomeric drive belts slippable drive spools . aline-shaft a frame to hold it all together ave en a motor to drive the line-shaft The function of the roller is to support and provide movement to the load. The function of the belt is to transmit torque and rotation from the line-shaft to the roller. a7Line-Shaft Conveyors The function of the spool is to protect the belt against abrasion by slipping on the line- shaft when the roller is stalled and to insulate the belt against heat buildup while the spool is slipping. The function of the line-shaft is to transmit and distribute power and. motion from the drive to all individual spools, belts, and rollers. The line-shaft from one section to another is connected through the use of double wide chain and coupler sprockets (see Figure 8.3) The drive spool may slip on the line-shaft, Hence, the maximum transmitted torque to the roller depends on belt tension and the coefficient of friction between the shaft and spool. The belt tension depends on its cross sectional area, the basic material properties (including durometer) and the amount of pre-stretch. ‘The resistance against the torque developed at the line-shaft depends on the roller size and bearing friction coefficient, weight of the roller, weight of the load being onveyed and the product surface compliance or indentation on the roller. This last item could be referred to as rolling resistance or conveyability of the product. Generally, load rolling resistance must be determined experimentally. The harder ang flatter the bottom surface of the load, the less its rolling resistance and the greater the weight that can be driven with the available torque. NER ROLLER Pee rete wiv / \ Levee gh a a j hy IN ie Gaus sn neaueo Figure 8.2 Roller Drive Configuration (top view) and Bed Cross Section (bottom view) 88SPROCKETS COUPLER Pa ™— COUPLER CHAIN Figure 8.3 Coupler Components for Shaft to Shaft Connection Application When conveyed loads (cartons, totes, fixtures, and end product —wheels/tires) stop. the roller, drive belt, and spool, the shaft continues to turn. Only minimal friction exists between the inner surface of the spool and the shaft surface, Unlike belt-driven live roller conveyors, the pressure of accumulated product is independent of its weight and is determined by the belt tension and spool friction, Long lengths of accumulated loads must be zoned. A braking device on specified centers reduces the total line pressure (also called back pressure) into smaller increments. Case stops can be used to accumulate loads prior to curves. Air or electrical sensor controls can be supplied to activate the stop device. The line pressure of accumulated loads can be reduced by removing belts at specified intervals on the conveyor. With rollers on 3” centers, the accumulated pressure can be reduced 25% by removing every fourth belt. The drive capacity, which is also reduced 25%, must be sufficient to convey the heaviest product, Line-shaft conveyor can also be zoned based on the longest load and‘controlled so only one load will be located in each zone for “non-contact” accumulation of fragile loads. Loads will not contact while conveying, accumulating, or releasing. This also enables single load release (induction) when discharging products. 89Line-Shaft Conveyors One of the most important features of line-shaft-driven conveyor is the ability to use universal joints to bend the line-shaft both horizontally (curves) and vertically. There are many instances in system design where itis desirable to make minor elevation changes. This may be to obtain necessary clearances, to meet the interface elevation of a machine, or to present the load at the proper elevation at a workstation. A moderate amount of inclining or declining may be used to achieve elevation changes without ending the line-shaft drive or using a belt conveyor. However, this must be done with caution especially when inclining. Most inclining situations will require testing. The roller capacity torque available to move the product is greatly diminished when inclining to another elevation. Line-shaft-driven live roller conveyor has been used successfully in many applications for declining cartons up to approximately 152 At this angle, cartons will not slide on the rollers or cause over-driving of the spools, forcing them to slip on the line-shaft faster than the shaft RPM, Totes on the other hand may slide at a smaller degree angle and need testing, Inclining line-shaft conveyor is less common than declining and must be done with caution. The amount of roller torque (drive) required to lift load is much greater than to move it horizontally. Compensate for this by reducing the load weight allowed per foot of conveyor. For example, with 4” of rise over 10" (1.9°), the load weight carried per foot must be decreased by 50%, With 8” of rise over 10' (3.8), the capacity to move load is only 25% of horizontal capacity. Roller-to-roller belts are required at the lower end of both inclining and declining areas for smooth load transition to horizontal. For both inclines and declines, universal joints are required on the line-shaft at the upper and lower transition points, Constant velocity universals are recommended to avoid phasing and pulsation problems. When line-shaft conveyors are in close proximity and parallel, crossovers may be used to drive both conveyors with a single drive motor. If the conveyors need to convey load in opposite directions, the drive bands may be twisted in opposite directions. ‘This produces opposite flow even with the line-shafts rotating in the same direction. CROSSOVER (JUMP CHAIN) Lint el TRAVEL » Figure 8.4 90Application Table 8.1 Common Line-shaft Conveyor Myths/Facts Myth Fact 1 Dirtand grit wears _Line-shaft conveyor installations in foundries and near drive spools sandblasting operations have not shown unusual wear ‘The twisting action of the drive belt keeps the roller groove. and face of the drive spool clean. In addition, the drive pulley page under accumulation or acceleration causes a cleaning action on the line-shaft. No lubrication is Some environments may reduce the coefficient of friction, permissible on the between the line-shaft and the spool. These include machine Tine-shatt operations or conveying oily parts. Fiour, detergents and soap products can also serve as lubricant, Understanding this possibility in advance allows the system designer to take steps to increase the drive to compensate by using higher tension. drive belts if required 3 Line-shaft conveyor Drive capacities are reduced with lower speeds. This may or cannot operate below — may not be a problem depending on the load weight. If itis, acertain FPM. steps can be taken to increase the capacity to compensate, The drive capacity at 5 FPM is still 70% of 60 FPM capacities 4 Line-shaft conveyor When inclining, drive capacities fall off sharply. Capacity at a can be inclined up to 9° incline will be approximately 14% of rated horizontal use and a certain stated angle approximately 25% al 5®. Declining does not present a problem without drive penalty. until the product begins to slide on the roller surface. Corrugated loads have not presented a problem up to 15%, while totes (with lower friction) should always utilize coated rollers over 5°. 5. High friction roller Drive capacity is only affected by belt tension and the friction surfaces increase drive between drive spool and line-shaft, combined with a low capacity. friction roller bearing. When the resulting roller torque is exceeded, the roller will stop whether it is coated or not. 6 Line-shaft conveyor speed can be accurately calculated Line-shaft conveyor speed calculations use an average slip, factor between the spool and line-shait. Light loads will convey faster and heavy products slower. and provided. 7 Drive capacity is This sounds good in theory since as the bore wears, the center reduced as spool bore of the spool moves up, reducing the belt tension; however, belt ‘wears. tension tolerance variation is greater than this theoretical loss. ‘There are many accessories used with line-shaft-driven conveyor. These include product stops, transfers, diverters, and speedup spools, The accessories contained in this section are all driven from the line-shaft and do not require a separate drive motor. onLine-Shaft Conveyors Timing Belts Timing belts transmit high RPM better than chains for high speed conveying. They require no lubrication, reducing maintenance. Timing belts are normally used at speeds above 120 FPM (feet per minute) Speedup Spools _Larger diameter spools, often referred to as speedup spools are used to’put a temporary gap between loads. Any roller driven by a larger diameter spool will run faster than a roller driven with a standard spool. This will result in a gap equal to a percentage of the case length while in this speedup zone. Speedup spools should be considered where a relatively short speedup area is required. Coated Rollers Roller coating has three normal uses. One is to increase the coefficient of friction between the rollers and the load (usually for stopping and holding). The second is to protect the load from the steel roller, and the third is to reduce noise, Caution should be used when considering roller coating with heavy rigid loads riding on square-edges. A sharp leading edge can damage the coating. Line-Shaft A crossover enables the transference of power from one side of the conveyor to the Crossover other, or between adjacent conveyors. This device can also create a speed change. EXTERNAL CROSSOVER INTERNAL CROSSOVER Figure 8.5 Crossovers Line-Shaft-Driven ‘The line-shaft-driven right angle transfer is used to transfer load either on or off of a ight Angle main line conveyor at a 90° angle. The carrying surface of the transfer can be chain Transfer or belt. When the transfer raises, it picks up the load and conveys it at right angles. ‘The transfer may be single direction or bi-directional 92Accessories Line-Shaft-Driven Diverter Line-Shaft Herringbone Merge Line-Shaft Curve Line-Shaft Intersection Line-Shaft-Driven Gate ‘There are various types of diverters that utilize different mechanisms to direct loads from a main line conveyor onto an adjacent conveyor. Some types are pop-up wheel, swivel roller, pivot roller and flipper chain. Figure 8.6 Right Angle Transfer Figure &7 Angle Diverter A wide straight section used to merge two parallel lines into one. The rollers are skewed to a center rail to direct the load to exit the downstream end on the centerline of the section. It is possible for both of the infeed lines and the take-away lines to be powered from the same source. I = : — jd I 7 Figure 8.8 Herring Bone => 1 \ Used to change horizontal directions. Common degrees are 30, 45, 60 and 90, Others are possible but are limited by the universal joints and the need to have two support bearings on each shaft segment. A spur section that is driven from the main line conveyor line-shaft. Commonly these are 30° or 45° for merging and diverging. A pivoted powered section that opens for passage by personnel. Power cannot be transferred through the gate; therefore, a drive is needed on each side of the gate. 93.Line-Shaft Conveyors son Figure 8.11 Gate UNIVERSAL JONNT Figure 8.10 Spur Intersection Aaa ROLLERS Figure 8.12 Brake Detail Line-Shaft Brake A device mounted within the conveyor for the purpose of stopping carrier rollers to prevent or restrict the advancement of products conveying over the brake, The rollers may be coated to increase the friction between the stopped rollers and the load to prevent push over. o4Accessor Drive Arrangement There are many variations in drive arrangements, A gearmotor is the most common. The output shaft of the reducer normally is connected to the line-shaft by a chain drive or synchronous belt drive or the gearmotor may be mounted directly to the line-shaft, ‘The gearmotor may be mounted internal or external to the frame and be under-hung or side-mounted. Supports Floor supports should be provided with vertical adjustment for leveling the conveyor. Adjustable hangers, such as rods with threaded ends, are generally used to support conveyors overhead. Support spacing is dependent on loading and in some cases on building construction. Supports must be spaced to limit frame deflections as detailed in CEMA Standard 401, “Roller Conveyors —Non-Powered”. Accumulation _Line-shaft accumulation conveyor is designed to minimize or eliminate the pressure Conveyor buildup between adjacent unit loads under blocked load conditions. Zero or low pressure can be obtained through zone controlled operation. Individual rollers or sections of the conveyor can be customized to create dwell stations, or accumulation zones. In zoned accumulation conveyor, mechanical or electronic sensors are used to sense and stop loads sequentially in zones as they are accumulated. Normally a brake is engaged to stop the carrying rollers in each zone where accumulation is required. Por more information on accumulation conveyors consult the manufacturers {also see “Definition”). Technical Data Line-shaft conveyor operates by the principle that each roller is driven by the tension in the elastomeric drive belt, which is pulling the spool against the driving line-shaft. Rollers may be in one of the following two conditions; + Transportation — Rollers are rotating, product is in motion and the drive belt, spools and line-shaft are all running. * Accumulation —Line-shaft is driving; however, the spool is slipping on the line-shaft because the load resistance is too high for the belt tension or a physical constriction such as a roller brake or stop is preventing the product (and rollers) from moving, In this condition the maximum torque requirement is experienced by the line-shaft and drive motor. Drive Basics ‘The torque developed at the shaft due to the belt tension and spool friction coefficient is transmitted to the roller surface by the belt. How far this tangential force goes in moving load weight depends on the rolling resistance of the product. For example, the roller force can move more weight if the weight is riding on plywood than ifthe weight 95Line-Shaft Conveyors is in a soft corrugated box. This tangential force at the rollers outer surface provides drive to move the load. This force is in direct proportion to the belt tension, ‘The rated drive capacity may vary widely and considers several factors, including belt diameter, belt material, amount of stretch, spool and roller diameters, spool to shaft coefficient of friction, and running efficiencies. Horsepower ‘The horsepower values for accumulation, transportation and all accessories must come from the manufacturer, Also reference CEMA Standard 406, Line-Shaft Driven Live Roller Conveyors. Principles + The horsepower requirement is based upon the total torsional load placed on the line-shaft at the drive location and on the conveyor speed. # The length that a line-shaft-driven conveyor can be operated with a single drive is limited by the acceptable torsional deflection of the line-shaft and the capacity of the components, The limitation is based on speed and required horsepower. + Locate the drive as close to the center of the torsional loading as practical, based on horsepower requirements of the conveyor and devices to maximize the drive length. * The total horsepower required on either side of the drive location cannot exceed 50% of the total horsepower maximum at the given speed. The torque required to flex the drive belts in all line-shaft-driven conveyor and ncreases steadily as temperatures become lower. Therefore, the horsepower to drive the conveyor and move the load increases during the transportation of the product, but not accumulation, Since the accumulation horsepower is the greater, this only affects conveyor used for transportation, The exact increase depends on the specific temperature and the mass or cross section of the belt. To keep this simple, add 50% to the horsepower for temperatures from 60°F to freezing and use accumulation horsepower below freezing. accessorit Belt Break-In It is very important to break-in the drive belts before allowing accumulation to take place on line-shaft-driven conveyor to prevent possible damage to both the products and the conveyor drive components. The tension of a drive belt is the highest before it is broken-in. After a break-in period, the tension will be reduced and then remains basically at that tension level for the rest of its flex life. Some run time is always required before the belts drop completely to their operating level. Line-shaft conveyors require at least 24 hours of initial run time. However, 48 hours of initial run time is recommended. When initially starting a line-shaft-driven conveyor, the roller drive as felt at the roller surface will be at its highest point, All capacities published are based on the lowest expected tension level after break-in. 96Maintenance Considerations Maintenance Considerations ‘The key to ensuring the expected return on investment is to protect against premature failure with a well-planned and follow-up program of preventive maintenance. General Preventive maintenance programs examine what may fail and then formulate action plans which will prevent failure or downtime. Preventive maintenance will save expensive downtime and wasted energy. It will increase the life of components. Along with preventive maintenance should be a record-keeping system. You must know what problems you have had in the past and when different components were serviced. & DANGER Do not perform maintenance on the conveyor until the startup controls are locked out and cannot be turned on by any person other than the one performing the maintenance. If more than one member ofa crew is working on the conveyor, EACH CREW MEMBER MUST HAVE A LOCK ON THE POWER LOCK OUT. The air pressure must be turned off to the work area. All pneumatic devices must be de-energized to prevent accidental cycling of the device. Make sure personnel are clear of all conveyor equipment before restarting the system. Drive Belts Drive belts should require no actual maintenance. Visually check for broken or worn belts. Periodically replace any broken belts. If belt shows signs of abrasion, check for belt rub against any object or foreign matter in roller groove, Line-Shaft Bearings ‘The drive spools must be under the roller to prevent the belt from contacting the flange. Universal Joints ‘To ensure proper lubrication of all four bearing assemblies on U-joints, add lubricant until it appears at all journal cross bearing seals. This assures removal of dirt particles and other contaminants that may find their way into the bearings and indicates that the bearings are fully lubricated, Do not assume that bearing cavities have been filled with new lubricant unless flow is noticed around all four bearing seals. 97Line-Shaft Conveyors Coupler Sprockets/Chains Air Systems fn As with all rotating machinery, the line-shaft, couplers and U-joints present the possible danger of entangling hair, fingers, jewelry or clothing, Never operate the conveyor without the guards in place. Coupler sprockets and chains located at the ends of line-shafts transmit rotational power from the conveyor drive to all connecting intermediate beds. To check or service couplers, shut off and lock out power supply. To provide access, remove necessary rollers. Visually inspect coupler chain for cracks or broken side links. If a coupler chain needs replacing, the coupler sprocket (ine-shaft) probably needs realigning, The best preventive maintenance for any air operated device.is clean air. Always be alert for air leaks anywhere in the system and correct promptly. Check all air line filter bowls for accumulated water and drain if necessary, Check for proper PSI settings on air regulators. Remove and replace clogged filter elements as required. Periodic maintenance intervals may vary with load, speed, hours of daily operation, ambient temperature, humidity, etc. Intervals can be established by fairly frequent maintenance at first, then lengthen the intervals as justified by observation of need based on history. Safety Considerations Line-shaft-driven live roller conveyor is powered by a motor and can be stopped only by turning off electrical power to the motor. As with all powered machinery, the drive related components including sprockets, chains, shafts, universal joints and pneu- matically actuated devices present a danger, Guards have been provided to prevent inadvertent contact with these components along with warning labels to identify the hazards, After maintenance, replace guards immediately, Keep all warning labels clean and clear of any obstructions, Never remove, deface or paint over warning labels. During installation remove any coupler sprockets which are not coupled. A set collar can be used to replace a sprocket and retain the last spool (see Figures 8.13 and 8.14), Additionally, the end of the line-shaft must be covered at all open terminations of the conveyor. Figure 8.14 shows an end cover at a line-shaft conveyor terminal end section. 98ened ose ‘A full width conveyor end cover plate may be substituted, Figure 8.14 Proper Line-Shaft Termination Safety Considerations rockets) 99CHAPTER 9 Belt Driven Live Roller Conveyors Definition 102 Design 102 Intermediates 102 Drive Belts 104 Drives 105 End Idlers/Pulleys. 106 Take-Ups 107 Complete Conveyors 108 Application 109 Conveyability of the Product 109 Determining Conveyor Width 170 Accessories 110 Turning Posts, Wheels, or Rollers 117 Spurs 117 Right Angle Pop-Up Transfers 111 Deflectors 177 Push-Offs 117 Technical Data 117 Maintenance Considerations 111 Safety Considerations 112 101Belt Driven Live Roller Conveyors Definition Belt driven live roller conveyors are a commonly used unit handling conveyor because of their simplicity, flexibility, and versatility. They are used to convey unit loads of various sizes and weights. Belt driven live roller conveyors use rollers to form the conveying surface. Unit loads are carried directly by the rollers. The rollers are powered by a belt that is held in contact with the bottom side of the rollers to create a friction coupling. They may be used to transport loads long distances with a single drive motor. Unlike belt conveyors, belt driven live roller conveyors are not well suited for incline or decline applications, although installations incorporating a slight pitch are sometimes possible. Design Intermediates 102 Complete belt driven live roller conveyors are made up of several modular components that are assembled together to create a conveyor of the desired length. The main components used are as follows: * Intermediates * Drive belt(s) * Drives + End Idlers/pulleys + Take-ups In most cases take-ups are incorporated into the drive component, further simplifying the conveyor assembly. These components are combined to form the complete conveyor assembly. Intermediate sections make up most of the complete conveyor. There will be at least one intermediate in every complete conveyor. ‘They are typically made in various lengths as required by the application, with a maximum section length of ten or twelve feet. Sections are combined to form long runs of conveyor. The main components of intermediate sections typically include: + Carrying (tread) rollers * Side frames * Cross ties (bed spacers) © Pressure rollers/sheaves © Return rollersDesign Carrying rollers support the unit loads and pass the drive force provided by the drive belt on to them. Theyare evenly spaced along the length of the section. The exact, spacing of the rollers usually depends on characteristics of the load such as size and weight, along with other factors such as the condition of the bottom surfaces of the loads, Increments of 2’, 3”, 4”, and 6” are common, Figure 9.1 Belt Driven Live Roller Cross Section ‘The rollers (and other components) are supported by (typically) steel side rails, usually with a channel cross section. The rollers may be mounted so that they form. a conveying surface that is higher than the side rails, This is referred to as “rollers set high.” They may also be mounted so that the conveying surface is lower than the side rails in such a way that the side rails form guides for the unit loads. This is referred to as “rollers set low.” For safety reasons the carrying rollers are usually installed in slots in the side rails that allow the rollers to “pop out” in the event that a foreign object is caught between the roller and the belt. Alternatives to the slotted side rails include using the minimum possible roller increment or providing a guard to fill the space between the rollers in the area over the belt. Figure 9.2 Intermediate Section Assembly The structural frame of the conveyor is completed by cross ties (bed spacers) that bolt or weld to the side rails and hold them apart and parallel to one another. Some manufacturers may support other components from the cross ties inside the conveyor. The belt is held against the carrying rollers by some method in order to provide the friction needed to transmit power from the belt to the carrying rollers. ‘The most commion method is to use what is kndwn as pressure rollers to hold the belt up. 103Belt Driven Live Roller Conveyors Drive Belts 104 Pressure rollers may extend across the full conveyor width and be supported by the side rails, or they may be just long enough to accommodate the width of the belt and ‘be supported by an internal framework. Another common method is the use of sheaves mounted to one side rail to support the belt. This method is used with belts with a narrow cross section, such as v-belts. ‘The sheaves are mounted in slotted holes in the side rail so that they may be adjusted vertically to bring the belt into contact with the carrying roller “Return rollers” spaced at wide intervals along the conveyor support the returning portion of the belt. A typical ten-foot long intermediate will have one or two return rollers mounted below the pressure rollers. Various forms of belts are used to drive the carrying rollers. Some of the more common drive belts found in industry include: © Flat belts * Narrow Kevlar reinforced flat belts * V-belts Flat belts are the most common type used in straight belt-driven live roller conveyors. ‘There are several types of belts used in industry. ‘They vary in width from around six inches to twelve or more inches. Some of the factors that are considered when selecting the belt to use include tensile strength, dimensional stability, surface friction, noise generation, and static dissipation. Please see the chapter on conveyor belts for more detailed information.Design Narrow Kevlar reinforced flat belts have emerged as a viable drive belt technology in recent years. These belts rely on the strength of the core fibers rather than belt width to provide adequate tensile strength to drive long runs of roller conveyor. These belts may be held in contact with the carrying rollers by small flat-faced idler sheaves, metal or plastic slider pans, or more conventional pressure rollers, They offer the advantage of requiring minimal tracking and leave room inside the conveyor for accessory equipment. V-belts (belts with a trapezoidal cross section) are used to drive the rollers on some light-to-medium duty straight roller conveyors and most live-roller curve sections. ‘These belts are driven by v-grooved drive pulleys and held against the rollers by v-groove pressure sheaves or normal pressure rollers. These belts are typically much shorter than flat belts. A common practice is to design each intermediate straight or curve section to use one complete v-belt. Each belt is coupled to the belt in the next section through the drive sheave system. While the traditional trapezoidal cross section is arguably the most common, other cross sections are also used, such as round and hexagonal, Drives Drives for belt driven live roller conveyors are similar, and in some cases identical, to the drives used with belt conveyors. Center drives (Figure 9.4 and 9.5) mounted to the underneath side of the conveyor are most often used. They use a lagged pulley to grip and pull the return portion of the belt. They may be located anywhere along the conveyor's length, but are typically located toward the infeed end. End drives us a similar drive pulley mounted at the end of the conveyor (usually the infeed end). By driving the pulley at the proper RPM (revolutions per minute) the belt, and hence the ‘ying rollers, will cause the unit loads to move linearly at the desired speed, usually expressed in feet per minute (FPM). A key difference between belt conveyors and belt driven live roller conveyors is that with belt conveyors the unit loads move in the same direction as the belt, while with belt driven live roller conveyors the unit loads move in the opposite direction from the belt. This is a result of the belt contacting the “bottom side” of the carrying rollers to impart rotating force. Figure 9.4 Center Drive Assembly Figure 9.5 Belt, Drive Pulley, and Take-Up Both center drives and end drives offer advantages in certain applications. End drives generally add less depth to the conveyor, which is helpful when low elevations are required. However, itis difficult to drive all of the carrying rollers over the drive 105,Belt Driven Live Roller Conveyors End Idlers/Pulleys pulley, and they typically require a separate belt take-up component, Center drives provide more flexibility in their location along the conveyor and almost always porate the take-up as a part of the assembly, at the expense of requiring more space under the conveyor. cor- In addition to the lagged drive pulley, drive assemblies also include additional non-coated pulleys and idler rollers that guide the belt through the drive. It is important to design the drives with belt wrap around the drive pulley at the optimum "contact angle” for the best performance. This insures optimum performance. Making one of the non-coated pulleys movable also creates a mechanism to provide belt take-up, which is required to compensate for the slack produced as the belt stretches over time. Figure 9.6 Motor, Reducer, Chain, Sprockets The drive pulley is turned at the required rotational speed through the use of a motor and gear reducer (Figure 9.6). These are coupled to the drive pulley using chain and sprockets, v-belts and pulleys, timing belts and sprockets, or directly using a “hollow shalt” gear reducer mounted onto the pulley shaft. Another common drive incorporates the motor and gear reduction inside the pulley itself, making a very compact drive assembly. The pulley RPM may be set by selecting the proper sprocket ratio, by using a variable frequency drive (VED), etc. There are many other devices used with motors that offer other benefits. Please see the chapter on motors for more information on this topic. End idlers, referred to by some in the industry as tail pulleys, are located at the end of the complete conveyor and facilitate the belts transition from the driving side to the return side and vice versa. The pulley is normally not lagged, but is crowned to assist in belt tracking. It is accompanied by a snub idler to create additional wrap around the pulley and enhance the tracking effect. End idlers may be a separate assembly that formsa portion of the overall length of the complete conveyor, or may be incorporated into the last conveyor section (Figure 9.7). 106In some cases the pulley is adjustable to allow it to be used for belt take-up. In other cases the pulley has only enough adjustment to allow for squaring of the pulley to the frame. See the pulley chapter for more information about pulleys, Figure 9.8 Take-Up as Part of Drive Assembly Take-Ups ‘Take-ups are a necessary part of any conveyor using a long belt. Take-ups provide a way to accommodate belt stretch due to use, temperature, or humidity. They also provide a way to give the belt an initial tension to that the drive pulley can drive the belt without slipping. Take-ups are commonly built into drive assemblies near the drive pulley, (Figure 9.8) but can be separate assemblies that may be installed anywhere along the bottom of the conveyor. A take-up consists of a pulley that is able to move in a straight (or near straight) path, The belt is wrapped around the pulley at or near 180° so that the pulley movement will achieve the maximum belt take-up possible. If the belt is wrapped at 180°, one inch. of pulley movement will take up two inches of extra belt. 107Belt Driven Live Roller Conveyors Complete Conveyors ‘The amount of take-up required for a conveyor depends on the characteristics of the belt and the length of the conveyor. A rule of thumb often used is to allow for about one percent of belt stretch. Remembering that the belt isa little over twice the length of the conveyor, one can arrive at a quick estimate of the amount of take-up required for a particular conveyor. Very long conveyors may require more take-up than a single take-up assembly can accommodate, While another take-up assembly may be used, this adds cost to the conveyor and requires more power from the drive motor. An alternative is to install a “dutchman’’ or short section of belt around two to five feet long, as part of the main belt of the conveyor. When the belt stretches beyond the range of the take-up, the dutchman may be removed to return the belt length to an acceptable length to work with the take-up, Most take-ups are adjusted manually using long take-up screws, one on each end of the pulley shaft. In applications where maintenance is difficult or for extra long conveyor lengths an automatic take-up may be used. These may use spring tension, counterweights, or pneumatic cylinders to keep the belt properly tensioned at all times, Such take-ups are especially helpful in applications where the belt may tend to stretch and shrink, as in buildings with large temperature and/or humidity swings. Figure 9.9 Complete Belt-Driven Live Roller Conveyor ‘A complete conveyor is made up of one or more intermediate sections, end idlers, a drive, a take-up (if the drive does not incorporate one), and the drive belt. The total length that a particular conveyor may be is dependent on several factors, including motor size, belt strength, the total weight of unit loads that may be on the conveyor at any one time, ete, 108Application Application Belt driven live roller conveyors are a reliable and cost effective way to convey unit loads from one location to another. They may be used to traverse short distances as well as very long runs. A belt driven live roller conveyor may be the right choice when one or more of the following statements are true: + When the unit must be moved along a substantially level path. + When positive tracking of unit load position is not needed. ‘The relatively low coefficient of friction between a metal roller and most conveyable unit loads means that some slippage of those loads may occur, making accurate tracking of cartons problematic. * When the conveyor may be loaded or unloaded in such as way that the unit loads may need to slide on the conveying surface. The low coefficient of friction men- tioned above makes this easier on live roller conveyors than on belt conveyors. * In some applications, when some amount of accumulation may need to occur on the conveyor. Conveyability of ‘The actual product being conveyed is an important consideration when applying live the Product roller conveyors, Some things to consider are: + Weight—The weight of the unit loads being conveyed must be considered when choosing the conveyor to use. Belt driven live roller conveyors typically have their capacity rated in pounds per foot of conveyor length. This rating is heavily based on the amount of force the friction coupling between the belt and the carrying rollers can transmit, and how many rollers are under the load at, any given time, The total weight of product that can be on the conveyor at any one time is used to determine the size of the drive motor that is required and ‘may limit the length of conveyor that may be driven by one drive assembly. * Condition of load “bottom” surface — Generally, a unit load is “roller conveyable” if the bottom surface (the surface in contact with the conveyor rollers) is firm, flat, and long enough to span at least three rollers. Uneven surfaces, “feet,” or soft surfaces that tend to conform to the shape of the rollers are examples of non-conveyable bottom surfaces. If the bottom is not continuous for the entire length of the unit load, then only those rollers actually in contact with the load can “pull” the load, Since the drive capacity of each roller is limited, this can reduce the unit load capacity of the conveyor significantly. * Very rigid bottom surfaces may only contact two rollers for the length of the load if the rollers are not perfectly level with each other. This again reduces the unit load capacity. Other factors — Other qualities of the unit loads being conveyed may affect the application. For example, if the weight of the unit load is distributed unevenly inside its container then the majority of the load’s weight must be supported and driven by only two or three rollers. Such uneven weighting can also result in carton rotation, which may be undesirable in certain applications. 109Belt Driven Live Roller Conveyors Determining Conveyor Width 2 IN. CLEARANCE RAIL WIDTH Between Rail Width (BRW) Formula BRW = |(Inside Radius-+ Package Width) + ) Inside Radius +2” Figure 9.10 Formula for Determining Width Between Frame Rails (or Guard Rails) for Curves "The dimensional data of the unit loads to be conveyed are used to determine the conveyor width required, Usually, a conveyor width is chosen that is slightly wider than the widest unit load, In other applications it may be permissible to allow the load to overhang the sides of the conveyor slightly (of course, this may only be done when the rollers are set high in the frame). In applications where curves are required, the width requirements of the curves generally determine the conveyor width used in the system (Figure 9.10). Accessories ‘There are many accessories available to enhance the functionality of belt driven live roller conveyors. Some of these accessories are discussed below. 110Accessories Turning Posts, ‘These common accessories help safely guide product around corners onto or off of the Wheels, or Rollers conveyor. Spurs Actually a specialized form of live roller conveyor, spurs allow loads to be merged into or transferred from a conveyor at some angle, usually 30° or 45°, Right Angle ‘These devices take advantage of the spaces between the carrying rollers by raising wheels, Pop-Up Transfers belts, or chains up through the conveying surface. Unit loads may then be transferred onto or off of the conveyor by the powering the belts or chains, or by force of gravity. Deflectors Deflectors come in several types, the simplest being straight, or sometimes curved, bars set at an angle to the conveyor. Loads moving along the conveyor make contact with the bar and are moved to one side as they slide along the bar. The bar may be a plain steel channel, coated with a slick wear surface, or even with a moving face, such as a y-belt powered by a motor. Deflectors may be fixed in position or pivoting, allowing them to be positioned to allow loads to pass unimpeded or to be deflected, as required. Push-Offs A push-off'is a device used to physically push unit loads off to other lines, usually at 90% Push-offs may be pneumatically powered or operated by motors. Technical Data Further detail on Belt Driven Live Roller Conveyor technical specifications can be found in the current version of CEMA Standard 403, The 403 standard includes detailed information on calculating belt pull and horsepower and other important design parameters, Additional data regarding product conveyability, conveyor width, roller spacing, roller capacity and bearing rating life can be obtained in CEMA standard 401 titled “Roller Conveyors —Non-Powered’, Maintenance Considerations As with any conveyor, proper maintenance is required to ensure proper operation and long life of a belt driven live roller conveyor, Maintenance procedures will vary depending on manufacturers actual design and actual application conditions, Some maintenance considerations include keeping the conveyor cleart and*free of paper, cardboard, tape and other contaminants that may accumulate on or within the con- veyor due to the nature of product being conveyed. The conveyor belt must be kept properly tensioned in order to prevent slipping on the drive pulley, however, over tensioning of the belt may result in damage to belt lacing and unnecessary bearing and m1Belt Driven Live Roller Conveyors shaft loads. The conveyor belt also must be kept properly tracked in order to prevent damage to the belt and unnecessary downtime. Regular visual and audible inspections while following the manufacturer's recommended maintenance procedures will ensure getting the optimum performance of the belt driven live roller conveyor. Safety Considerations nz All powered equipment including belt driven live roller conveyors contain inherent hazards to personnel that need to be safe guarded. Some hazards include the chain or timing belt on the drive. Also nip points between the belt and drive pulley, idler pulleys, and snub rollers must be safe guarded. These areas are typically protected by guards that must be kept in place and in good condition, The nip point between the belt and carrying rollers is a little less obvious but also presents a hazard. It may be protected by using close roller centers, finger guards between rollers or pop out roller construction. Pop out roller construction utilizes slots for mounting of carrying rollers allowing rollers to lift out of the frame should something get caught between the roller and the belt. If the conveyor will be located overhead, the rollers must be retained to prevent them from falling on someone below. If personnel are likely to work on or hear the elevated conveyor, pop out slots must be used with safety netting and decks must have kick plates to insure that dislodged rollers cannot injure personnel below. Please refer to the safety page of the CEMA website and the CEMA Safety Video for additional information. Other CEMA standards and documents that provide useful information include: * CEMA B105.1— Welded Steel Conveyor Pulleys * CEMA 102—'Terms and Definitions * CEMA 201— Safety Label Brochure * CEMA 403 — Belt Driven Live Roller Conveyors ‘© CEMA Safety Poster for Package conveyors * CEMA Unit Handling Conveyor Safety Video (DVD)CHAPTER 10 Chain Driven Live Roller Conveyors Definition m4 Roll-to-Roll_ 114 Continuous Chain 114 Design 115 Drive Sections 115 Intermediate Sections 116 Curves 117 Transfers. 117 Turntables 116 Application 178 Load Information 119 Effective Conveyor Width 119 Curve Width 119 Roller Spacing. 119 Conveyor Capacities 120 Frame Capacities 120 Drive Mounts 120 Speeds 121 Load Drift/Application of Motor Brakes 121 Environmental Factors 121 Load/Unload Stations 121 Conveyor Pitch 122 Blocked Load Condition 122 Accessories 122 Technical Data 122 Horsepower Calculations 122 Pallet Types 122 Load Width—Curves 124 Maintenance Considerations 125 Preventive Maintenance 125 Safety Considerations 125 113Chain Driven Live Roller Conveyors Definition Roll-to-R uous Chain Chain Driven Live Roller (CDLR) conveyor is a positively driven, heavy-duty, live roller conveyor. The positive drive makes it ideal for transporting pallet/unit loads, containers, drums and fixtures, It is better suited in environments where dirt, oil or other contaminants are present than other styles of live roller conveyors, There are two styles in common use: roll-to-roll and continuous chain (single strand) ‘Two plate sprockets are welded to each roller, Individual loops of chain connect rollers in a staggered pattern, As one roller is turned, the plate sprocket drives the adjacent chain loop to turn the next roller and sprocket. This pattern continues for the entire length of the CDLR conveyor (Figure 10.1). ‘This type is driven by one continuous strand or loop of chain, engaging only the top or bottom teeth ofa sprocket attached to each driven roller, causing the roller to rotate. Only one sprocket is required for each driven roller. Because of the limited tooth engagement, this type of CDLR should not be used for long CDLR conveyors and should only be used with moderate unit loads (Figure 10.2). ” @O@®O © © Figure 10.1. Roll-to-Roll CDLR Conveyor 4Definition Plan And Side View Plan And Side Views Single-Strand Chain “Two-Sttand Chain CDLR Conveyor igure 10.2 Continuous Cl Design Drive Sections CDLR conveyors can be individually driven and controlled or, depending on load weight and configuration, two or more sections of CDLR can be linked together effectively making one longer conveyor section. CDLRs are typically built by attaching a series of pre-manufactured sections together to achieve long runs. CDLRs come in a variety of configurations consisting of the following: * Drive Section (drive unit included) __ * Intermediate Sections (slave driven from drive section) * Curves * Transfers © Turntables Drive sections are the most common of the pre-manufactured CDLR conveyor sections, ‘They make up the majority of the finished operable conveyor, Exact section lengths are roller spacing dependent. Typical standard bed lengths are between four and ten feet. CDLR conveyors are generally available in left/right hand configurations, (although intermediate and drive beds are often non handed) various widths, various drive package arrangements, and various conveying speeds. Rollers are the carrying surface, These rollers are evenly spaced along the length of the section. The selection of roller spacing depends on product characteristics such as pallet size, weight, and configuration. Roller spacing can also vary due to roller chain pitch, Chain pitches +¥40, #50, #60, and #80 are typical.