Belt Manual 3.2

For internal use only Airport Logistics
BELT Conveyor System

User Manual
Description and Configuration Rules
Siemens Industry - Mobility

September 15, 2010 V. 3.2 Industry, IL LS
www.siemens.com/airports
© by Siemens AG 2010
This is a copyrighted documentation of Siemens AG. It may not be altered, amended or repro-
duced without the prior written approval of Siemens AG and may not be used in any other manner
that is contrary to their legal interests.
All trademarks and registered trademarks are the property of the individual owners. The use of
registered names, trade names, description of goods etc. in this manual, even if not specially iden-
tified, does not imply that such names may be regarded as free in the sense of legislation pertain-
ing to registered trademarks and protection of trademarks and may therefore be used by anyone.
Responsible for the contents:
Engineering J. Bruett Phone +49 (0) 911 145 7602

Text editing H. Steinke Phone +49 (0) 911 145 6933
Postal address Siemens AG

Sector Industry, Airport Logistics
Colmberger Straße 2
90451 Nuremberg
Germany
The right to make modification to design and equipment is reserved.
Industry, IL LS September 15, 2010 V. 3.2

BELT Conveyor System User Manual History of Changes
Conveyor System Concept Description and Configuration Rules
History of Changes
Version Date Change/Comment

1.0 27.11.2002 Original document
1.1 17.12.2002 minor changes (e.g. in section about merges)
1.2 27.01.2003 reversible turns, calculation of energy consumption
1.3 13.02.2003 updates with turns and configuration rules for TRAY
loading stations
1.4 05.05.2003 Amendments to the technical data of vertical sorters
13o and 18o.
2.0 09.09.2003 Sections on straights, meterings, piers and HSD
new, various minor changes at other sections
2.1 04.11.2003 Height of side guards 400 mm
2.2 05.05.2004 Update to Siemens L&A, many technical changes
(spiral turns, configuration rules etc.)
2.3 07.10.2004 Speed and configuration rules for flat carousels
2.4 26.10.2004 Section 14 Tilt Tray Sorter revised
2.5 30.03.2005 New sections on turns and carousels, various
changes to all other sections
2.6 18.09.2006 New sections on vertical sorters and merges, vari-
ous changes to all other sections
2.7 17.04.2007 New section on configuration of right angle connec-
tions
2.8 03.07.2007 New sections on check-in and vertical sorter 1200
bph
2.9 08.02.2008 Minor changes, new cover sheet
2.10 14.04.2008 New HSD II
3.0 03.03.2008 Variobelt 2.0 , new carousels
3.1 19.10.2009 Terminology adapted
3.2 15.09.2010 Minor changes description Variobelt 2.0
This version supersedes all previous versions of the manual.
The BELT user manual is available in a German and an English version.
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September 15, 2010 V. 3.2 Industry, IL LS i
BELT Conveyor System User Manual Contents
Contents
1 Introduction and Overview.............................................................1
2 Check-in conveyors ........................................................................5

2.1 Functional specification of equipment ...............................................5
2.2 Technical data...................................................................................9
2.3 Drive ratings ....................................................................................10
3 Straight Conveyor .........................................................................11

3.1 Functional specification of equipment .............................................11
3.1.1 Beds ................................................................................................12
3.1.2 Side guards .....................................................................................13
3.1.3 Return station..................................................................................13
3.1.4 Drive stations ..................................................................................15
3.1.5 Straight conveyors of different lengths............................................19
3.1.6 Knee sections between straight conveyors.....................................21
3.1.7 Photo electric cell (PEC) holder ......................................................22
3.2 Technical data.................................................................................22
3.3 Drive ratings ....................................................................................27
4 Metering Conveyor........................................................................28
4.2 Technical data.................................................................................30
4.3 Drive ratings ....................................................................................32
5 Pier conveyor ................................................................................33

5.2 Technical data.................................................................................34
5.3 Drive ratings ....................................................................................34
6 Power Turn TS 1600......................................................................35

6.2 Technical data.................................................................................37
6.3 Drive ratings ....................................................................................40
7 Spiral Power Turn TS 1600 Helix .................................................41

7.2 Technical data.................................................................................43
7.3 Drive ratings ....................................................................................46
8 Baggagge Topplers.......................................................................47
8.1 Overturn tapers in the Check-in area ..............................................47
8.2 Toppler after turns in downhill inclined conveyors ..........................47
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9 Vertical sorter unit 1200bph.........................................................49

9.2 Technical data.................................................................................52
9.3 Drive ratings ....................................................................................53
10 Vertical Sorter 1800 bph TS 6600 ................................................54

10.2 Technical data.................................................................................55
10.3 Drive ratings ....................................................................................57
11 High-speed Diverter ......................................................................58

11.2 Technical data.................................................................................59
11.3 Drive ratings ....................................................................................61
12 See-saw..........................................................................................62
12.2 Technical data.................................................................................64
12.3 Drive ratings ....................................................................................64
13 Merge / Divert TS 6200..................................................................65

13.2 Technical data.................................................................................68
13.3 Drive ratings ....................................................................................69
14 Tilt-tray Sorter ...............................................................................70
15 Sorter Chute ..................................................................................71

16 Flat Carousel .................................................................................72

16.2 Technical data.................................................................................75
16.3 Drive ratings ....................................................................................79
17 Inclined Carousel ..........................................................................80

17.2 Technical data.................................................................................82
17.3 Drive ratings ....................................................................................84
18 Configuration Rules......................................................................85
18.1 Energy consumption of a belt conveyor system..............................86
18.2 Speed profile ...................................................................................86
18.3 Bulky baggage and length detection ...............................................87
18.4 Check-in area..................................................................................88
18.5 Straight sections..............................................................................90
18.6 Right angle connections..................................................................90
18.7 Incline and decline conveyors .........................................................91
18.8 Baggage singulation........................................................................92
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18.9 Automatic tag readers (ATR) ..........................................................93

18.10 Manual encoding.............................................................................94
18.11 Explosive detection systems ...........................................................96
18.12 Pier conveyor loading and unloading ..............................................97
18.13 Turns ...............................................................................................98
18.14 High-speed diverter.........................................................................99
18.15 TRAY loading station ......................................................................99
18.16 Vertical sorters ................................................................................99
18.17 Pusher lines ..................................................................................100
18.18 See-saw ........................................................................................100
18.19 Merges ..........................................................................................101
18.20 Induct conveyor for sorters............................................................102
18.21 Chutes...........................................................................................102
18.22 Spiral chutes .................................................................................103
18.23 Early bag storages (EBS)..............................................................104
18.24 Fire protection gates .....................................................................106
18.25 Carousels ......................................................................................107
18.26 Baggage lifts .................................................................................109
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BELT Conveyor System User Manual Illustrations
Illustrations
Figure 1 Typical arrangement of a two-segment check-in conveyor...............6

Figure 2 Weight display and push buttons ......................................................6
Figure 3 Weighing & Labeling Conveyor.........................................................7
Figure 4 Dispatch Conveyor............................................................................7
Figure 5 Typical arrangement of a three-segment check-in conveyor ............8
Figure 6 Labeling conveyor partly pulled out...................................................9
Figure 7 Bed section with pulley in adjustable bearing block ........................12
Figure 8 Section of straight conveyor with 400 mm high side guards ...........13
Figure 9 Transition of conveyors with cascade .............................................13
Figure 10 Head/tail pulley pulled out sideways ...............................................14
Figure 11 Transition between straight conveyors............................................14
Figure 12 Compact straight with integrated drive station ................................15
Figure 13 Drive pulley pulled out sideways .....................................................16
Figure 14 Head drive station (view on both sides) ..........................................16
Figure 15 Belt run for center drive stations .....................................................17
Figure 16 Head drive station ...........................................................................18
Figure 17 Under-slung drive station SPW 168 D110 ......................................18
Figure 20 RBO 12o with filling plate.................................................................21
Figure 21 Photo of PEC holder and opposite reflector....................................22
Figure 22 Photo of rubber-metal vibration damper..........................................24
Figure 23 Photo of standard metering conveyor .............................................29
Figure 24 Section of Metering .........................................................................29
Figure 25 Metering conveyors with “cascade” transition .................................30
Figure 26 Reclaim pier conveyor (with one side guard) ..................................33
Figure 27 Drawing of the belt turn TS 1600 ....................................................36
Figure 28 Functional principle .........................................................................36
Figure 29 Main dimensions of power turn TS 1600 - 105 ...............................38
Figure 30 Main dimensions of power turn TS 1600 - 140 ...............................38
Figure 31 Side guides of power turn TS 1600.................................................39
Figure 32 Supports for power turn TS 1600 ....................................................39
Figure 33 Drive position for power turn TS 1600.............................................40
Figure 34 Overview of spiral turn TS 1600 Helix.............................................42
Figure 35 Functional principle .........................................................................43
Figure 36 Main dimensions of power turn TS 1600 – 105 Helix......................45
Figure 37 Side guides of power turn TS 1600.................................................45
Figure 38 Drive position for power turn TS 1600.............................................46
Figure 39 Photo of Check-in collecting belt with overturn tapers ....................47
Figure 40 Drawing of baggage toppler ............................................................48
Figure 41 Photo of opposing baggage overturners .........................................48
Figure 42 Vertical sorter overview (shown without covers) .............................50
Figure 43 Vertical sorter with tilting belt ..........................................................51
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BELT Conveyor System User Manual Illustrations
Figure 44 Vertical sorter front view..................................................................51

Figure 45 Vertical sorter overview (shown without covers) .............................55
Figure 46 High-speed diverter with flaps swiveled out and in .........................58
Figure 47 Drawing of high-speed diverter .......................................................59
Figure 48 Drawing of see-saw.........................................................................62
Figure 49 Photo of side view of see-saw and detail view of excenter .............63
Figure 50 Photo of height differential at the see-saw output ...........................63
Figure 51 Layout example for see-saw use ....................................................64
Figure 52 Photo of belt merge TS 6200 ..........................................................66
Figure 53 Main dimensions of belt merge TS 6200.........................................67
Figure 54 Carousel with integrated E-stop pushbutton ...................................73
Figure 55 View of flat carousel with slat removed ...........................................74
Figure 56 Chain with tensioning detail ............................................................74
Figure 57 Arrival: Cross-sections flat carousel, different backguards .............76
Figure 58 Sorting: Cross-sections flat carousel, different heights ...................77
Figure 59 Top view of friction drive .................................................................78
Figure 60 Drawing of friction drive...................................................................78
Figure 61 Overall view of inclined carousel.....................................................81
Figure 62 View of inclined carousel with bed section and different slat types.82
Figure 63 Cross-section of inclined carousel ..................................................83
Figure 64 Friction drive....................................................................................84
Figure 65 Cascade for right angle connections...............................................90
Figure 66 Drawing of 360o scanner gate.........................................................93
Figure 67 Photo of spiral chute with rolling bag ............................................104
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September 15, 2010 V. 3.2 Industry, IL LS ii
BELT Conveyor System User Manual 1 Introduction and Overview
1 Introduction and Overview
Contemporary transport of passenger baggage at airports is accomplished by

automatic conveyor systems. The equipment developed for this purpose trans-
ports the baggage either in trays or loose on conveyor belts. This document de-
scribes the BELT conveyor system from Siemens AG.
At most airports, passengers place their baggage on the first belt conveyor of the
baggage handling system at the check-in counter. From there, the bags are
transported through the various elements of the belt conveyor system, identified,
checked for safety and sorted in a largely automated process, until they are
loaded manually onto baggage trucks and transported to the aircraft. The same
technology is used for incoming and transfer baggage.
The different elements of the belt conveyor systems can be combined to build
especially compact baggage handling facilities with integrated and automated X-
ray testing and fine sorting to flight-specific sorting destinations. The technology
is also suitable for small baggage handling systems in which baggage sorting
need not necessarily be automated.
As long as the flow of baggage does not branch and the items do not need to be
tracked or examined individually, they can also be transported on the belts
densely packed. In each case, the individual conveyors are controlled via sen-
sors (e.g. photoelectric cells or PECs) that detect the presence of baggage.
Within chapters 2 to 17 this User Manual describes the conveyors applied for our
baggage handling systems and from chapter 18 onwards the configuration rules
for their application. These rules combine the exact knowledge of the products
used with the experience gained in earlier projects.
This means that the application of the rules is mandatory. If it is absolutely nec-
essary to make project-specific deviations or to use different conveyors in indi-
vidual cases, AL PE Solutions will have to be consulted.
The following conveyors are used in baggage handling systems:
Straight conveyors
These conveyors are used to build connecting segments. They can run horizon-
tally or as inclined conveyors.
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September 15, 2010 V. 3.2 Industry, IL LS 1
Turns
Turns change the conveying direction. Spiral turns can also be used to negotiate
height differentials.
Vertical sorters
This sorting equipment can distribute the baggage flow between two belt con-
veyors running at different elevations.
Diverters
Diverters divert to redundant conveyor lines or sort between two belt conveyor
lines at the same height.
Pushers
Pushers are sorting devices that branch the baggage flow between conveyor de-
vices at the same height.
Merges
This system merges two baggage flows at an angle of 300 or 450 on to one
common belt conveyor. Technically, the merge is similar to a merge on to a tilt-
tray sorter. As a variant, the device is also available as a divert.
Tilt-tray sorters
A closed chain of individual tilting trays that are loaded with one bag each sorts
the baggage to the available destinations.
Carousels
Carousels are closed conveyor loops in which bags are loaded by belt conveyors
and are unloaded manually. This allows the baggage to be sorted in the bag-
gage hall and the passengers pick up their baggage from the carousel in the ar-
rival hall.
Other, complementary components are Check-in belts, metering conveyors, pier

conveyors, see-saws and baggage overturners.
The baggage handling system can be assembled from the above standardized
basic elements. Project-specific adaptations are also possible. The conveyor
lines can be arranged side by side or also in several vertically stacked levels.
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These basic elements are largely pre-assembled at the factory and supplied to
the site as a unit. Long conveyors, such as straight conveyors or pier conveyors,
are shipped as modules. Drives and supports are installed on site.
Baggage specification
The system components described in this manual for regular baggage are de-
signed for the following baggage range:
● Suitcases with or without casters

● Bags, soft and hard
● Garment bags
● Backpacks
● Sea sacks
● Official mail of airlines and travel agencies
within the parameters stated in the following table:
Length Width Height Weight
max. 1000 mm 450 mm 800 mm 50 kg

min. 350 mm 70 mm 350 mm 2 kg
:NOTE: The use of Explosive Detection System machines can further limit these
maximum dimensions that apply to the mechanical structure of the baggage
handling system (size of the Explosive Detection System machine tunnel).
Bags that are smaller than one of the lower limits must be transported in bins,
with the limits for regular baggage also being applicable to the bins.
Bags that exceed a limit are considered bulky baggage and must be considered
as a special case.
:NOTE: Unless otherwise specified, the given throughput values always refer to
regular pieces of baggage with a length of 900 mm and a gap of 500 mm to the
next piece of baggage.
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Theoretical machine output

This is the maximum throughput of the isolated machine with optimum loading
and unloading, i.e. without any hold-up. The only limiting factor is the machine it-
self, but not its environment in the installed system.
Achievable process output

The theoretical machine performance is usually not achieved in a system. Gaps
between different items of baggage or a pile-up of baggage before or after a sys-
tem element can interrupt the continuous transport flow, thereby reducing the
theoretical machine throughput to the achievable process output. Within a chain
of sequential elements, the element with the lowest machine performance will
determine the throughput of the entire chain. This means that all other system
elements in the chain will not be able to achieve their full machine output.
Environmental conditions
The components of a belt conveyor system are designed for normal environ-
mental conditions (ambient temperature in the shade +5oC to +40oC). Subtropi-
cal temperatures and humidity can, for example, cause fogging of the PECs. The
limits for humidity are 5 to 95% non condensing.
In extreme environmental conditions (extreme temperatures, aggressive air, high

dust content etc.), consultation with BL Solutions will be required.
Drive ratings
The drive ratings specified in the manual are provided as guidelines. The exact
dimensioning will be defined during the detailed configuration after the order has
been placed.
Layout planning and engineering tool CONCEPTIX

The configuration program CONCEPTIX (CAD add-on) helps the planning engi-
neers create a customized layout design based on the described standard ele-
ments.
The basic elements of the belt conveyor system are designated with a unique
name in CONCEPTIX. So-called attributes are then used to define and describe
the different versions of this basic element.
Installation on site
During installation on-site welding is not necessary. Connections are made with
threaded fasteners.
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BELT Conveyor System User Manual 2 Check-in conveyors
2 Check-in conveyors
Designation in the Bill of Quantities

Weighing Weighing conveyor
Labeling Labeling conveyor
Dispatch Dispatch
Representation of the check-in conveyors in the layout (for three-conveyor units)
2.1 Functional specification of equipment

The main design considerations were to achieve a
● Low Insertion height, hence easy access to passenger’s baggage

● Professional appearance
● Silent operation
● Cost effective solution
● Check-in for easy use and maintenance
● Casing made of Stainless Steel 304, and finished to #4
The check-in conveyor is oriented 90 degrees to the take-away conveyor and is

normally configured in a two-segment design as indicated in the drawing below
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(depending on customer requirements and site space availability a three-

segments model is available as an option).
Figure 1 Typical arrangement of a two-segment check-in conveyor
In a two-segment check-in model, the first segment (the weighing & labeling
conveyor) is mounted on a base bed with four load cells for weighing. The sec-
ond segment (the dispatch conveyor) injects the baggage onto the take-away
conveyor. These two segments are designed with a cascading transition.
During checking-in, the passenger places the baggage directly onto the stopped
weighing conveyor. The display panels on both the operator and passenger side
display the weight of the bag.
Figure 2 Weight display and push buttons
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As soon as the operator has checked the bag’s weight and labeled the bag, he
starts the weighing conveyor to transfer the bag to the dispatch conveyor. There
the bag will wait to be inducted automatically onto the take-away conveyor.
Weighing & labeling conveyor

At the passenger side of weighing and labeling conveyor the height is only
200mm, which makes it easy for the passenger to load his bag onto the con-
veyor.
The conveyor consisting of bed section, belt, pulleys, side guards, etc is directly
mounted on top of the weighing load cell steel bed section anchored to the
ground. The conveyor’s weight is offset at the weigh scales to show the empty
conveyor without weight.
Figure 3 Weighing & Labeling Conveyor
Dispatch conveyor
Similar to the weighing conveyor, the dispatch conveyor can be moved on rails
with a base bed section anchored to the floor. The baggage-toppling device at
the end of the conveyor overturns bags at the induct conveyor to the take-away
conveyor into a stable position.
Figure 4 Dispatch Conveyor
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Three-segment check-in conveyor model – weighing, label & dispatch conveyor

With the three-conveyor segments check-in model, labeling of baggage is done
at a separate conveyor installed between the weighing and dispatch conveyor.
The three-segment conveyor model can cope easier with baggage congestion
on the take-away conveyor.
Figure 5 Typical arrangement of a three-segment check-in conveyor
Maintenance friendly pull out design

Both conveyors can easily be pulled forward for maintenance purposes. The pic-
ture shows the labeling conveyor partly extracted.
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Figure 6 Labeling conveyor partly pulled out
2.2 Technical data
Table 1 Weighing and Dispatch Conveyors
S/No. Parameter Standard Design Optional Design

1 Conveyor design 2 Segments, pull-out design 3 Segments, pull-
with quick release connectors out design
for power and sensor cables
2 Length Check-in 1200mm Dispatch conveyor
Dispatch 1500mm range from 1200 -
1600mm
3 Width Between guides 600mm 500 - 1000mm
Overall width 700mm (side
guard width of 50mm for each
side)
4 Height Weighing conveyor at passen- Dispatch conveyor
ger side: 200mm – height of 350 -
Dispatch conveyor at take-away 400mm at take-
conveyor: 350mm away conveyor.
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Table 1 Weighing and Dispatch Conveyors
S/No. Parameter Standard Design Optional Design

5 Motor ● Motorized pulley (drum ● With lagging
Motor) ● Size 0.55KW
● Crowned pulley with no ● With brake
lagging
● IP 65, 3 phase
● No brake
6 Speed 0.5 meter / sec
7 Casing material Stainless steel 304, finish 4 Other type of finish
optional
8 Baggage weight Baggage loads 0.5 kg to 60 kg Higher baggage
load up to 100Kg
9 Weighing scale ● Single frame 4 load cell.
Bed section also functions
as rail track for conveyor.
● Baggage load 0.5kg to 60kg
● Capacity – 150kg typical,
300kg, maximum
● LCD displays for both op-
erator and passenger
● With heavy baggage limiter,
baggage counter and
weight accumulator
● OIML certificate of confor-
mity
10 Belt Make – Ammeraal Beltech
Profile – with Siemens logo
Flame retardant to ISO 340
11 Noise level Maximum 65 dBA
12 Drive reversibility Yes for weighing conveyor
13 Baggage toppling Included – refer to Figure 4 Toppling device in
device shape of conical or
cylindrical roller
2.3 Drive ratings

Drum motor with 0.37 KW per conveyor.
BELT Manual 3_2.doc

BELT Conveyor System User Manual 3 Straight Conveyor
3 Straight Conveyor

STRAIGHT up to 9o incline/decline
INCLINE from 9o up to 15o incline
DECLINE from 9o up to 18o decline
in the following configurations:
● Drive side right / left

● Nominal width 1050 / 1200 / 1500 mm 1
Representation of the straight conveyor in the layout

Straight conveyors are the connecting sections in a belt conveyor system. They
consist of only a small number of modular subassemblies which are combined to
build the variants that are required in a baggage handling system (e.g. different
lengths, inclination, transition, drives).
Depending on their length, the conveyors essentially consist of frames (beds)

with two side guards, a drive station and one or two return stations. Conveyors
up to a length of 20 m (in special cases up to 30 m) only require one drive.
The modular subassemblies are designed so that different variants of the con-
veyor can be built just by combining them in different configurations. This re-
duces the number of individual parts and facilitates the maintenance of the con-
veyors.
Straight conveyors for bulky baggage differ from ordinary conveyors only in that
they are wider.
1
In addition the conveyors are available with a nominal width of 800 mm.
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3.1.1 Beds
The length of the belt conveyor results from the combination of bed sections of
different lengths. The bed sections constitute the support for the other subas-
semblies. A bed section can be equipped with one or two end deck pans.
The desired conveyor lengths are obtained by combining end or intermediate

bed sections of fixed length. The different standardized bed sections currently
available can be combined to any length in 50 mm grid starting at a fixed min.
length of 3200 mm. For shorter conveyors a combination of bed-sections is not
guaranteed to be available.
Compact straights (same design as metering conveyors) are available in a 200

mm grid.
Return idlers can be installed at the front, in the middle or at the back end of
each bed section. They are adjustable via elongated holes. The distance be-
tween two adjacent return idlers should not exceed 3 m. The bed section is al-
ready prepared for the installation of the head / tail pulleys.
Figure 7 Bed section with pulley in adjustable bearing block
One end deck pan
Head / tail pulley
Adjustable bearing block
The figure shows the one end deck pan and the head/tail pulley. The pulleys are
mounted in adjustable bearing blocks that are bolted to the exterior side of the
bed section.
Each bed section is prepared for the installation of a drive station, either a head
drive station at one end or an under-slung drive station.
BELT Manual 3_2.doc

3.1.2 Side guards

The side guards are bolted onto the frames and can easily be removed to ser-
vice or change the belt.
Figure 8 Section of straight conveyor with 400 mm high side guards
3.1.3 Return station

The head/tail pulley is fitted into the end deck pan of a bed section. Each end
deck pan can be mounted within the bed section in two different ways, either
straight so that the belt runs parallel to the bed section or with a downward slope
of approx.4°. The downward slope of the belt creates a step of 50 mm at the
transition to the adjacent conveyor, typically called a “cascade”. In this case the
adjustable bearing block will be mounted upside down. This cascade setup helps
to prevent loose parts of baggage from getting trapped.
Figure 9 Transition of conveyors with cascade
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The gap between the head and tail pulley of two adjacent conveyors is 50 mm
(or optionally <= 5 mm).
The crowned head/tail pulleys can be adjusted with a set screw individually on
each bed section side of the conveyor by +/- 3 mm (integral functionality of the
adjustable bearing block) to adjust the belt tracking or to adjust the gap size to-
wards the head/tail pulley of an adjacent conveyor.
Since the adjustable bearing blocks are mounted to the exterior bed section
sides they are easily accessible for maintenance and allow for the head/tail pul-
leys to be pulled out sideways.
Figure 10 Head/tail pulley pulled out sideways
Connecting plates are mounted onto the adjustable bearing blocks of two adja-
cent conveyors thus connecting the conveyors with a fixed gap size as well as
covering the gap and the turning shafts. The gap between the side guards at the
transition is filled with standardized filling plates.
Figure 11 Transition between straight conveyors
Set screw
Adjustable bearing
block
BELT Manual 3_2.doc

The filling plates between side guards and connections plates are removed. The
set screw in the roller head is available to adjust the deflection roller.
Integrated nip guards ensure, that even if the belt does not run exactly in the
center during operation all gaps are covered securely.
3.1.4 Drive stations

All drive stations are driven by gear motors that are mounted directly on the drive
pulley shaft. The standard setup for the gear motors is the vertical position.
(horizontal position optional)
A drive station always incorporates a take up mechanism for tensioning the belt.
Integrated drive station for compact straights
Figure 12 Compact straight with integrated drive station
Under-slung drive station

Within the under-slung drive station the take up pulley can be adjusted by a
threaded spindle on each side. For more comfort an optional chain drive will link
both spindles together so that the belt tension can be adjusted by operating only
one single spindle. This is maintenance friendly and also allows the straight con-
veyor to be installed closer along a wall. A clearance of at least 350 mm must be
observed for maintenance purposes.
:NOTE: The optional chain drive allows belt tensioning from either side, but
once the maintenance side is determined the assembly will be fixed accordingly
at the factory.
BELT Manual 3_2.doc

The all steel drive pulley drives the belt on the rubber-coated side. This elimi-
nates the need for the usual lagging of the drive pulleys (vulcanized rubber coat-
ing). The return idlers are slightly crowned. For easy maintenance the drive pul-
leys can be pulled out sideways.
Figure 13 Drive pulley pulled out sideways
The pre-punched hole pattern in the bed sections allow a variable lateral posi-
tioning of the under-slung drive station. This facilitates accessibility for assembly
and also for later maintenance. If required, due to space restrictions, the under-
slung drive station can easily be repositioned on site.
In general the under-slung drive station should be installed at the “head” side of
the conveyor in respect to the conveying direction, but this is not mandatory. For
example if a belt conveyor shall be operated in reversing mode the under-slung
drive station is usually installed in the middle at half conveyor length.
Head drive station

A head drive station can also be installed at the end of a bed section instead of
an under-slung drive station. In difference with the under-slung drive station is
the drive pulley is lagged and the station is equipped with only one more pulley
which accommodates the take up for the belt tensioning as well as the belt track-
ing. This pulley can be adjusted by a threaded spindle on each side individually.
Figure 14 Head drive station (view on both sides)
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The drive station at the head end of the conveyor drives the belt on the fabric
side.
Drive station models

Five different drive station models are available. Depending on the specific ap-
plication, different gear motors will be used (please also refer to paragraph 3.3 )
The four different under-slung drive station models are coded by the max. travel
distance of the take up pulley (SPW) and the diameter of the drive pulley (D).
Each drive station is available with a left-hand or right-hand drive position.
Head drive SPW168 D110 SPW168 D160 SPW455 D240
SPW455 D160
Length of
500 mm 830 mm 830 or 1170 mm 1170 mm
drive station
Diameter of
160 mm 110 mm 160 mm 240 mm
drive pulley
Diameter of
89 mm 89 mm 89 mm 89 mm
take up pulley
Diameter of
89 mm 89 mm 89 mm 89 mm
return idlers
Diameter of
99 mm 99 mm 99 mm 99 mm
head/tail pulley
Travel of take
up pulley 40 mm 168 mm 168 or 455 mm 455 mm
Applicable for
1.2–6.0 m 1.2 – 6.2 m 6.2 – 20 m > 20 m
conv. lengths
Figure 15 Belt run for center drive stations
BELT Manual 3_2.doc

Figure 16 Head drive station
Figure 17 Under-slung drive station SPW 168 D110
BELT Manual 3_2.doc

The under-slung drive station SPW 455 D240 is used if the conveyor is longer
than 20 m, the belt runs faster than 2 m/s or extremely heavy items need to be
conveyed.
For high loads, often 3-layer belts are used that require larger pulley diameters
(>90 mm).
3.1.5 Straight conveyors of different lengths

As a general rule for the minimum length of a conveyor it should always be
longer than wide, which means that the possible min. length of a conveyor is
predetermined by the nominal width:
● NW 1200 mm -> minimal conveyor length is 1400mm

● NW 1500 mm -> minimal conveyor length is 1700mm
:NOTE: The length of the shortest conveyor (metering, see section 4) depends
on the longest piece of baggage that the system is designed for.
Compact straights (same design as meterings) - Length 1,200 mm to 3,200 mm / grid 200 mm
The conveyor consists of
● One bed section with two end deck pans

● One drive station assembly integrated into bed section
● Head and tail pulley
Height of conveyor (= bed section height): 230 mm
:NOTE: For compact conveyors with NW 1500 mm head/tail pulleys with diame-
ter 130 mm are used instead of the usual 100 mm pulleys. The available lengths
therefore range from 1660 mm to 3260 mm in 200 mm increments.
BELT Manual 3_2.doc

Conveyors with head drive station - Length 1,250 mm to 6,200 mm / grid 50 mm

● One or more bed sections that are bolted together; one end deck pan
(bed section height 150 mm, max. length of a section 3,000 mm)
● One head drive station
● One tail pulley
● Return idlers if applicable
Height of conveyor (lowest point of head drive station to top of bed section):
260 mm over full width , 400 mm at the torque arm
Conveyors with center drive station - Length 3,250 mm to 20,000 mm / grid 50 mm

● One or more bed sections that are bolted together; two end deck pans
● One under-slung drive station (model depends on application)
● Return idlers if applicable
Height of conveyor (lowest point of center drive station to top of bed section):
350 mm
:NOTE: For maintenance purposes additional 50 mm below the drive station

are required.
Conveyors with center drive station - Length 20,250 to 30,000 mm / grid 50 mm

● Multiple bed sections that are bolted together; two end deck pans
● One under-slung drive station, model SPW455 D240
● Return idlers
Height of conveyor (lowest point of center drive station to top of bed section):
350 mm
:NOTE: Straight conveyors of this length must be checked/released individually

by the engineering department.
BELT Manual 3_2.doc

3.1.6 Knee sections between straight conveyors

Knee sections between straight belt conveyors in convex and concave configura-
tions can be installed with the conveyors remaining unchanged in all other re-
spects, including the side guards.
Convex configuration with Radius Break Over (RBO)

This setup permits to build conveyors with convex knees in fixed articulation an-
gles of -6°, -12°, -18°.
The gap between the conveyor deck pans is closed with convex joint connection
pans, the side guards with standardized filling plates. An additional return idler is
mounted between the filling plates.
Figure 20 RBO 12o with filling plate
Filler plate
Return idler
Convex configuration with Nose Over

Alternatively a convex knee can be generated by using a so called nose over
configuration. This setup is more complex than the RBO solution (two additional
deflection rollers) but offers the advantage of a continuously variable articulation
angle between 0° and +18°. The gap between the sidewalls is closed with stan-
dard sliding filling plates. An additional deflection roller guides the belt.
Concave configuration
A knee in concave configuration can be implemented with two conveyors. Stan-
dardized filling plates close the gap between the sidewalls. A cascade is imple-
mented for declining conveyors, whereby no cascade is used in the case of in-
clining conveyors.
BELT Manual 3_2.doc

3.1.7 Photo electric cell (PEC) holder

A permanent magnet with anti-slip rubber coating fixes the PEC on the exterior
side of the side guards. The strong magnet force retains the holder in its position
under all operating conditions.
During assembly, the PEC holder must be loosely placed in its approximate posi-
tion. The exact position of the PEC is then adjusted by means of elongated
holes.
The patented Siemens PEC holder significantly reduces installation and adjust-
ment work.
Figure 21 Photo of PEC holder and opposite reflector
3.2 Technical data

Product specification
Regular baggage
Nominal width between side guards 1,050 mm
Belt width 1,000 mm
Irregular baggage
Nominal width between side guards 1,200 / 1,500 mm
Belt width 1,150 / 1,450 mm
Static load 150 kg/m (bed section can

be stepped on)
Dynamic load 75 kg/m
1
Height of side guard above bed section 400 mm
Thickness of sheet metal of the side guards 3 mm
Thickness of bed section panels 3 mm
1
As an alternative side guards are available in 150, 300 or 600 mm height.
BELT Manual 3_2.doc

Standard length of bed sections:
● With one end deck pan 1,0 / 1,2 /1,4 / 1,6 / 1,8 / 2,0 / 2,5 / 3,0 m
● Without end deck pans 0,25 / 0,5 / 1,0 / 1,2 /1,4 / 1,6 / 1,8 / 2,0 / 2,5 / 3,0 m
● Nose over 1,0 / 1,5 / 2,0 / 2,5 / 3,0 m
The side guards typically have the same length as the bed sections.
Each adjustable bearing block contributes 100 mm length to the total conveyor
length. (e.g. the total length of a conveyor with a 3.000 mm bed section and two
adjustable bearing blocks is 100 + 3.000 + 100 = 3.200 mm)
Drive shaft mounted gear motors in different

drive ratings
Weights (NW 1,050 mm)

Intermediate bed section ca. 92 kg/m (including belt, pulleys etc.)
Drive stations (without gear motor)
● Head drive station ca. 132 kg

● SPW 168 D110 ca. 142 kg
● SPW 455 D160 ca. 169 kg
● SPW 455 D240 ca. 192 kg
Gear motor ca. 35 kg
:NOTE: As a guideline, an additional 20 kg/m should be provided for the cables.

Example: Weight of a 1,050 mm wide straight conveyor with a length of 9 m and
a center drive station model SPW 455 D160:
9 m x 92 kg/m + 169 kg + 35 kg + 9 x 20 kg = 1,212 kg
Noise level
An empty conveyor generates a noise level at a distance of 1m from the drive
station of approximately 73 dbA at 1 m/s, which rises up to 75 dBA at high
speeds (strong noise increase above 2.0 m/s).
:NOTE: The noise level in baggage handling systems depends on the noise
emissions of all noise sources that affect the respective area, as well as on the
BELT Manual 3_2.doc

acoustic characteristics of the building. The critical noise level relevant for labor
protection or public passenger areas cannot be calculated or measured in ad-
vance. The need for additional sound insulation in certain areas can only be de-
termined with noise measurements under operational conditions..
Rubber-metal vibration damper
Figure 22 Photo of rubber-metal vibration damper
Bearings
The bearings used for the head/tail pulleys in the adjustable bearing block are
standard sealed spherical bearings.
The drive pulleys are seated in standard flange bearings with grease nipples.
The bearings of straights up to 15 m length are dimensioned for a L10 lifespan of

50,000 hrs, assuming a permanent dynamic load of 50 kg/m.
The bearings in straights over 15 m length reach a L10 lifespan of 50,000 hrs only
when a reduced dynamic load of 25 kg/m is assumed.
Finish
The beds and side guards are provided with an antistatic powder coating that re-
sists impact and friction damage, made from a mix of epoxy resin and polyester,
with a coating thickness of 50 – 200 µm.
The standard color is RAL 7035 (light gray). Other RAL colors are available op-
tional. The normal gloss level is 50%.
BELT Manual 3_2.doc

Belt types
Standard belt (2-layer)
These belts are used for flat conveyors without any particular stresses, for up-
slopes with an inclination of less than 8o and in cases where not more than one
merge feeds onto one straight conveyor.
● Example type: EX 10/2 0+05 black M2 AS FR

● Laterally stable polyester fabric
● Hardness 80 A Shore
● Overall thickness 2.5 mm
● Surface weight 2.9 kg/m2
● Tensile force per width unit (for 1% of stretch)
10 or 12 N/mm
● Operating temperature 0o C to +80o C

● Coefficient of sliding friction against
steel according to EN 1724 0.2
● Flame-retardant according to standard ISO 340 / EN 20340
Longitudinally grooved belt (2-layer), rough surface
These high-grip belts are used for up-slope belts above 8o inclination.
● Example type: EX 10/2 0+A32 black AS FR

10 or 12 N/mm

BELT Manual 3_2.doc

Low friction belt (3-layer)
These belts are used for high loads in combination with the model SPW 455
D240 drive station. Due to its significantly stiffer fabric, the belt is also used for
dynamic pushers, as well as in applications where more than one merger feeds
onto one straight conveyor.
● Example type: EX 15/3 0+10 black M2 AS FR

● Low-noise polyester fabric
15 N/mm

Restriction to belt types

Since the Variobelt 2.0 is designed to drive the belt on the rubber-coated side
with an all steel drive pulley, it is not possible to use knurled belts (Knurls might
tear off when the belt starts, which may damage the belt).
Inclined conveyors use longitudinally grooved belts.
Performance data
Straight conveyor speed 2.6 m/s max.
Speed difference between two adjacent conveyors 0.3 m/s max.
BELT Manual 3_2.doc

3.3 Drive ratings

The following table is a guideline for the drive ratings. The exact drive ratings al-
ways have to be specified within the detailed engineering phase of a project
based on the requirements.
Conveyor speed (m/s)
Conveyor 0.2 0.5 0.7 1 1.2 1.4 1.6 2

● Straight conveyors < 5 m 1.1 1.1 1.1 1.1 1.5 1.5 1.5 1.5
KW KW KW KW KW KW KW KW
● Pier conveyors < 5 m
● Horizontal or down-slope 2.2 2.2 2.2 2.2 2.2 2.2 2.2 3KW
straight conveyors from 5 to KW KW KW KW KW KW KW
< 15 m
● Up-slope straight conveyors
from 5 to < 10 m
● Pier conveyors from 5 to < 10
m
● Horizontal or down-slope 3KW 3KW 3KW 3KW 3KW 3KW 3KW 4KW
straight conveyors from 15 to
20 m
● Up-slope straight conveyors
from 10 to 15 m
● Pier conveyors from 10 to 15 m
Up to 9o inclination, the drive ratings are the same as with horizontal straight
conveyors. Up-slope conveyors can have an inclination up to 15o.
BELT Manual 3_2.doc

BELT Conveyor System User Manual 4 Metering Conveyor
4 Metering Conveyor

METERING

● Cascade with / without
● Nominal width 1050 / 1200 / 1500 mm
Representation of the metering conveyor in the layout

Metering conveyors are straight conveyors with a high start/stop frequency and
high acceleration/deceleration rates. They always feature longitudinally-grooved
2-layered belts with high co-efficients of friction in order to minimize the slip be-
tween baggage items and the belt during start/stop operation.
The drive station is integrated into the bed section. It drives the belt on the fabric
side. In contrast to the under-slung drive station, the drive pulley is lagged and
the station is equipped with only one more pulley which accommodates the take
up for the belt tensioning. This pulley can be adjusted by a threaded spindle on
each side individually.
For more comfort an optional chain drive will link both spindles together so that
the belt stretch can be adjusted by operating only one single spindle. This is
maintenance friendly and also allows the straight conveyor to be installed closer
BELT Manual 3_2.doc

along a wall. A clearance of at least 350 mm must be observed for maintenance

purposes.
:NOTE: The optional chain drive allows the adjustment of the belt tension from
either of the two sides, but once the operation side is predetermined the assem-
bly will be fixed accordingly at the factory.
Figure 23 Photo of standard metering conveyor
Figure 24 Section of Metering
BELT Manual 3_2.doc

Figure 25 Metering conveyors with “cascade” transition
Reversing metering conveyors are designed without height differential.
4.2 Technical data

Regular baggage
Nominal width between side guards 1,050 mm
Belt width 1,000 mm
Irregular baggage
Nominal width between side guards 1,200 / 1500 mm
Belt width 1,150 / 1450 mm
Static load 150 kg/m (bed section can be

stepped on)
Dynamic load 75 kg/m
Height of side guard above bed section 400 mm 1
Thickness of sheet metal of the side guards 3 mm
Thickness of bed section panels 3 mm
In baggage handling systems the length of the shortest conveyor will typically be
determined by the length of the largest baggage item for that the system is de-
signed for.
For baggage lengths of up to 900 mm, typically metering conveyors with a length
of 1,200 mm are used. 2
For systems that handle larger baggage items, the following rule of thumb ap-
plies:
Rule of thumb: Metering length = max. baggage length + 300 mm
1
As an alternative side guards are available in 150, 300 or 600 mm height.
2
The min. length depends on the nominal width.
For meterings NW1200 the min. length is 1400 mm, for meterings NW1500 the min. length is 1700 mm.
BELT Manual 3_2.doc

Standard length of metering conveyors (NW1050):
1,2 / 1,4 / 1,6 / 1,8 / 2,0 / 2,2 / 2,4 / 2,6 / 2,8 / 3,0 / 3,2 m
The length of the side guards is equal to the length of the metering conveyor
minus 200 mm. (100 mm for each adjustable bearing block). The standard
lengths include head / tail pulley.
Drive shaft mounted gear motors

with a disk brake in different drive ratings
● Diameter of deflection roller 99 mm

● Diameter of drive pulley 110 mm
Weights (NW 1050 mm)

The following example applies to a standard metering conveyor 1,200 mm long.
175 kg + 30 kg (motor) + 38 kg (side guard) = 243 kg
Noise level
An empty conveyor generates a noise level at a distance of 1m from the drive
station of approximately 75 dbA.
:NOTE: The noise level in baggage handling systems depends on the noise
emissions of all noise sources that affect the respective area, as well as on the
acoustic characteristics of the building. The critical noise level relevant for labor
protection or public passenger areas cannot be calculated or measured in ad-
vance. The need for additional sound insulation in certain areas can only be de-
termined with noise measurements under operational conditions.
Bearings
The bearings in the adjustable bearing bracket used for the head/tail pulleys are
standard sealed spherical bearings.
The drive pulleys are seated in standard flange bearings with grease nipples.
The bearings are dimensioned for a L10 lifespan of 50,000 hrs, assuming a per-
manent dynamic load of 50 kg/m.
Finish
The beds and side guards are provided with an antistatic powder coating that re-
sists impact and friction damage, made from a mix of epoxy resin and polyester,
with a coating thickness of 50 – 200 µm.
BELT Manual 3_2.doc

The standard color is RAL 7035 (light gray). Other RAL colors are available op-
tional. The normal gloss level is 50%.
Start/stop rates
Conveyor speed 0.5 - 1.2 m/s 1800 start/stops per hr
Conveyor speed >1.2 m/s 1200 start/stops per hr
Belt types
Longitudinally grooved belt, 2-layer
● Example type: EX 10/2 0+A32 black AS FR

10 or 12 N/mm

4.3 Drive ratings

The following table is a guideline for the drive ratings. The exact drive ratings al-
ways have to be specified within the detailed engineering phase of a project
based on the requirements.
Conveyor speed (m/s)

Metering conveyor 0.5 0.7 1 1.2 1.4 1.6 2
non FC-controlled 1.1 1.1 1.1 1.5 1.5 2.2 2.2
KW KW KW KW KW KW KW
FC-controlled 1.5 1.5 1.5 1.5 1.5
KW KW KW KW KW
When the drive is not FC controlled, it has an integrated DC relay.
BELT Manual 3_2.doc

BELT Conveyor System User Manual 5 Pier conveyor
5 Pier conveyor

PIER

● Nominal width 1050 / 1200 / 1500 mm
● Side guard right / left / without
Representation of the pier conveyor in the layout (without side guards)

Pier conveyors are used to manually load and unload pieces of baggage. They
are used, for example, for transfers or as laterals downstream of a tilt-tray sorter.
Loading and unloading is done from one side or both sides.
Figure 26 Reclaim pier conveyor (with one side guard)
BELT Manual 3_2.doc

BELT Conveyor System User Manual 5 Pier conveyor
Because pier conveyors are loaded and unloaded manually, they run at low
speeds (typical speed is 0.5 m/s).
Technically, pier conveyors correspond to the straight conveyors described in

Section 3. On the operator side, the side guard that is normally bolted onto the
bed section is eliminated. Instead, the bed section and possibly also the drive
station is covered with a corresponding wooden or synthetic panel.
If the pier conveyor is used as a baggage check-in conveyor (e.g. for transfer
baggage), the belt edge on the operator side is covered and thus protected by a
corresponding plastic profile.
5.2 Technical data

Please refer to straight conveyor, refer to Section 3.2.
5.3 Drive ratings

Please refer to straight conveyor, refer to Section 3.3.
BELT Manual 3_2.doc

BELT Conveyor System User Manual 6 Power Turn TS 1600
6 Power Turn TS 1600

TURN
● Turn angles 30°, 45°, 60°, 90° or 180°

● Turn radius 1550 / 1710 mm
● Turn direction right / left
● Drive side inside / outside
● Turn types TS 1600-105, TS 1600-140
Representation of the turn in the layout

The belt power turn is a driven belt that is used to transport baggage through a
curve. In the process, the transported baggage maintains its position and dis-
tance to the following piece of baggage.
Representing the core element of the innovative TS 1600 family of belt power
turns; the TS 1600-100 and TS 1600-140 can be used for baggage handling sys-
tems with a maximum loading capacity of 120 kg (TS1600-100) or 250 kg (TS
1600-140).
The 1600 series combines top-class performance and reliability with an inte-
grated design concept. It minimizes the effective space requirements of the
overall system and simplifies all manual operations including belt replacement.
BELT Manual 3_2.doc

Figure 27 Drawing of the belt turn TS 1600
Thanks to its modular, bolted aluminum design this key component can be easily
integrated in a wide range of different conveying systems.
Advantages:
● Top-class performance and reliability

● Minimum weight, space and time of installation
● Continuous operation almost free of maintenance
A belt (A) cut to take a conical shape is placed into a horizontal plane and ten-
sioned around two conical tail pulleys (B). The belt tends to shift to the centre of
the belt power turn. Longitudinal and transversal forces (C) have to be absorbed.
Figure 28 Functional principle
The patented solution: A strong, highly elastic plastic bead is attached along the
outer edge of the conical belt. The beading side of the belt is engaged and cen-
tered along the entire outer bed section radius between two angled precision ball
BELT Manual 3_2.doc

bearings (D). Forces are deflected towards the guiding, yielding a long service
life and absolutely low operating noise levels even at high loads and speeds.
6.2 Technical data

TS 1600 - 105 TS 1600 - 140
Types used Middle radius: 1550 mm Middle radius: 1710 mm
Width between guards: Width between guards:
1050 mm 1200 mm
Middle radius: 1710 mm Middle radius: 2160 mm

Width between guards: Width between guards:
1050 mm 1500 mm
Max. loading: 60 kg / 900 125 kg / 900
Max. speed at outer ra- 4.0 m/s 4.0 m/s
dius:
Conveyor design: bolted aluminum chassis bolted aluminum chassis
with undercover with undercover
Belt support: composite wood panel composite wood panel
Drive and tail pulleys: conical conical
Pulley-Ø at outer radius: 100 mm 140 mm
Drive: shaft mounted motor shaft mounted motor
Side guides: flat profile guides flat profile guides
Supports: galvanized steel galvanized steel
Min. conveying height: 230 mm 250 mm
Max. conveying height: 1700 mm 1200 mm
BELT Manual 3_2.doc

Figure 29 Main dimensions of power turn TS 1600 - 105
Figure 30 Main dimensions of power turn TS 1600 - 140
Side Guides
Height of side guards: 400 mm
Material: painted steel
Installation: at inner and outer radius
BELT Manual 3_2.doc

Figure 31 Side guides of power turn TS 1600
Supports
Material: galvanized steel
Adjustment range: 100 - 200 mm
Footplates: with fixing holes
Figure 32 Supports for power turn TS 1600
Weights
Turn angle Turn weight Side guard Drive Total
900 360 kg 70 kg 35 kg 465 kg
0
60 290 kg 47 kg 35 kg 372 kg
0
45 260 kg 35 kg 35 kg 330 kg
0
30 210 kg 25 kg 35 kg 270 kg
Shaft-Mounted Motor
Drive mode: pulling in conveying direction
Drive position: at outer radius
BELT Manual 3_2.doc

Figure 33 Drive position for power turn TS 1600
6.3 Drive ratings

The drive ratings (in kW) depend on the turn speed, the turn type and the turn
angle:
m/s 1.0
TS 1600-105/1050
30o 0.75
o
45 0.75
o
60 1.1
o
90 1.1
TS 1600-140/1200
30o 1.1
45 o 1.1
60 o 1.1
o
90 1.1
TS 1600-140/1500
30o 1.1
o
45 1.1
o
60 1.1
o
90 1.5
BELT Manual 3_2.doc

BELT Conveyor System User Manual 7 Spiral Power Turn TS 1600 Helix
7 Spiral Power Turn TS 1600 Helix

SPIRAL TURN
● Turn angle 90°, 135° or 180°

● Turn direction
■ right ascending
■ right descending
■ left ascending
■ left descending
● Drive side inside / outside
● Turn types TS 1600-105 (1550) Helix
TS 1600-105 (1710) Helix
● Height differential as required
limits depending on turn angle and type
Representation of the spiral turn in the layout
BELT Manual 3_2.doc


The spiral version of the power turn is a driven belt that is used to transport bag-
gage through a curve with entry and exit at different levels. In the process, the
transported baggage maintains its position and distance to the following piece of
baggage.
This type of turn can be used for baggage handling systems with a maximum
loading capacity of 100 kg at speeds up to 4 m/s (at the outside radius) and in-
clinations up to 180 (at the inner edge of the belt).
Figure 34 Overview of spiral turn TS 1600 Helix
The 1600 series combines top-class performance and reliability with an inte-
grated design concept. It minimizes the effective space requirements of the
overall system and simplifies all manual operations including belt replacement.
Thanks to its modular, bolted aluminum design this key component can be easily
integrated in a wide range of different conveying systems.
Advantages:
● Top-class performance and reliability

● Minimum weight, space and time of installation
● Continuous operation almost free of maintenance
BELT Manual 3_2.doc

A belt (A) cut to take a conical shape is placed into a horizontal plane and ten-
sioned around two conical tail pulleys (B). The belt tends to shift to the centre of
the belt power turn. Longitudinal and transversal forces (C) have to be absorbed.
Figure 35 Functional principle
The patented solution: A strong, highly elastic plastic bead is attached along the
outer edge of the conical belt. The beading side of the belt is engaged and cen-
tered along the entire outer bed section radius between two angled precision ball
bearings (D). Forces are deflected towards the guiding, yielding a long service
life and absolutely low operating noise levels even at high loads and speeds.
7.2 Technical data

TS 1600 – 105 Helix
Types used Middle radius: 1550 mm
Width between guards:
1050 mm
Middle radius: 1710 mm

Width between guards:
1050 mm
Max. loading: 100 kg
BELT Manual 3_2.doc

TS 1600 – 105 Helix

Max. speed at outer ra- 4.0 m/s
dius:
Conveyor design: bolted aluminum chassis
with undercover
Belt support: galvanized steel sheet
segments
Drive and tail pulleys: conical
Pulley-Ø at outer radius: 100 mm
Drive: shaft mounted motor
Side guides: flat profile guides
Supports: galvanized steel
Min. conveying height: 230 mm
Max. conveying height: 1700 mm
Height differentials
Type Inside Centerline Height Differ-
Width Radius ential
12o / 18o
TS 1600- 1050 mm 1550 mm 340 / 520 mm
105 (1550)
TS 1600- 1050 mm 1710 mm 395 / 605 mm
105 (1710)
The specified height differentials are the maximum values for a 90o turn. For
other turn angles, these values apply pro rata. The values are referred to a
maximum inclination of 12o (with tracking) or declination of 18o (without tracking)
at the steepest point (inner side of belt).
BELT Manual 3_2.doc

Figure 36 Main dimensions of power turn TS 1600 – 105 Helix
Side Guides
Height of side guards: 400 mm
Material: painted steel
Installation: at inner and outer radius
Figure 37 Side guides of power turn TS 1600
Supports
Material: galvanized steel
Adjustment range: 100 - 200 mm
Footplates: with fixing holes
BELT Manual 3_2.doc

Shaft-Mounted Motor
Drive mode: pulling in conveying direction
Drive position: at outer radius
Figure 38 Drive position for power turn TS 1600
7.3 Drive ratings

The drive ratings (in kW) depend on the turn speed, the turn type, the inclination
and the turn angle:
m/s 1.0
TS 1600-105 Helix
90o 1.5
o
135 2.2
o
180 3.0
These are approximate ratings for the maximal height differential.
BELT Manual 3_2.doc

BELT Conveyor System User Manual 8 Baggagge Topplers
8 Baggagge Topplers
8.1 Overturn tapers in the Check-in area

At the check-in counter, baggage is usually placed upright on the belt. This per-
mits narrower Check-in belts and makes it easier to attach the label to the han-
dle. In the automated baggage handling system, the baggage must then be
transported in as stable a position as possible, i.e. lying down.
The movement of the collecting belt transversely to the merging belt, as well as
fixed overturn tapers, gently make upright baggage lie flat on the belt.
Figure 39 Photo of Check-in collecting belt with overturn tapers
8.2 Toppler after turns in downhill inclined conveyors

Baggage may turn upright again in turns after downhill inclined conveyors. This
means that the piece of baggage must then be overturned once more. This is
done by a spring-loaded lateral tilt arm. Depending on the mounting side at the
side guards of the belt conveyor, there is a right and a left configuration.
The spring-loaded tilt arm is 120 mm high and is arranged at an angle of 57°
approx. 370 mm above the running belt. If an upright piece of baggage is moved
against the toppler, the tilt arm will press against the upper edge of the piece of
baggage from the side until it overturns. The spring action increases the tilting
force along with the extension of the tilt arm.
BELT Manual 3_2.doc

BELT Conveyor System User Manual 8 Baggagge Topplers
Figure 40 Drawing of baggage toppler
The tilting force is limited in order to avoid damage to the baggage. To ensure
that each piece of baggage is overturned on to a conveyor, multiple tilt arms can
be arranged one after the other and facing each other.
Figure 41 Photo of opposing baggage overturners
The adjusted spring force prevents that a piece of baggage slips on the running
belt. This preserves the ability to track the baggage.
BELT Manual 3_2.doc

BELT Conveyor System User Manual 9 Vertical sorter unit 1200bph
9 Vertical sorter unit 1200bph

VERTICAL SORTER 15DEG
● Width between side guards 1050 / 1200 mm
Representation of the vertical sorter in the layout
Vertical sorters sort a baggage flow on to two belt conveyor lines that are
stacked vertically. For this purpose a belt conveyor that can be swiveled is ar-
ranged in a frame. Depending on the swiveling direction, the input conveyor
forms a contiguous conveyor section with one of the output conveyors. The input
conveyor is arranged at a level between the output conveyors.
The belt conveyor has its own drive. The swiveling operation is initiated by a
separate crank drive.
The same device can also be used as a merge in the opposite direction of belt
travel.
The vertical sorter consists of the following basic modules:
1. the basic chassis with safety paneling

2. the crank drive for moving the tilting belt conveyor
3. the tilting belt with its own pulley motor
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4. the transmission, consisting of two toothed belts at the left and right hand
side of the device.
The tilting belt consists of a rugged single conveyor driven by a slip-on geared
motor. Photoelectric cells at the input and output monitor the secure transport of
the bag.
Figure 42 Vertical sorter overview (shown without covers)
The whole unit does not contain any welded parts. All connections are screwed.
Even the drums are designed without weld seams. This allows for instance to
replace the axle without replacing the whole drum.
Adjustable tilting angle

The tilting angle is defined by the position of two inductive proximity sensors.
The position of the sensors can be adjusted to set the tilting angle at any value
up to +/- 15 degrees. For instance, if tracking is required, the angle shall be set
at 12 degrees. The tilting angles up and down are independent from each other
and can be set at different values.
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Figure 43 Vertical sorter with tilting belt
Figure 44 Vertical sorter front view
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9.2 Technical data

Frame
● Steel tube profile powder coated
● Easy assembly on site, no welding needed
Conveyors
● Standard heavy duty
● Fixed length (independent of belt tensioning)
● Equipped with slip-on gearmotors
● Steel side guards powder coated
Diverting system
● Linear guides and maintenance free toothed belt
● Swivel drive with frequency converter
Electrical wiring
● Prewired with all sensors and actors signals integrated into one interface
● Inductive proximity switch as brake sensor
● Inductive proximity switch as stop sensor
● Emergency stop (toggle switch)
High level of security

● Complete protection with perforated covers right and left
● Safe access doors. Automatic stop if door is opened/restricted access by
requiring special key tools
High level of quality

● All modules are completely checked at workshop before delivery to site
Angle of inclined conveyor max +/- 15 degrees (to be adjusted
to system requirements)
Dimensions (L x H x W) 3,113 x 2,456 x 1,945 mm
Insertion length 2,900 mm
BELT Manual 3_2.doc

Connecting height of the individual conveyors
■ Induct conveyor 1115 mm

■ Upper position for discharge 1,890 mm
■ Lower position for discharge 340 mm
Overhead clearance 900 mm
(for bags with max. height 750mm)
Length of the swiveling belt conveyor 3,000 mm
Load for the belt conveyor 75 kg max
Height of side guards 400 mm
Temperature range (operative) 0 – 400C
Weight (1050 /1200 mm) 1000 / 1050 kg
Performance data 1
● Nominal throughput 3,000 bags/hr
This is the process throughput without swivel movements and at 1 m/s. This
throughput relates to a gap of 1.2 m between bags (between leading
edges).
Limits
● Sorting performance 1,200 bags/hr for +/- 15 deg
This is the machine throughput for the angles shown with front to front spac-
ing of 1.2 m.
The maximum sorting performance means swiveling after each bag. To

achieve a load balancing between two lines (sorting ratio is not 1:1), the
achievable throughput exceeds these values.
The achievable throughput depends on the pivoting angle and is increased

with lower angles set.
9.3 Drive ratings

Belt drive 1.1 KW
Pivot drive 4 KW
1
The data given under performance data and limits are based on a bag length of 900 mm.
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BELT Conveyor System User Manual 10 Vertical Sorter 1800 bph TS 6600
10 Vertical Sorter 1800 bph TS 6600

VERTICAL SORTER 18DEG
Representation of the vertical sorter in the layout
Vertical sorters sort a baggage flow on to two belt conveyor lines that are
stacked vertically. For this purpose, three short belt conveyors (including two that
can be swiveled) are arranged in a frame. Depending on the swiveling direction,
the input conveyor forms a contiguous conveyor section with one of the output
conveyors. The input conveyor is arranged at the same level as the upper output
conveyor.
Each belt conveyor has its own drive. The swiveling operation is initiated by a
separate crank drive.
The same device can also be used as a merge in the opposite direction of belt
travel.
The vertical sorter consists of the following basic modules:
1. the basic chassis with Plexiglas or grillwork paneling

2. the lifting motor for moving the tilting belts
3. the tilting belts with their own pulley motors
4. the transmission, consisting of a lever, connecting rods, and eccentric lever.
BELT Manual 3_2.doc

The tilting belts consist of rugged single conveyors driven by pulley motors. Pho-
toelectric cells at the input and output and/or at the transfer point between two
tilting belts monitor the secure transport of the bag.
Figure 45 Vertical sorter overview (shown without covers)
10.2 Technical data

Frame
● Steel tube profile powder coated
Conveyors
● Standard heavy duty (special aluminum profile designed for this issue)
● Fixed length (independent of belt tensioning)
● Equipped with drum motor drive (variable speed)
● Steel side guards painted or powder coated
Diverting system
● Mechanical system with steel pushing rods (high rigidity compared to timing
belt)
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● Swivel drive with variable speed
Electrical wiring
● Entirely Plug&Play wired, all sensors and actors signals integrated into one
interface according to customer description
High level of security

● Complete protection with perforated aluminum sheet right and left
● Safe access doors available (optional). Automatic stop if door is
opened/restricted access by requiring special key tools
High level of quality

● All modules are completely checked before delivery at workshop
Angle of inclined conveyor 18.3 degrees
Dimensions (L x H x W) 4,070 x 2,940 x 1,650 mm
Connecting height of the individual conveyors
■ Induct conveyor 1,600 mm

■ Upper discharge conveyor 1,600 mm
■ Lower discharge conveyor 400 mm
Overhead clearance 900 mm
(for bags with max. height 750mm)
Length of each swilling belt conveyor 1,615 mm
Length of fixed belt conveyor 1,630 mm
Load for each belt conveyor 60 kg max
Overall weight 1,600 kg
Height of side guards 400 mm
Temperature range (operative) 5 – 400C
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Performance data 1
● Nominal throughput 3,000 bags/hr
This is the process throughput without swivel movements and at 1.0 m/s.
This throughput relates to a gap of 1.2 m between bags (between leading
edges), which is too short to swivel the conveyors. To swivel, the conveyor
line needs to be stopped briefly to get the time needed for the swivel move-
ment.
Limits
● Maximum throughput 3,900 bags/hr
This is the machine throughput without swivel movements and at 1.3 m/s.
This throughput relates to a gap of 1.2 m between bags (between leading
edges), which is too short to swivel the conveyors. To swivel, the conveyor
line needs to be stopped briefly to get the time needed for the swivel move-
ment.
● Sorting performance 1,800 bags/hr at 1.3 m/s
1,600 bags/hr at 1 m/s
This is the machine throughput at the speed shown. The time needed for
the swivel movement is approx.1 s.
The maximum sorting performance means swiveling after each bag. To

achieve a load balancing between two lines (sorting ratio is not 1:1), the
achievable throughput exceeds these values.
10.3 Drive ratings

Belt drives 3 x 0.75 KW (drum motor)
Crank drive 2.2 KW (Siemens with gearbox)
1
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BELT Conveyor System User Manual 11 High-speed Diverter
11 High-speed Diverter

HIGHSPEED DIVERTER
● Width between side guards 1050 / 1200 mm

● Direction of diversion right / left
● Transition width 180 / 250 mm
Representation of the diverter in the layout

The high-speed diverter sorts a baggage flow horizontally from a straight con-
veyor to another conveyor or a chute. The device can also be used in order to
reroute baggage in case of failure.
Figure 46 High-speed diverter with flaps swiveled out and in
The diverter surface is divided into two vertical flaps that are swiveled by 45o into
the conveyor path from the side. In the swiveled position, the flaps form a con-
BELT Manual 3_2.doc

tinuous diverter that diverts the baggage through the movement of the driven
vertical conveyor belts.
When positioned at 45°, the flap belts transfer the item smoothly from the main
to the secondary line or to a chute, take away conveyor, etc. This minimizes the
deviation forces as well as the impact that the item is subject to during sorting.
Figure 47 Drawing of high-speed diverter
The flaps remain in the current swiveled position until an incoming bag must be
rerouted. This minimizes the required swivel cycles.
A single servo gearmotor efficiently powers the diverting action of the High
Speed Diverter, rotating the paddles 45 degrees across the conveyor belt be-
tween their diverting and non-diverting positions. It delivers motion to the pivot
shaft of both the drive side and non-drive side paddles simultaneously via a tie
rod assembly. This switches the diverter flaps with high accuracy and short tran-
sition time. A drive pulley powers the belt on each paddle.
11.2 Technical data

Welded steel construction, can be mounted on support stands or suspended.
The high-speed diverter is not a self-contained conveyor but is installed in a

straight conveyor instead of an intermediate bed section. An adapter bed section
BELT Manual 3_2.doc

(SL 272mm) allows mounting of a head drive station and brings the system
length to the 50 mm grid.
It is composed of the following elements:
● Side member with servo drive and first flap

● Intermediate bed section with secondary flap and transition chute in light
slope
● Electrical cabinet with digital interface to PLC
Length of intermediate bed section 1,828 mm (1050 mm)

1,978 mm (1200 mm)
Adapter bed section 272 mm
Total length 2,100 mm (1050 mm)

2,250 mm (1200 mm)
Lateral clearance of side guards 1,050 mm (for normal baggage)

1,200 mm (for OOG bags)
Total width beyond clearance of side guards + 347 mm + transition width
Total height (to top of control box) 1,500 mm
Height above belt level 597 mm
Weight of the high speed diverter 694 kg (1050 mm)

774 kg (1200 mm)
Divertible baggage weight 0.5 to 60 kg
Flap cycle time (opened to close position) 0.31 s
Transition chute:
● 250 mm with six 30 mm rollers for parallel take-aways

● 180 mm with four 30 mm rollers for all other take-aways
Position control and feedback:
● Siemens Sinamics drive with programmable control unit CU320

● Basic Operator Panel BOP20
BELT Manual 3_2.doc

Flap belts
Example type: Chiorino 2M8 U0-U-G15 FL, green
● Hardness 65 Shore A durometer

● Conveying side (1.5mm) synthetic elastomer (NBR)
● Total thickness 3.0 mm
● Weight 3.4 Kg/m2
● Tensile force per width unit (for 1% stretch)
8 N/mm Belt width
● Operating temperature 00 C to +70° C
● Electrostatic properties permanent antistatic dynamically
(UNI EN 1718)
Performance data (standard bags) 1

Sorting rate 3,400 bags/hr
This is the process performance at 1.9 m/s and transition to a chute or parallel
conveyor. With 45 deg transitions 2800 bags/hr are achievable.
Gap between bags 1.5 m at 1.9 m/s
Limits (standard bags)

Sorting rate 4,500 bags/hr
11.3 Drive ratings

Flaps motion drive: 2.3 KW
Flaps belt drive: 2 x 0.37 KW
1
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BELT Conveyor System User Manual 12 See-saw
12 See-saw
Designation and representation in the layout

The see-saw is not yet included in the layout program.

The see-saw is a special version of a short straight conveyor with a special
width, which can be swiveled around the transverse axis. The conveyor is used
as the connection between conveyor sections that run in parallel and at the
same height, if the connection is used in both directions (e.g. as a bypass be-
tween 2 conveyor sections).
Figure 48 Drawing of see-saw
BELT Manual 3_2.doc

The conveyor is moved depending on the desired direction of transport.
Figure 49 Photo of side view of see-saw and detail view of excenter
The end of the see-saw can be raised or lowered by means of an excentric disk.
Through the transversely arranged swivel axis, one side is raised (on the side of
the discharge conveyor section) and the other side lowered at the same time (on
the side of the induct conveyor section). The resulting height differential ensures
the transfer of the bag without any risk of trapping.
Figure 50 Photo of height differential at the see-saw output
A diverter on the induct conveyor diverts the baggage flow to the see-saw con-
veyor. The conveyor runs at an angle of 90o to the parallel conveyor sections.
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Figure 51 Layout example for see-saw use
12.2 Technical data

● Height differential through see-saw movement 25 mm
● Length x width of conveyor 1,600 x 1,800 mm
The width of 1800 mm ensures a safe transport across the diverter.
Other lengths are also available after consultation with AL PE Solutions. To ob-
tain the necessary adjusting height, it may be necessary to modify the position of
the excentric drive accordingly.
The see-saw weighs approx. 275 kg.
12.3 Drive ratings

A 0.37 KW drive is used for the swivel operation.
The drive rating for the belt drive is 1.1 kW at a length of 1,600 mm.
BELT Manual 3_2.doc

BELT Conveyor System User Manual 13 Merge / Divert TS 6200
13 Merge / Divert TS 6200

MERGE 30, MERGE 45 Belt merge
● Induction angle 30o / 45o

● induction from right / left
DIVERT 30, DIVERT 45 Belt divert
● Ejection angle 30o / 45o

● Divert to right / left
Representation of the merge / divert in the layout
45o 30o
BELT Manual 3_2.doc


Belt merges and diverts are available in the following versions:
● Induction from a secondary line at 30o to a main line

● Ejection from a main line at 30o to a secondary line
● Induction from a secondary line at 45o to a main line
● Ejection from a main line at 45o to a secondary line
The different direction of travel of the belt for the induction and ejection functions
requires a modification of the drive concept. In each case, the belt is driven at
the conveyor end (in the direction of transport). The drive is always installed on
the longer side of the belt merge.
The right and left versions of the belt merge have a correspondingly mirrored de-
sign.
Figure 52 Photo of belt merge TS 6200
BELT Manual 3_2.doc

Figure 53 Main dimensions of belt merge TS 6200
BELT Manual 3_2.doc

13.2 Technical data

Bed section
Special outside profiles bolted to a steel upper frame that holds the nose bars.
Outside profiles with 8 mm grooves for easy mounting of accessory parts. The
bed section is designed for only certain angles (30 or 45°). The belt bed section
is a low friction deckboard. All maintenance can be done from above.
Drive station
End drive unit Ø 130 mm drive pulley for full through bushing hollow shaft gear-
box, spring load belt pre-tensioning and self-tensioning by pivoting snub roller.
Position of snub roller depends on conveying direction of unit, merge or divert,
no reverse operation.
Nose bar
40 mm solid steel shafts with hard chrome finish.
Tail unit
Ø 65 mm galvanized steel roller with long life roller bearings.
Tracking station
Consists of Ø 65 mm snub rollers mounted in a pivoted rack with sensor rollers
inside the bed section. Galvanized steel with long life ball bearings is used.
Dimensions (total incl. drive):
● 30o induction / ejection

■ Length x width 3,100 x 2,000 mm
■ Length at center of belt 1,900 mm
● 45o induction / ejection
■ Length x width 3,000 x 1,600 mm
■ Length at center of belt 1,500 mm
Height of Merge / Divert 290 mm
Diameter of drive pulley 130 mm
BELT Manual 3_2.doc

Belt type Siegling KT 124

type E12/0/2 0 /U2 MT-C-SE
Belt width 995 mm
Inside width of side guard 1,050 mm

Height of side guard 400 mm
The drive is a slip-on geared motor with a disk brake.

Motor type (example type) Siemens 2KG3361-2KG07-
4BA1-Z (with gearbox)
Degree of protection IP54
Deck board 21 mm special plywood with low

friction coating
Operating temperature - 50C to 400C
Lifetime of bearings > 50.000 hrs
Weight approx. 500 kg
Performance data
Possible belt speeds
● 30o 0.7 m/s, 1.4 m/s, 1.8m/s

● 45o 0.7 m/s, 1.0 m/s, 1.8m/s
Limits
Belt speed 2.0 m/s (pulsing)
Pulse rate max. 400 /hr
Baggage weight max. 60 kg
13.3 Drive ratings

Merge / Divert 3 KW
BELT Manual 3_2.doc

BELT Conveyor System User Manual 14 Tilt-tray Sorter
14 Tilt-tray Sorter
Designation in Bill of Quantities

SORTER Tilt-tray sorter circuit
SORTER-INDUCT Induct conveyor
Representation of tilt-tray sorter in the layout
This layout section shows the line, injections and the integration of a manual en-
coding line.
:NOTE: The technical features and availability of the tilt tray sorter are currently
being clarified. If such a sorter is needed in a project, please contact I MO BL.
BELT Manual 3_2.doc

BELT Conveyor System User Manual 15 Sorter Chute
15 Sorter Chute

SORTER CHUTE
● Ejection direction to the sorter parallel to the sorter, 30o, 90o
Representation of the sorter chute in the layout

Because the sorter chute is project-specific, it is contained in the layout program
as a component but not as a drawing template.

From the tilted tray of the tilt-tray sorter, the piece of baggage will slide into the
chute.
The further process is specific to each project. The following variants are com-
monly used:
● The chute is followed by a braking belt. Technically, the braking belt corre-
sponds to a straight conveyor with a high-grip grooved belt. It ensures that
the bags are transported to the take-off boxes. The braking belt is sloped by
30o.
Braking curtains prevent that bags roll down the sorter chute. This is fol-
lowed by a chute section and the box from where the bags can finally be
taken off.
● After the chute, a braking belt transports the bags to a pier conveyor (lat-
eral), from where they can be taken off. On the pier conveyor, the bags are
separated over the length of the belt, which greatly simplifies the take-off
and loading on to the baggage truck.
In case of overload of the pier conveyor, a warning tone will sound, and a
warning beacon will begin to flash. The chute remains blocked until space is
again available for new pieces of baggage.
BELT Manual 3_2.doc

BELT Conveyor System User Manual 16 Flat Carousel
16 Flat Carousel

RT-FLAT 1
● Loading height Arrival 380mm +/- 30mm

Sorting 700mm +/- 30mm
● Finish Arrival stainless steel 1.4016
Sorting painted
● Backguard 400mm painted single side
150mm stainless steel one part
● Base cladding Painted at outside / both sides
Representation of the flat carousel in the layout

This type of carousel is used as a reclaim carousel in the arrival area and for
manual sorting in the baggage hall. In the passenger area, the stainless steel
version is commonly used, while the cladding is painted in the baggage handling
area.
1
As long as straight and turn sections of the carousel loop are not joined, the parts are called with designations
STRAIGHT and TURN. Once the parts are joined, their designations change to RT-FLAT.
BELT Manual 3_2.doc

The flat carousel can be provided in a wide range of configurations ranging from
simple loops to multi-level, complex shapes incorporating both internal and ex-
ternal curves.
The simple construction of the system makes it quick to install and bring into op-
eration. Maintenance is made simple by the ease of access to both the drive and
drive belt. If necessary, the belt can be changed quickly. Its reliability and long
service life guarantee the operator an excellent life cycle return.
Carousels are driven by single (or multiple) low noise friction drives, depending
on overall length and load requirements.
Figure 54 Carousel with integrated E-stop pushbutton
In front the backguard for arrival carousels is shown. Further behind the back-
guard for make-up carousels can be seen.
The main features include:

● Rugged steel profiles
● Available in standard width 1010 mm (O/A width)
● Stainless steel or painted mild steel claddings
● New chain for simple tensioning using excentric bolts
● Low noise<59dBA
● Modular sections for fast installation
● Multiple drive capability for extended lengths- no expensive synchronization
required
BELT Manual 3_2.doc

● Low maintenance requirement – no lubrication (except drive) required

● Split base cladding to compensate uneven floors
Figure 55 View of flat carousel with slat removed
Figure 56 Chain with tensioning detail
BELT Manual 3_2.doc

16.2 Technical data

● Useful width 982 mm (width of slat)
● Overall width 1010 mm
● Finish Stainless steel or painted mild steel cladding
● Wheels 80 mm x 26 mm Ø Polyurethane wheels with
precision sealed for life ball bearings.
● Direction of travel CCW or CW
● Temperature range +5°C to +45°C
● Straight track Standard 2980 mm, 1980 mm & 980 mm lengths
● Bed section Mild steel profiles, powder coated
● Turns 90°, 60°, 45°, 30°
Standard 1000 mm centerline radius
● Spine Extruded aluminum sheath spine supported by low
noise polyurethane wheels
● Standard paint RAL 7035 light grey for supports
optional: for cover and blackguards too
RAL 9005 deep black for kick panel
Gloss level 50%, paint thickness 60 μm
● Slat Polymer PUR slat with quick installation/removal via
clips, fire rating B2 (DIN 4102-1)
● Chain Die cast aluminum links with maintenance-free
bush and hardened steel pins. Easy tensioning with
eccentric bolt. The chain is identical for flat and
inclined carousels.
● Drive style/type Friction drive – capable of starting under full load
● Weight 80 kg/m for the sorting carousel (backguard
400 mm)
65 kg/m for the arrival carousel
200 kg for each drive unit
BELT Manual 3_2.doc

Figure 57 Arrival: Cross-sections flat carousel, different backguards
BELT Manual 3_2.doc

Figure 58 Sorting: Cross-sections flat carousel, different heights
Make-up carousels in the departure area are frequently mounted on a concrete

pedestal (approx. 150 mm high and approx. 800 mm wide as a walkway). This
facilitates the loading of the baggage trucks. The pedestal also serves as a colli-
sion protection.
Options
● Side panel with integrated E-stops pushbutton (s)
● Stainless steel or painted mild steel cover for infield
● Soft start for each drive
● Motor with plug able connector
Drive
The flat carousel uses a low noise friction drive consisting of a flat belt which en-
gages the side of the die cast aluminum links. The drive has been designed for
low maintenance and long life, and particular attention has been paid to optimiz-
ing the drive pressure to prevent accelerated wear of the chain links and belt.
The drive unit is identical for flat and inclined carousels.
BELT Manual 3_2.doc

Figure 59 Top view of friction drive
Figure 60 Drawing of friction drive
Performance data
Flat carousel moving in both the horizontal and vertical plane:
● Maximum static load: 150 kg/m

● Maximum operating load 100 kg/m
● Maximum speed 30 m/min
BELT Manual 3_2.doc

16.3 Drive ratings

The standard friction drive is equipped with a SEW bevel gear motor DV 100
M4/L4 2.2 kW or 3 kW with temperature sensor.
Length 10 – 45 m 46 – 60 m 61 – 90 m 91 – 120 m
Drive 2.2 kW 3 kW 2 x 2.2 kW 2 x 3 kW
BELT Manual 3_2.doc

BELT Conveyor System User Manual 17 Inclined Carousel
17 Inclined Carousel

RT-INCL 1
● Finish Stainless steel / painted

● Slat Polymer / Stainless steel
Representation of the inclined carousel in the layout

This type of carousel is used as a reclaim carousel in the arrival area and for
manual sorting in the baggage hall. In the passenger area, the stainless steel
version is commonly used, while the framework is painted in the baggage han-
dling area.
With just two different modules special designs are no longer needed. The mod-
ules are tested at the factory and supplied ready for use. The simple construction
of the system makes it quick to install and bring into operation. Maintenance is
made simple by the ease of access to both the drive and drive belt. If necessary,
the belt can be changed quickly by means of a lever tensioning device. Its reli-
ability and long service life guarantee the operator an excellent life cycle return.
1
As long as straight and turn sections of the carousel loop are not joined, the parts are called with designations
STRAIGHT and TURN. Once the parts are joined, their designations change to RT-INCL.
BELT Manual 3_2.doc

Figure 61 Overall view of inclined carousel
The main features include:

● Slats available in standard width 1400mm (O/A slat width). Slats could be
polymer or ground stainless steel
● Narrow surround fascia with stainless steel or optional painted mild steel fin-
ish. Painted deep kick plate.
● Low noise<65dBA
● Bolted construction for easy installation and shipping
● Multiple drive capability for extended lengths- no expensive synchronization
required
● Low maintenance requirement – no lubrication (except drive) required
BELT Manual 3_2.doc

Figure 62 View of inclined carousel with bed section and different slat types
17.2 Technical data

● Loading elevation 518 mm
● Overall width 1534 mm
● Inclined Slat Angle 22.5°
● Finish Stainless steel or painted mild steel cladding as
required
● Wheels 80 mm x 26 mm Ø polyurethane wheels with
precision sealed for life ball bearings.
● Direction of travel CCW or CW
● Temperature range +5°C to +45°C
● Support Modular design in painted mild steel
● Carrier High strength steel profile supported by low noise
polyurethane/nylon wheels
● Chain Die cast aluminum links with maintenance-free
bush and hardened steel pins. Easy tensioning with
eccentric bolt. The chain is identical for flat and
inclined carousels.
● Slats Standard polymer (fire rating B2 – DIN 4102-1) or
optional ground stainless steel slats in 1400 mm
width
● Straight track Standard 2980 mm, 1980 mm & 980 mm lengths
BELT Manual 3_2.doc

● Turns Outside turn 90°, 45°, 60°, 22.5° with 1618 mm

centerline radius, inside turn 22.5° with 6500 mm
centerline radius
● Bumper High impact strength polymer bumper with
inter locked design to prevent pinch points
● Standard paint RAL 7035 light grey for supports, optional: cover
RAL 9005 deep black for base cladding
Gloss level 50%, paint thickness 60 μm
● Drive style/type Friction drive – capable of starting under full load
● Weight 105 kg/m for the carousel with polymer slats
125 kg/m for the carousel with stainless steel slats
200 kg for each drive unit (incl. the drive)
Figure 63 Cross-section of inclined carousel
Options
● Side panel with integrated E-stops pushbutton
● Stainless steel slats
● Load station
● Soft start for each drive
● Motor with plug able connector
Drive
The inclined carousel uses a low noise friction drive consisting of a flat belt that
engages the side of the cast aluminum links. The drive has been designed for
low maintenance and long life, and particular attention has been paid to optimiz-
ing the drive pressure to prevent accelerated wear of the chain links and belt.
BELT Manual 3_2.doc

Figure 64 Friction drive
Performance data
● Maximum static load 200 kg/m
● Maximum operating load 100 kg/m
● Maximum speed 30 m/min
17.3 Drive ratings

The standard friction drive is equipped with a SEW bevel gear motor DV 100
M4/L4 2.2 kW or 3 kW with temperature sensor.
Length 10 – 45 m 46 – 60 m 61 – 90 m 91 – 120 m
Drive 2.2 kW 3 kW 2 x 2.2 kW 2 x 3 kW
BELT Manual 3_2.doc

BELT Conveyor System User Manual 18 Configuration Rules
18 Configuration Rules
For smaller baggage handling systems, the customer’s tendering documentation

often already specifies the layout and thus the configuration of the conveyor sys-
tem. In such cases, the supplier can only correct any mistake and specify the
prices.
Other tenders do not specify the layout (functional tenders) and expect the sup-
plier to do the layout planning and configuration of the system. This includes the
following typical restrictions:
● Building floor plans including the spaces available for the baggage handling
system
● Number, position, and interfacing of check-in counters
● Number and position of sorter chutes with service routes
● Integration with existing system parts
● System performance data
● etc.
On the other side, there is our product range, including the supply of internal and
external suppliers and the available expertise and experience from earlier bag-
gage handling system implementations. This manual is designed to leverage this
knowledge in order to
● enable the planning of new systems so that they meet the customer’s re-
quirements,
● facilitate and accelerate the planning of baggage handling systems, and
● minimize costly rework after the order has been received.
The configuration rules describe the proper use of individual items of equipment
(pier conveyors, turns, vertical sorters, etc.) and the structure of entire functional
areas (Check-in, manual encoding, early bag storage, etc.).
Deviations from these rules are only acceptable after consultation with AL PE
Solutions.
The manual provides a working basis. New findings will be included in future is-
sues of the manual.
BELT Manual 3_2.doc

18.1 Energy consumption of a belt conveyor system

The energy consumption of a belt conveyor system installed depends on the
system’s parameters as well as its operation (e.g. hours of operation, load pro-
files etc.). An approximation of the energy consumption would be:
W [kWh] =
 P ⋅ 0,55 ⋅1,1⋅ T
η
P Sum of drive ratings in [kW] (as per name plate)
T Number of annual hours of operation
η = 0,82 Average degree of efficiency of the drives
0,55 Partial load factor (deducted from current measurements)
1,1 Factor to compensate lower efficiency of the drives during partial load
operation
18.2 Speed profile

The following transport speeds are typical in belt conveyor systems (in m/s):
0.3 0.5 0.7 1.0 1.2 1.4 1.7 2.0 2.5
Slow Normal range Acceleration High Speed

range
Application examples:
Check-in Collecting belts Inductions High-speed

Pushers diverters (1.9 m/s)
:NOTE: These are approximate values. Unless an FC is used, the exact speed
depends on the gearbox used.
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18.3 Bulky baggage and length detection

The maximum bag length is important in many areas of system functionality.
To avoid that the system is loaded with bulky baggage, length detection is re-
quired in all positions where baggage is inducted.
This usually includes
● collecting belts from Check-in

● transfer Check-in lines after Bag separation
The length detection must be positioned so that bulky baggage can be removed
manually in these positions (easily accessible without the use of ladders). If the
length detection is tripped, the belt will stop.
If the maximum permitted length is exceeded nevertheless, the following conse-

quences can be expected:
Check-in belts
Since the Check-in belts are narrower than the collecting belt, baggage may jam.
Metering conveyors
The throughput is reduced because bags may occupy 2 positions.
Explosives detection systems

Lengths up to 1200 mm are usually uncritical in Level 1/2. A minimum gap of
200 mm (0.4 s at 0.5 m/s) between bags is required. The Explosive Detection
System machine will request the baggage ID from the baggage handling system
and start the generation of a new image. In case of excessive length, the bag
will not be checked, and an error message is issued to the baggage control sys-
tem. Bulky bags must then be checked in Level 3.
Turns, merges, see-saw

Bulky baggage may jam.
Vertical sorters
Bulky baggage is uncritical because it behaves like a train.
Pushers
Without length detection, bulky baggage may result in a crash of the pusher.
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Tilt-tray sorters
Bulky baggage may result in a sorter crash because it may be trapped between
trays (e.g. in turns).
Inductions are usually equipped with length detection. The induct conveyor will
stop in case of bulky baggage. The bag must then be removed manually. This
will require a working position that must be accessible accordingly.
Tray conveyor system loading station

In order to prevent loading errors, bulky baggage is detected, which will stop the
loading station.
18.4 Check-in area

The position and arrangement of the check-in counters are usually specified by
the customer. The belt conveyors at each check-in coun ter (common configura-
tions are either 3 separate belts – weighing, labeling and induct conveyor belts,
or 2 belts with combined labeling and weighing belt) route the baggage flow on
to one or more collecting belts. The following configuration rules apply to this
area:
Standard Check-in
1. If the customer agrees, the last Check-in belt should be inclined (5o incline
contrary to the running direction of the collecting belt).
2. The collecting belt should be installed 50 mm lower than the last Check-in
belt, so that a height differential is created.
3. The collecting belt usually runs at 0.5 m/s.
4. The induct conveyor to the collecting belt is made to virtual windows that are
assigned by the control system. As long as bags wait at check-in areas to
be inducted, the windows will be assigned in the order of applications. The
remaining windows will initially remain empty and can be occupied in case if
short-time applications.
Static windows
have a fixed length independent of the bag. The window size is assumed to
be twice the bag length.
Throughput of the collecting belt:

(3,600 bags/hr x 0.5 m/s ) / (2 x 1 m) = 900 bags/hr
If higher throughputs are required, the collecting belt can be divided, or vari-
BELT Manual 3_2.doc

able windows can be used.
Variable windows
depend on the current bag length + 0.8 m. For this purpose, the bag length
is determined on the Check-in belts. The throughput will then be determined
not by the largest but rather by the average bag length.
Throughput of collecting belt:

(3600 bags/hr x 0.5 m/s ) / (0.8 + 0.7 m) = 1200 bags/hr
at an assumed average length of 0.7 m.
Group Check-in
The control of the standard check-in counter is not suitable for group check-in.
Due to the assignment of the windows based on application times at all check-in
counters, long waiting times must be expected at group Check-in. To avoid this,
the following alternative solutions can be used:
1. The group check-in is provided with a separate collecting belt.

2. With a special priority of the group check-in area over the standard check-in
areas, all bags at the group Check-in will be sequentially inducted. How-
ever, this will block the collecting belt for other check-in areas.
Bulky baggage Check-in

Bulky baggage cannot be transported on the same conveyors as regular bag-
gage. In baggage handling systems where bulky baggage shall also be trans-
ported over automated conveyors, a separate conveyor system with wider con-
veyors and higher-radius turns is used for this purpose.
Tracking and throughput

The baggage must often be tracked during its transport from the check-in area.
The throughput must be correspondingly low. An empirical value is approx. 600
bags/hr per collecting conveyor. An event-based tracking approach enables
higher throughputs than the tracking in virtual windows.
For the purpose of data tracking, the collecting conveyor must be divided into
sections. The leading and trailing edges of bags are detected by means of light
barriers. This is the solution that provides the highest throughput because gaps
based on the length of the bags will be created.
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18.5 Straight sections

The standard position of the photo eye is designed for 1 m/s.
:NOTE: for construction:

Depending on the speed and bag weight, the trailing path (braking distance) may
be too long. In this case, the position of the photo eye must be advanced.
18.6 Right angle connections

At right angle connections a cascade of 100mm from the induct conveyor belt
conveyor needs to be maintained. This will lead to a gap of 10mm between the
leading edge of the drum and the side guard. Because the conveyors are over-
lapping the feeder conveyor needs to be 60mm longer than needed for a cas-
cade of 50mm.
Figure 65 Cascade for right angle connections
With a cascade of only 50mm the gap between the leading edge of the drum to
the side guard would be 70 to 80mm. For a larger overlap between the convey-
ors, the cascade needs to be increased accordingly.
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18.7 Incline and decline conveyors

For incline and decline conveyors the following integration rules apply:
1. A continuous belt can be used for convex knee conveyors. This should be
preferred because it saves one drive. For the design of the drive, the overall
length of both conveyors is handled like an uphill conveyor.
3. Limits for up and down gradients:
with tracking without tracking
permitted incline gradient 12o 15o
permitted decline gradient 12o 18o
No separation is required for down gradients without tracking.
4. In order to prevent rolling baggage, pulsing should be avoided on inclined

belts.
5. No cascade transition must be used at the transition from the horizontal belt
to an uphill conveyor, because this would exceed the permitted gradient
(and cause bags to roll).
6. In the area of the knees, the overhead clearance must be larger than in
straight sections. The longest diagonal of the bag should be used as a
guideline.
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18.8 Baggage singulation

In certain areas of the baggage handling system, baggage can be present in
bulk form. This bulk condition can occur
● On collecting belts without controlled induct conveyor (i.e. without window

technique)
● On pier conveyors
● After up or down gradients >120
● After chutes without tracking
As long as baggage only needs to be transported through the system, this will be
uncritical. Only in areas, in which the individual items need to be handled differ-
ently, they must be placed on the belt separately and with a distinctive spacing.
This is the case
● before automatic scanner gates (ATR)

● before Explosive Detection System machines
● before all sorting equipment, such as
■ Tilt-tray sorters
■ Pushers
■ High-speed diverters
■ Vertical sorters
In order to separate the baggage, increasing speed transitions at consecutive

straight conveyors or metering conveyors are used. The speed transition should
be at least 0.22 m/s.
A typical arrangement uses three metering conveyors: 0.5 -> 0.7 -> 1 m/s
:NOTE: The speed of transportation should be reduced before the separation if

possible, so that no further deceleration of the separated bags is required.
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18.9 Automatic tag readers (ATR)

Figure 66 Drawing of 360o scanner gate
The following configuration rules apply to the integration of scanner gates for la-
bel recognition:
1. The baggage flow must first be separated (see paragraph 18.8). A gap of
500 mm must be present between bags.
2. The last conveyor before the scanner and the first conveyor after the scan-
ner should have a height gradient (cascade). Due to the multi-read process,
the risk of non-recognition is lower with the new scanners than the risk of
pinching.
3. The conveyor after the scanner needs to be at least 2.5m long.
4. The achievable throughput is 3,600 bags/hr. Belt speeds up to 2 m/s are
permitted.
5. Dimensional specifications for the scanner gate (e.g. Incheon from Sick):
■ Overall width of scanner gate 2,400 mm
■ Height of scanner gate above belt surface 1,450 mm
■ Overhead clearance above belt surface 1,200 mm
■ Scan area above belt surface up to 900 mm
BELT Manual 3_2.doc

6. If scanning on belt conveyors is also required from below (e.g. with 3600
scanners), the following applies:
■ Conveyor gap 50 mm
■ Minimum clearance floor to belt surface 750 mm
:NOTE: At loading stations the scanner with 3600 reading can be installed
without raising the belt conveyor line. The gap of 850mm between top of
tray belt and top of belt of the belt conveyor is sufficient.
7. At narrow sections a mirror based solution is available, that needs only
200mm at the conveyor side. The read rate is not impaired.
8. While planning the ATR a sufficient distance to the next decision point
needs to be taken into consideration. The minimum distance depends on
the conveyor speed, the bag’s length and the IT reaction time (approx. 3s):
Belt speed Distance ATR – Decision point

0,25 m/s 3,25 m
0,5 m/s 4m
0,75 m/s 4,75 m
1 m/s 5,5 m
1,2 m/s 6,1 m
1,5 m/s 7m
2 m/s 8,5 m
This relates to a bag length of 900mm.
18.10 Manual encoding

Manual encoding lines are required in automated baggage handling systems be-
cause
● not all baggage labels can be read automatically. With Check-in baggage,
about 5 % of all labels cannot be identified at the scanner gate. This propor-
tion can be 30 – 40 % for transfer baggage. The value strongly depends on
the flight.
● labels may be missing. If the operator at the manual encoding station can
identify the bag in any other way, he/she can create and attach a replace-
ment label. Otherwise, the bag will remain unknown to the baggage han-
dling system and cannot be sorted automatically. Often reserved sorter
chutes are used for the personalized clarification of such bags (“problem
chute”).
BELT Manual 3_2.doc

● it may not be possible to sort a bag despite a good label that can be read
automatically because the associated BSM (Baggage Source Message) is
missing. Experience has shown that this is the reason of about 20 % of all
no-reads.
● a clearly readable label exists but does not comply with the 10-digit IATA
code.
At the inspection station, the flight number is identified, and the bag is assigned
to the proper sorter chute. The achievable throughput depends on the label qual-
ity, the operators and the workload (must replacement labels be created?). The
following guidelines apply:
● scan and acknowledge: approx. 6 – 8 secs

● print new label: approx. 20 secs
The time required for the operator to move to and from the inspection station
must also be taken into account.
The following rules shall be applied for the design of the manual encoding line:
1. An adequate distance must be provided between the scanner gate and the
divert to the manual encoding line. As a guideline, this requires a transporta-
tion time of approx. 2 secs (processing time scanner + response time at
computer level + divert at PLC level). The distance is a function of the
transportation speed.
2. If possible, multiple manual encoding stations should be arranged so that
they can be manned with a reduced number of operated during off-peak
hours (e.g. with a single operator).
3. In order to cover peak workloads, it is possible to man an inspection station
with multiple operators. However, since obstructions cannot entirely be
eliminated, using 2 operators will only slightly increase the throughput.
4. At least 5 accumulator positions are required upstream of the inspection
belt.
5. Cascade transitions make sense on all conveyors to avoid the risk of pinch-
ing.
6. Baggage may also arrive as bulk. An additional separation is not necessary.
7. All belts in the work area run at 0.5 m/s.
8. The inspection belt is equipped with a standard 2-layer belt.
9. The belt surface must be at a working height that is customary in the coun-
try of use (approx. 700 – 900 mm).
10. For all conveyors in the work area, the drives should be located on the off-
side.
BELT Manual 3_2.doc

11. Within the work area, all moving, sharp or protruding parts must be covered
in compliance to the applicable safety regulations.
12. The accessibility of the workstations, escape routes and the necessary
overhead clearance must be observed.
13. Depending on the applicable workplace regulations, it can be necessary to
use housings, heating etc..
14. The baggage data are tracked from the inspection station to the next sorter
line. It does not make sense to use an automatic scanner gate downstream
from a manual encoding station. This is not cost-effective and may create
additional no-reads.
18.11 Explosive detection systems

The following configuration rules apply to the integration of Explosive Detection
System machines of Level 1 or combined Level 1/2 devices:
1. The baggage flow must be separated first (see paragraph 18.8).

2. The last conveyor before the machine and the first conveyor after the ma-
chine must not have a height transition relative to the belt conveyor of the
Explosive Detection System machine.
3. The achievable throughput varies depending on the manufacturer. The
manufacturer’s specifications are machine performances that are higher
than the process performances that can be reached in operation. They are
e.g. given for
■ a specific belt speed
■ an average bag length
■ defined gaps between bags
■ and can vary for different countries.
These specifications must be clarified prior to configuration.
:NOTE: Frequently, the supplier of the Explosive Detection System ma-

chines has not yet been determined at this time. In such cases, planning
should be based on ‘worst case‘ assumptions.
4. The subsequent installation and removal of Explosive Detection System

machines is requested more often and must be planned accordingly.
5. The machine must remain accessible for maintenance purposes.
6. The Explosive Detection System machines present considerable loads for
the support stands / suspensions. This must always be taken into account.
BELT Manual 3_2.doc

7. The baggage flow should not be branched during the evaluation time for
Level 2 (branching prior to the Level 2 decision will increase the control ef-
fort – Tracking until decision on different transportation paths – and the me-
chanical effort – multiple connection tracks to Level 3 required). A common
value is 20 secs for Level 2.
X-Ray Level 1
Upon passing through the Hold Baggage Screening, the security status is also
forwarded in addition to the usual baggage information. In the case of tracking
errors, it may no longer be possible to allocate the security status which will then
become useless.
An Explosive Detection System machine is currently able to check up to about

1200 bags/hr.
X-Ray Level 3
The Level 3 Hold Baggage Screening should be performed in the vicinity of the
passenger waiting areas so that it is possible to quickly request the passenger to
open his or her bag should a Level 4 Hold Baggage Screening become neces-
sary. However, this is often not possible in practice.
For various reasons, e.g. in the case of a tracking loss after the Level 1 X-ray
station, the load for X-Ray Level 3 can suddenly increase. It should be possible
to route recirculated bags to a Level 3 X-Ray station again.
18.12 Pier conveyor loading and unloading

Loading conveyor
The typical application are loading lines for transfer baggage.
The following rules must be observed for the design of the pier conveyors:
1. The belts in the work area run at 0.5 m/s. To prevent a back-up, it can be
helpful to reduce the speed further, e.g. to 0.3 m/s (with FC).
2. The pier conveyor shall be equipped with a 3-layer low friction belt.
3. In the loading area, the drives should be located on the off-side if possible.
4. The intermediate bed section must be clad over its entire length.
5. The baggage is usually loaded in bulk form. Bag separation or accumulator
positions are not yet required on the pier conveyor.
6. Since loading is manually, the throughput will depend on the downstream
conveyors.
BELT Manual 3_2.doc

7. A cascade transition after the pier conveyor makes sense in order to mini-
mize the risk of pinching.
Unloading pier conveyor

The typical application are laterals after a sorter.
The following rules must be observed for the design of the pier conveyors:
1. Bag separation before the pier conveyor is not required.

2. A cascade transition before the pier conveyor makes sense in order to
minimize the risk of pinching.
3. The belts in the work area are pulsed and run at 0.5 m/s.
4. The pier conveyor shall be equipped with a 3-layer low friction belt.
5. In the loading area, the drives should be located on the off-side if possible
(not possible for pier conveyors that are open on both sides).
6. For very long pier conveyors, it can make sense to move the belt via a foot
switch.
18.13 Turns
The following rules apply to the use of turns:
1. Bag separation is not required before a turn.

2. A cascade transition can be used before and after the turn, but is not man-
datory. This may be difficult to implement after the turn because the next
conveyor would have to be installed lower.
3. Bags may be pinched in turns that are too narrow. The permitted minimum
radius does not depend on the bag length but rather on the diagonal size
(for L x W = 1 x 0.65 m, the diagonal is 1.2 m).
4. A turn must never be installed with a gradient. There must be no height dif-
ferential between the input and output of the turn.
5. For 30o and 45o turns, the drive must be located on the outside of the turn.
For 60o or 90o turns, the drive can be located on the outside or inside. It
should be preferred to install the drive on the outside of the turn.
6. The turn speed is referred to the centerline radius. The throughput corre-
sponds to that of a straight conveyor at the same speed.
7. Turns are not suitable for continuous pulsing.
BELT Manual 3_2.doc

18.14 High-speed diverter

The exact configuration for the high-speed diverter is still being developed.
Pending the release of the configuration rules, please consult AL PE Solutions.
18.15 TRAY loading station

The length of the BELT meterings is determined by the max. length of the bag
(please refer to the formula in section 4.2). This is not applicable for the loading
conveyor. This conveyor is not counted with the number of meterings before
loading.
The configuration rules are included with the TRAY Conveyor System User
Manual.
18.16 Vertical sorters

The following configuration rules apply to the integration of vertical sorters:

2. Three metering conveyors should be provided upstream from the input con-
veyor as induct conveyors.
3. A height differential should be provided upstream and downstream from the
vertical sorter.
4. The weight of the vertical sorters must be considered in the design of the
suspensions and support stands.
5. Tracking of bags is only possible with the 13o vertical sorter. If no tracking is
required, it is also possible to use the 18o vertical sorter.
6. The use of the vertical sorter to merge two baggage flows is much more ex-
pensive than a horizontal merge and should therefore be avoided.
7. In the presence of adjacent turns, the motor of the vertical sorter must be
located on the inside of the turn.
8. Sufficient space for the necessary housing must be provided around the
vertical sorter.
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18.17 Pusher lines

Definition
A pusher line is formed by one or more pushers that are sequentially arranged in
a straight line. The pusher line can consist of one or more consecutive straight
conveyors. (Any turn between the straight conveyors would create an additional
pusher line that would require separate control).
The following configuration rules apply to the integration of pusher lines:

2. Tracking is required before sorting. This is not necessary if a baggage flow
is only separated (load balancing).
3. Not cascade transitions are permitted in pusher lines.
4. The conveyors run at 1.4 m/s. A process performance of 2,600 bags/hr can
be achieved.
5. The minimum clearance between consecutive pushers is 2,500 mm. The in-
termediate frames can be directly installed next to each other.
6. For performances above 2,000 bags/hr, the first pusher of a line must be
preceded by a metering conveyor as a induct conveyor belt. The metering
conveyor can be omitted for lower performances.
7. A photo eye for tracking is required at the beginning and end of each con-
veyor (transition between conveyors).
8. A position encoder must be provided below each conveyor (design as with
the belt monitoring with incremental encoder).
9. Control is made by means of a window technique, i.e. defined gaps between
the front edges of consecutive bags. Commonly used window lengths are
1,400 mm (e.g. bag length 900 mm + gap 500 mm).
18.18 See-saw
The following configuration rules apply to the use of the see-saw:
1. The see-saw must be wider than the straight conveyor, at least as wide as
the length of the longest bag.
2. The see-saw runs 1.5 times faster than the main line.
BELT Manual 3_2.doc

18.19 Merges
The following configuration rules apply to the integration of 300 and 450 belt
merges:
1. The baggage flow in both induct conveyor lines must be separated first (see
paragraph 18.8).
3. The required induct conveyors can be metering conveyors (preferred solu-
tion) or turns of 600 or more (avoid if possible).
4. Any turns can be used in the induct conveyor line. Turns of 600 or more can
be used for pulsing (see above).
5. The main line and the induct conveyors run slower (e.g. at V1 = 1.2 m/s)
than the secondary branch of the merge runs (e.g. at V2 = 1.4 m/s), so that
bags can be merged reliably and as far as possible to the straight conveyor.
The following relationship applies:

V2 of secondary branch Height Differential
Merge 300 V1 x 1,2 50 mm
0
Merge 45 V1 x 1,4 50 mm
Single feed with tracking: Process performance 3000 bags/hr

6. At least one induct conveyor is required in the main and secondary lines
each upstream from the merge.
7. For throughputs > 1,800 bags/hr and <2,400 bags/hr, an additional induct
conveyor is required in the upstream secondary line. For throughputs
>2,400 bags/hr, an additional induct conveyor is required in the upstream
secondary line (total of 3). If the main and secondary lines have equal priori-
ties, this rule also applies to the main line.
Single feed without tracking: Process performance 3,100 bags/hr

8. At least one induct conveyor is required in the main and secondary lines
9. For throughputs >2,400 bags/hr, an additional induct conveyor is required in
the upstream secondary line. If the main and secondary lines have equal
priorities, this rule also applies to the main line.
10. At 1.5 m/s, up to 3,600 bags/hr can be achieved.
Multiple feed with tracking: Process performance 1,200 bags/hr

11. At least one induct conveyor is required in the main and all secondary lines
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Multiple feed without tracking: Process performance 1,800 bags/hr

12. At least one induct conveyor is required in the main and all secondary lines
18.20 Induct conveyor for sorters

1. The induct conveyor to a sorter is configured based on the following rules:
3. The bags must have a minimum gap and speed of transportation that de-
pend on the sorter manufacturer.
The specifications of the sorter supplier must be observed.
Example Crisplant: Minimum gap 200 mm, transportation speed 0.8 m/s
4. A cascade transition is useful before the induct conveyor. This requires the
last conveyor before the induct conveyor to be installed 50 mm higher.
5. Metering conveyors must be provided before the induct conveyor if peaks
occur in the induct conveyor line, which exceed the machine performance of
the induct conveyor (example: Pusher with a process performance of 2,600
bags/hr acting on a n induct conveyor with a machine performance of 2,000
bags/hr).
6. Metering conveyors are required before the induct conveyor if it is desired to
achieve the machine performance of the induct conveyor. After a Level 3
baggage check, a metering conveyor is usually not required.
7. The number of bags inducted to the induct conveyor line must not exceed
the number of bags that is accepted by the induct conveyor without pulsing.
This is done by counting the bags at the control level. Ejection to the induct
conveyor line is controlled as a function of the occupation of the metering
conveyors.
8. If pulsing is required, 2 metering conveyors (and a maximum of 3) should be
used before the induct conveyor. In case of doubt, the exact number should
be clarified with the simulation.
9. The signal exchange between the last conveyor of the induct conveyor line
and the induct conveyor (handshake) should be clarified with the manufac-
turer of the induct conveyor in each case.
18.21 Chutes
Chutes are used at the transition of tipper (tilt-tray sorters or tipper) on to belt
conveyors. The following configuration rules apply to the integration of output
chutes to the baggage handling system:
BELT Manual 3_2.doc

1. The chute plate in the direction of transportation of the tipper must be longer
than the longest bag, so that the funnel can reliably accept the bag. Chutes
downstream from tippers must have a minimum length of 1.5 x bag length.
2. If tracking is required, the chute path must be short (a rule-of-thumb value is
the bag length). It must always be possible to discharge the bag. This re-
quires that the belt that follows the chute must run and that a position for the
bag is available.
3. The chute angle must be at least 30o (preferable are 35o). The critical as-
pect is not the gradient of the chute plate but rather the angle on which the
bag slides down. If the bag rests against the inclined side guards when slid-
ing down, the chute angle can be smaller than the gradient of the chute
plate.
4. The tipper must only be allowed to tilt if the sorter chute is empty, i.e. the
chute funnel is not occupied with a bag. Otherwise bags could jam in the
chute funnel, which could result in a crash. For this reason, a sensor must
be provided at the chute funnels to ensure that the chute is empty. Only
then may the tilting operation be initiated.
With tilt-tray sorters, the arrangement of the switching link that initiates the
tilting operation can result in a situation where the chute funnel is empty at
the time of initiation but is then occupied by the next tray. If this bag is not
transported off in time, a back-up can occur in the chute funnel. For this
reason, the bags for which the tilting operation has already been initiated
are included in the count.
In some systems, consecutive trays cannot be tilted into the same sorter
chute. However, this simple approach results in unnecessary recirculated
bags on the sorter that reduce the sorter throughput and extend the bag-
gage processing time.
18.22 Spiral chutes

Spiral chutes should be avoided if possible. Their use in baggage handling sys-
tems is difficult because
● the baggage flow cannot be controlled. Rolling baggage can hardly be pre-
vented. Wet baggage can stick to the chute.
● only a few manufacturers build acceptable chutes.
Spiral chutes may only be used after consultation with AL PE Solutions.
BELT Manual 3_2.doc

Figure 67 Photo of spiral chute with rolling bag
18.23 Early bag storages (EBS)

In belt conveyor systems, baggage storage is implemented as static early bag
storage (dynamic storage is only useful in tray conveyor systems). For this pur-
pose, parallel belt conveyor systems are used as storage loops. The storage is
organized by flights or time slices.
Organization by flights
All bags in a storage loop belong to the same flight. The entire loop is discharged
in time for sorting and can then be reused for another flight.
This organization prevents re-circulated bags (bags that need to the stored again
after being discharged from the storage), but it is often not the best solution be-
cause the storage capacity of the loop does not match the volume of early bag-
gage of individual flights.
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Organization by time slices

The bags that need to be sorted at a specific period of time are collected in a
loop. In this organization, re-circulated bags regularly occur when
1. the time slice includes bags that cannot be sorted yet (the duration of the
tine slice is based on the volume of early baggage and the available storage
loops), or when
2. bags are delayed beyond the end of the time slice due to flight changes.
Since both forms of organization have their specific advantages and disadvan-
tages, the types of early bag stores are frequently used in various combinations
during operation.
A small number of long belts are more cost-effective than a larger number of
short belts, providing the same storage capacity. A storage with many short
belts can be used more flexibly in both forms of organization.
The following rules have proven their value for the integration of an early bag
store:
1. The storage loops run at 0.5 m/s or even slower.

2. The straight conveyor is pulsed. Metering conveyors are not required (and
not cost-effective) as accumulation conveyors.
3. The achievable filling degree results from the average bag length +
100 mm.
Example: (10 storage loops x 20 m length ) / (0.7 m +0.1 m) = 250 bags

4. If the ejection from the early bag store shall be made to a tilt tray sorter, the
storage loops must be merged to a collecting conveyor, which then leads to
an induct conveyor to the sorter.
5. After discharge from a storage loop, the baggage flow must be separated
(see paragraph 18.8).
6. Re-circulated bags must be possible. For this purpose, not only the trans-
portation path for re-circulated bags back to the entrance of he early bag
store must be clarified, but also the additional loading of the other conveyor
lines due to the re-circulatd bags. The main line must be designed with ade-
quate reserves.
7. If only some of the bags from a storage loop are required, the entire loop
must be discharged. No tracking occurs within a storage loop. The remain-
ing bags will be restored after a re-circulation (so-called restoring operation).
8. Normally, the storage loops are significantly slower than the main line.
Example: Ejection by the high-speed diverter at 1.9 m/s to a storage loop at

0.5 m/s, then induct conveyor on to another main line at 1.5 m/s
BELT Manual 3_2.doc

Depending on the speed differential, metering conveyors are required be-

fore and after the storage loop:
< 0.8 m/s: per 1 metering conveyor using the arithmetic mean of the speeds
> 0.8 m/s: per 2 metering conveyors using the arithmetic mean of the
speeds or
per 1 metering conveyor with FC
9. In the design of the induct conveyor and ejection line, it should be observed
that the throughputs are equal.
18.24 Fire protection gates

At simple smote protection gates, it is sufficient to cut out the side guard.
The following rules apply to the integration of fire protection gates into the bag-
gage handling system:
1. If F90 is required, or if conveyors must run across the fire opening at differ-
ent levels, it is necessary to interrupt the conveyor line. A contiguous gap of
50 mm is required.
2. If the conveyor line is interrupted, the conveyor before and after the fire pro-
tection gate must be connected to the emergency power supply, so that
they can be cleared in an emergency. A clearing control must be provided.
3. If F90 is not required and a single conveyor lines extends across the fire
opening, the conveyor may also be continuous. The area from the floor to
the belt surface must be sealed. In case of a fire, the belt will stop in a man-
ner that makes sure that no bag is positioned under the fire protection gate.
The gate can then close the opening.
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18.25 Carousels
Standard lengths for straight track sections
Prefabricated modules exist for straight track sections at 980, 1980 and 2980mm
length. They can be combined to the following lengths (in mm) of straight track
sections. Where a range is shown, the lengths in between are available in 20mm
intervals.
For flat carousels
980, 1960..1980, 2960..2980, 3940..3960, 4940.. 4960, 5940..5960, 6920..6940,

7920..7940, 8900..8940, 9880..9920, 10880..10920, 11880..11920,
12860..12900, 13860..13900, 14860..14900, 15840..15880, 16840..16880,
17840..17880, 18820..18860, 19820..19860, 20820..20860, 21800..21840,
22800..22840, 23800..23840, 24780..24820, 25780..25820, 26780..26820,
27760..27800, 28760..28800, 29760..29800, 30740..30780, 31740..31780,
32740..32780, 33720..33760, 34720..34760, 35720..35760, 36700..36740,
37700..37740, 38700..38740, 39680..39720, 40680..40720, 41680..41720,
42660..42700, 43660..43700, 44660..44700, 45640..45680, 46640..46680,
47640..47680, 48620..48660, 49620..49660
For inclined carousels
980, 1960..1980, 2960..2980

In addition price efficient preferred lenghts are 4960, 5960, 7940, 8940, 10920,
11920, 13900, 14900, 16880, 17880, 19860, 20860, 22840, 23840, 25820,
26820, 28800, 29800, 31780, 32780, 34760, 35760, 37740, 38740, 40720,
41720, 43700, 44700, 46680, 47680, 49660
Intermediate lengths inside the intervals lead to extra cost and are to be
avoided.
Outside the intervals the length will be built using components with application
specific design. In this case the exact length is not relevant. Any length in be-
tween is possible at reasonable cost.
The calculation will show if a combination of available standard components is

available close to the desired length.
:NOTE: The chain can be tensioned and thus does not determine the length of
the carousel.
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Ejection to a carousel
The following configuration rules apply to the integration of re-circulated bags to
the baggage handling system:
1. The last conveyor before the carousel can be a metering conveyor (pre-
ferred solution) or a 900 turn (to be avoided if possible). A minimum distance
of 200 mm to the next turn of the carousel is required.
2. Maintain a height differential of 80 mm to slat surface.
3. The induct conveyor on to the carousel should be at an angle of 900 if pos-
sible, since this permits the use even of smaller gaps on the carousel.
4. An induction point should be positioned so that as much space for passen-
gers remains downstream in the direction of transportation.
5. Permitted speeds of transportation for induct conveyors on to a carousel:
flat carousel inclined carousel
Departure area 1.4 m/s 0.7 m/s
Passenger area 0.7 m/s 0.7 m/s
In the passenger area, the speed of transportation can possible be reduced

further) please observe customer’s specification).
6. The carousels are usually operated at 0.5 m/s.

7. Inclined carousels can be used for separated baggage and for bulk bag-
gage. Flat carousels can only be used for separated baggage.
Carousel instead of automatic sorter

Our carousels are designed to withdraw the baggage manually (at arrivals or
make-up carousels). It is not permitted to withdraw bags with a vertical belt di-
verter. The present carousel must not be used as a sorter.
With the vertical belt diverter on top the slats are subject to forces that can not
be calculated. Bags and ripped off parts seize and wedge between the lower part
of the diverter belt and the slats. This does not happen during normal operation
with manual unloading, because the force on the slat is limited by baggage
weight times friction factor.
Holding the outer edge of the slat, approx. 1500N are needed to break the con-
nection between chain and traverse. This force would be generated only by a
300kg bag.
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Throughput of a carousel
These units are usually uncritical. At a speed of 0.5 m/s, the throughput of a car-
ousel is approx. 1200 bags/hr (depending on bag length).
18.26 Baggage lifts

In rare cases, continuous baggage lifts and discontinuous elevators for passen-
ger baggage are also used in automated baggage handling systems.
Basis types are:
● C-conveyor Entrance and exit on the same side

● S-conveyor Entrance and exit on opposite sides
The products from different manufacturers may vary considerably. For this pur-
pose, the technical data, throughputs etc. must always be requested from the
manufacturer.
The following rules apply to the integration of baggage lifts in the baggage han-
dling system:

2. Upstream from the lift, length detection to determine the permitted loading
length of the lift is required.
3. Upstream from the lift, a metering conveyor must be used as a induct con-
veyor. The induct conveyor must be synchronized with the entrance of the
lift.
4. The achievable throughput depends on the lift. Usually the conveyor lines
upstream and downstream from the lift are faster.
5. The lifting mechanism must be equipped with an FC with a special lift func-
tionality.
Depending on the supplier of the lift, other conditions may apply. In any case, in-
stallation must be accurately coordinated with the supplier of the lift.
BELT Manual 3_2.doc

BELT Conveyor System User Manual Index
Index
Fire protection gates..............................................106

A Frame ......................... 11, 12, 13, 16, 23, 24, 31, 100
Attributes................................................................... 4 G
Automatic tag reader....................... 92, 93, 94, 95, 96
Gap... 3, 12, 14, 21, 53, 57, 87, 93, 94, 100, 102, 106
B
Baggage
H
bulky .............................................. 3, 11, 87, 88, 89 Height differential .... 2, 13, 30, 44, 46, 63, 88, 98, 99,
lifts ..................................................................... 109 108
regular ............................................................. 3, 89 Hole pattern .............................................................16
specification........................................................... 3
Bearings..................14, 24, 31, 37, 43, 68, 69, 75, 82 I
Belt types .......................................... 1, 25, 32, 59, 69
Bins ........................................................................... 3 Inclination ....................................... 11, 25, 27, 44, 46
Bulk ..................................................... 92, 95, 97, 108 Intermediate frame ......................................... 12, 100
Bulky baggage .................................. 3, 11, 87, 88, 89
Bypass .................................................................... 62 K
Knee joint cover.......................................................21
C
Cable ducts ............................................................. 23 L
Cascade.................................................................. 13
Check-in.................... 2, 34, 47, 85, 86, 87, 88, 89, 94 Lateral......................................................................60
CONCEPTIX ............................................................. 4 Length of a piece of baggage........................... 19, 30
Lifts ........................................................................109
Load..... 22, 24, 30, 31, 33, 53, 57, 68, 73, 75, 78, 83,
D 84, 86, 100
Drive station Load balancing ......................................... 53, 57, 100
Type L160 ..................................................... 20, 23
Type S110 ..................................................... 19, 23 M
Type XL240 ......................................................... 23
Machine output ..........................................................4
Merge .. 2, 25, 26, 49, 54, 65, 66, 67, 68, 69, 99, 101,
E 102
End part .................................................................. 13
Energy consumption ............................................... 86 N
Environmental conditions .......................................... 4
Explosive detection system .................... 3, 87, 92, 96 Noise ................................................................ 23, 31
Explosive detection systems................................... 96 Noise level ...............................................................23
F O
FC-controlled .......................................................... 32 Out of gauge............................................................60
BELT Manual 3_2.doc

BELT Conveyor System User Manual Index
Output Tracking14, 16, 44, 68, 91, 92, 97, 99, 100, 101, 102,
machine................................................................. 4 103, 105
process.................................................................. 4 Transfers .................. 1, 33, 34, 55, 59, 63, 87, 94, 97
TRAY System ..........................................................99
P Turn
angle ............................................................. 35, 41
Process output .......................................................... 4
Protection...................... ii, 24, 31, 52, 56, 69, 77, 106 V
Pulsing rate ............................................................. 32
Variable length.........................................................12
R Vertical knee
concave................................................................21
Reversing conveyor ................................................ 16 convex........................................................... 21, 91
Vibration damper .....................................................24
S Vibrations.................................................................24
Scanner gate................................... 92, 93, 94, 95, 96

Side guide ......................................................... 38, 45
W
Simulation ............................................................. 102 Weight ... 3, 23, 25, 26, 31, 32, 36, 42, 56, 60, 69, 75,
Slip ............................................22, 23, 28, 31, 50, 69 83, 90, 99, 108
Stainless steel...........................72, 75, 77, 80, 82, 83
X
T
X-ray check..............................................................97
Tensioning station................................................... 15 X-ray machine ........................................ 3, 87, 92, 96
Throughput...................................................... 89, 109
Tilt-tray sorter................................................ 2, 70, 88
BELT Manual 3_2.doc


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For internal use only Airport Logistics

BELT Conveyor System

Siemens Industry - Mobility

Responsible for the contents:

Engineering J. Bruett Phone +49 (0) 911 145 7602

Postal address Siemens AG

The right to make modification to design and equipment is reserved.

Industry, IL LS September 15, 2010 V. 3.2

Version Date Change/Comment

This version supersedes all previous versions of the manual.

The BELT user manual is available in a German and an English version.

BELT Manual 3_2.doc

1 Introduction and Overview.............................................................1

2 Check-in conveyors ........................................................................5

3 Straight Conveyor .........................................................................11

5 Pier conveyor ................................................................................33

6 Power Turn TS 1600......................................................................35

7 Spiral Power Turn TS 1600 Helix .................................................41

BELT Manual 3_2.doc

9 Vertical sorter unit 1200bph.........................................................49

10 Vertical Sorter 1800 bph TS 6600 ................................................54

11 High-speed Diverter ......................................................................58

13 Merge / Divert TS 6200..................................................................65

14 Tilt-tray Sorter ...............................................................................70

15 Sorter Chute ..................................................................................71

16 Flat Carousel .................................................................................72

17 Inclined Carousel ..........................................................................80

BELT Manual 3_2.doc

18.9 Automatic tag readers (ATR) ..........................................................93

BELT Manual 3_2.doc

Figure 1 Typical arrangement of a two-segment check-in conveyor...............6

BELT Manual 3_2.doc

Figure 44 Vertical sorter front view..................................................................51

BELT Manual 3_2.doc

1 Introduction and Overview

Contemporary transport of passenger baggage at airports is accomplished by

The following conveyors are used in baggage handling systems:

BELT Manual 3_2.doc

Other, complementary components are Check-in belts, metering conveyors, pier

BELT Manual 3_2.doc

● Suitcases with or without casters

Length Width Height Weight

max. 1000 mm 450 mm 800 mm 50 kg

BELT Manual 3_2.doc

Theoretical machine output

Achievable process output

In extreme environmental conditions (extreme temperatures, aggressive air, high

Layout planning and engineering tool CONCEPTIX

BELT Manual 3_2.doc

Designation in the Bill of Quantities

Labeling Labeling conveyor

Representation of the check-in conveyors in the layout (for three-conveyor units)

2.1 Functional specification of equipment

● Low Insertion height, hence easy access to passenger’s baggage

The check-in conveyor is oriented 90 degrees to the take-away conveyor and is

BELT Manual 3_2.doc

(depending on customer requirements and site space availability a three-

Figure 1 Typical arrangement of a two-segment check-in conveyor

Figure 2 Weight display and push buttons

BELT Manual 3_2.doc

Weighing & labeling conveyor

Figure 3 Weighing & Labeling Conveyor

Figure 4 Dispatch Conveyor

BELT Manual 3_2.doc