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Equipment Application 1.

Accumulation The Beginning of the System


1. Accumulation 2. Central Merge 3. Induction

4. Sortation
5. Recirculation

6. After-sort Lines

Slide 1

Equipment Application: Accumulation

The operation of accumulation conveyor consists of


FILLING the conveyor and DRAINING the conveyor

There are different modes of operation for FILLING and DRAINING depending on the conveyor type:

Filling

Draining
Singulation Mode Slug Mode

LR or MDR
LR or MDR

Singulation Mode Slug (blow through)

Slide 2

Equipment Application: Accumulation LR - Belt Driven Live Roller Fill The Conveyor Singulation Mode
Case Ft/Min. = 50% of Belt Speed CONTACT accumulation!
Speed Formula:

Speed = (Ave. Case Length) x (Case Rate) 0.5

Product Load "C"

Product Load "B"

Product Load "A"

Transport

Accumulate

Accumulate

Power to rollers in discharge zone dropped

Slide 3

Equipment Application: Accumulation AR+ Motor Driven Roller Fill The Conveyor Singulation Mode
Non-CONTACT accumulation! Speed = minimum rate required
Faster is better for rate spikes! Speed Formula:

Speed = (Ave. Case ) x (Case Rate) 0.9

Slide 4

Equipment Application: Accumulation Belt Driven Live Roller Drain The Conveyor Singulation Mode
Case Ft/Min. = 50% of Belt Speed CONTACT accumulation!

LR Belt Speed Formula:

Speed = (Ave. Case Length) x (Case Rate) 0.5

Product Load "D"

Product Load "B"

Product Load "C"

Product Load "B"

Accumulate

Accumulate

Transport

Power to rollers in discharge zone Engaged

Slide 5

Equipment Application: Accumulation AR+ Motor Driven Roller Drain The Conveyor Singulation Mode
Non-CONTACT accumulation! Belted zones required for better accuracy and problem products
Speed Formula:

Speed = (Ave. Case + Zone) x (Case Rate) 0.9

Slide 6

Equipment Application: Accumulation Belt Driven Live Roller Drain The Conveyor Slug Mode
Release a 10 ft. or 20 ft. or 30 ft. long slug of cartons at the same time, with no gaps between cartons! A slug release signal will cause all accumulation in the slug zone to be powered at the same time. All cartons will then move forward at the same time leaving no gap between cartons. When the slug release signal is stopped, the zones will enter standard singulation release mode. PhotoEye Sensor Accumulation requires the addition of a Slug Input Module and a Slug Isolation Link to control the slug zone.

Case Ft/Min. = 95% of Belt Speed

Speed Formula: Speed = (Ave. Case Length) x (Case Rate) 0.95

Slug is a high rate drain mode!

Slide 7

Equipment Application: Accumulation AR+ Motor Driven Roller Drain The Conveyor Slug Mode (Train)
Non-CONTACT accumulation! Belted zones required for better accuracy and problem products Maintains gap from zone to zone upon discharge of conveyor Caution Power supply requirements change with slug release of MDR.

Speed Formula:

Speed = (Zone Length) x (Case Rate) .95

Slide 8

Equipment Application: Accumulation Belt Driven Live Roller


Things to watch out for:
At higher speeds, cartons will not start up as quickly from accumulation mode causing longer gaps and lower effective cast Ft/Min. Depending on case sizes and weights, the accumulation factor will degrade from .5 to .4 or even .3 at higher speeds. Considering these factors, Automotion does not recommend running accumulation conveyors faster than 200 FPM. Carton inertia at higher speeds will cause increasing forward push during accumulation. Consider using a longer break belt to control higher product back pressure.

Rule of Thumb: The slower you run conveyor the better. Keep the speeds around 160 fpm or slower (120 fpm is an optimum accumulation speed). Carton side-by-sides and jams occur more frequently as speeds go over 180 - 200 fpm.

Always consider the carton size range and weight range when selecting conveyor speeds.
180 FPM - ABEC1 IS NOW OUR STANDARD PRODUCT FOR ALL SPEEDS! 230 FPM - Machine Crowned Pulleys required Slide 9

Equipment Application: Accumulation Belt Driven Live Roller


Things to watch out for:
Big cartons will have a tendency to rotate when accumulating against small cartons. At the entry to each accumulation conveyor, always align, or re-align, cartons to the side of the conveyor. If you have very small (6 wide) and very large (30 wide) cartons accumulating on the same conveyor special attention should be used to control carton alignment and back pressure to avoid this. Non-contact AR+ accumulation should be considered for best results.

Side by side jams occur!

Slide 10

Equipment Application: Accumulation Autoroll + Live Roller


Remember this problem with contact accumulation:
Side by side jams can occur!

You dont have it with non-contact accumulation:

One carton per zone. No contact No Side by side jams occur!

Slide 11

Problem Set #1

LR Accumulation Speed Accum Slug Speed = (Ave. Case Length) x (Case Rate) Factor
Conveyor Type LR Photo Eye LR Photo Eye Mode Singulation Slug CFPM Factor .5 .95

MDR Accumulation Speed

Speed = (Ave. Case + Zone) x (Case Rate) Factor Speed = (Zone Length) x (Case Rate) Factor
Conveyor Type AR+ AR+ Mode Singulation Slug CFPM Factor .9 .95

Slide 12

Equipment Application: Accumulation Belt Driven Live Roller


Speed Calculation Examples

Problem Set #1

#1

24 Rate Carton using LR Phote Eye Singulation Release 40CPM 24/12 x 40 CPM = 80 Case Ft./Min. Required 80 cfpm / .5 Factor = 160 Ft/Min Belt Speed 24 Rate Carton using LR Photo Eye Slug Release 40CPM 24/12 x 40 CPM = 80 Case Ft./Min. Required 80 cfpm / .95 factor = 85 Ft./Min. Belt Speed

Speed Formula: Speed = (Ave. Case Length) x (Case Rate) Factor

#2

Conveyor Type LR Photo Eye LR Photo Eye

Mode Singulation Slug

CFPM Factor .5 .95

Slide 13

Equipment Application: Accumulation Autoroll+ Motor Driven Roller


Speed Calculation Examples
#1 24 Rate Carton using Singulation Release 40 CPM, 30 Zone
(24 carton + 30 zone) x 40 cpm = 180 Ft./Min 180 ft./Min / .9 factor = 200 Ft./Min Conveyor Speed

Problem Set #1

Autoroll+ is Non-contact accumulation!

Singulation Mode Formula:

Speed = (Ave. Case + Zone) x (Case Rate) Factor


Conveyor Type AR+ #2 24 Rate Carton using Slug Release 40 CPM, 30 Zone (30 zone) x 40 cpm = 100 Ft./Min AR+ Mode Singulation Slug CFPM Factor .9 .95

100 ft./Min / .95 factor = 105 Ft./Min Conveyor Speed Slug Mode Formula:

Speed = (Zone Length) x (Case Rate) Factor

Slide 14

Equipment Application 2. Central Merge Bringing It All Together


1. Accumulation

2. Central Merge 3. Induction

4. Sortation
5. Recirculation

6. After-sort Lines

Slide 15

Equipment Application: Central Merge


Purpose
Product flow from multiple infeed lines to a sorter. V-belt Sweep Merge Table Live Roller Sawtooth Belt Sawtooth

Types

Slide 16

Equipment Application: Central Merge V-Belt Sweep


Perpendicular or Parallel merge on to Live Roller Takeaway.
Recommended Maximum merge rate 20-30 CPM. Why: Merge points and carton release points are far apart Air brakes are used for merge control No guaranteed gap between cartons at the air brake to insure you can stop a small carton before it dribbles onto the constant-running sweep Advantages: Low cost the sweeps can be slave-driven from the infeed accumulation conveyors saving a motor charge and field wiring cost.

A word or two on Air Brakes: Always use coated rollers at merge points. Actually, I recommend you always use coated rollers on air brakes, period. Consider your product: Light totes, pushed by heavy totes, can be pushed over the air brake and into the merge point causing a jam. Small cartons (9 or shorter) can dribble past an air brake if the stop signal is not timed right. Slide 17

Equipment Application: Central Merge V-Belt Sweep


Perpendicular or Parallel merge on to Live Roller Takeaway
Alternate Roller Sawtooth Module Instead of Sweep Junction

Recommended Maximum merge rate 20-30 CPM.


Recommended for small cartons or square cartons The sawtooth module will accept cartons that are not aligned to the transfer side and transfer consistently with minimum carton rotation

Slide 18

Equipment Application: Central Merge V-Belt Sweep


Perpendicular or Parallel merge on to Live Roller Takeaway. Things to Remember:
Carton Alignment is important for consistent transfer Increasing Conveyor Speeds are important to pull cartons around the sweep and transfer point. Run the take-away conveyor:
25% faster when using a 45 deg. sweep 15% faster when using a 30 deg. sweep

Align cartons to the inside of the sweep. Not the outside.

Run the sweep 10% to 15% faster than the infeed accumulation conveyor

Slide 19

Equipment Application: Central Merge V-Belt Sweep


Perpendicular or Parallel merge on to Live Roller Takeaway. Things to Remember:
Carton Alignment is NOT so important for consistent transfer Increasing Conveyor Speeds are important to pull cartons around the curve and transfer point. Run the take-away conveyor 15% faster than the infeed accumulation line

Align cartons to the inside of the sweep. But the outside is ok.

Run the curve 10% to 15% faster than the infeed accumulation conveyor Slide 20

Equipment Application: Central Merge Live Roller Merge Table


Parallel Accumulation lines merge into one line Maximum merge rate 30-40 CPM.

Higher rates (40 to 60CPM) if brake meters are used

Slide 21

Equipment Application: Central Merge Air Brakes and Brake Meter Belts
A word or two about air brakes and brake meter belts
Air Brakes

Brake Meter Belts

When to use Brake Meter Belts:

At higher rates.
When to use Air Brakes (with Coated Rollers): When merging slugs of product. Why? Air brakes will not guarantee a gap between cartons, so individual carton cannot be stopped 100% of the time. Why? You start merging smaller slugs, maybe individual cartons, to get the higher rate. To merge small slugs, you need gapped cartons that only the speed change of two belts can generate. Wide range of product size and weight, and small boxes. Why? The brake belt will do a better job of holding back the impact of accumulation products and prevent cartons from being pushed over the brake and into the merge. Small boxes (<9 Lg.) can sometimes dribble past the air brake causing a jam. Brake meter belts reliably stop small boxes.

Slower Speed / Rate Merge Points


Why? Boxes can be pushed over the brake rollers by the inertia of heavy and higher speed cartons. Plastic totes or empty cartons may be pushed over the brake rollers by other heavy product At speeds of 120 FPM air brakes work great. At speeds of 180 FPM air brakes dont work. What about the speeds in-between? Depends on product type (Totes? Cartons?), Product Weight (1 Pound? 10 Pounds?), Product condition (Good Boxes? Bad Boxes?).

For Merge Control: 10 to 30 cpm: use air brakes 40 to 50 cpm: start thinking about brake meter belts 60 cpm or higher rates: use brake meter belts.

Slide 22

Equipment Application: Central Merge Live Roller Sawtooth


45 degree Sawtooth Module Sawtooth should be 1 standard width above the infeed width. 20 to 40 CPM with air brakes when merging 20-30 ft. slugs of product. Note the curve and alignment sections are the same width as the sawtooth. 50 to 90 CPM with brake meter belts. The high rate is possible because the release points are close together. Air brakes can be used when merging slugs of product.

Slide 23

Equipment Application: Central Merge Belt Sawtooth


30 or 45 degree sweep. 30 degree is preferred. Takeaway should be 1 standard width above the infeed width. Order wide slic-top belting and belt guides 60 to 120 CPM with brake meters. Belt sawtooth is a very dependable high speed merge. Cartons transfer dependably and consistently. Carton alignment is preferred, but not required. Cartons transfer from either side. Preferred merge for small cartons, square cartons, lightweight cartons, and bags.

Slide 24

Equipment Application: Central Merge Live Roller & Belt Sawtooth


Things to Remember:
Increase the sawtooth width by 6 Allows the big and long cartons swing room Use slic-top belt and belt guides on the belt conveyor Nominal width + 6 conveyor widths Nominal width + 6 conveyor widths

Slic-top belt and belt guides on this conveyor

Nominal system width conveyors

Nominal system width conveyors

Slide 25

Equipment Application: Central Merge Live Roller & Belt Sawtooth


Things to Remember:
Carton alignment Preferred to align to the inside but it is not required Re-align after the merge. Align to the correct side for the sorter device.

Re-alignment section

Re-alignment section

Preferred case side alignment

This side works ok as well

Preferred case side alignment This side works ok as well

Slide 26

Equipment Application: Central Merge Carton Alignment


Typical Sorter System with Case Alignment After the Central Merge

A Common Problem Cartons can accumulate back into the alignment section (a hard drive section) causing carton rotation, side-by-sides, and jams. Solution #1 Locate the accumulation line-full photo eye downstream at a distance that avoids accumulating on the skew section. For this layout, this solution wont work! The accumulation conveyor is not long enough to accept all the cartons on the sawtooth, the skew section, and the accumulator. Solution #2 Put a motor on the skew section. The sawtooth has a motor already. When the accumulation conveyor fills up, simply turn off the sawtooth and skew conveyors. All merge and alignment conveyors must be cleared or stopped to avoid carton side-by-side problems.

Slide 27

Equipment Application: Central Merge Recap of merge configurations and rate


Air Brake merge 20-30 cpm

Meter belt merge 40-50 cpm

Meter belt belt sawtooth 70-130 cpm

Air brake roller sawtooth 20-50 cpm

Brake belt roller sawtooth 50-90 cpm Air brake merge. 20-40 cpm

Air brakes can be used at lower rates when merging slugs of product. Brake belts can be used at higher rates when merging single cartons Higher rates are possible when the release points are close together.

Meter belt merge. 40-60 cpm Slide 28

Which central merge did you choose for this application?

Problem Set #2

B
Why that one?
50# carton could push through the air brakes on the other options.

Could any of the others work in this situation?


With lighter product or less rate, yes.

What about other options?

Slide 29

Which central merge did you choose for this application?

Problem Set #2

B
Why that one?
50# carton could push through the air brakes on the other options.

Could any of the others work in this situation?


With lighter product or less rate, yes.

What about other options?

Slide 30

How fast would belt driven live roller PE accumulation run in this example if the rate was 55 CPM?

Problem Set #2

Would you choose slug or singulation release for this merge area and why?

Slide 31

How fast would belt driven live roller PE accumulation run in this example if the rate was 55 CPM?
#1

Problem Set #2

24 Rate Carton using LR Phote Eye Singulation Release 55CPM 24/12 x 55 CPM = 110 Case Ft./Min. Required 110 cfpm / .5 Factor = 220 Ft/Min Belt Speed 24 Rate Carton using LR Photo Eye Slug Release 55CPM 24/12 x 55 CPM = 110 Case Ft./Min. Required 80 cfpm / .95 factor = 115 Ft./Min. Belt Speed

#2

Would you choose slug or singulation release for this merge area and why?
Slug, to avoid running the accumulation too fast. Opinions?

Slide 32

Equipment Application 3. Induction Feeding The Machine


1. Accumulation

2. Central Merge 3. Induction

4. Sortation
5. Recirculation

6. After-sort Lines

Slide 33

Equipment Application: Induction


Single Line Induction Systems 10 to 120 cpm

Multi Line Induction Systems 50 to 250+ cpm

There are different carton spacing / induction methods depending upon the carton rate.

Slide 34

Equipment Application: Induction


Three methods of carton induction / spacing:
1. Speed Space Induction
Uses a constant running belt to release cartons onto the sorter. Carton gaps are established by the simple speed difference between belts. High speed with variable gaps between cartons depending on the various carton lengths. Works best with similar length products. BMB Induct Brake Motor Set for constant run Uses a stop / start control over the induction belts to release cartons onto the sorter Creates relatively consistent gaps between cartons.. BMB Induct Simple stop/start control 2-3 Start/Stops per minute Brake Motor IMB Induct Fixed accel / decel ramps added to stop/start motor control Up To 60 Start/Stops per minute Inverter Duty Motor with variable frequency controller

3. Dynamic Induction Uses slow-down / speed-up control over induction belts to release cartons onto sorter. Creates consistent gaps between cartons. BGO, SGO
Variable accel / decel ramps and variable speed motor control. 60 to 250+ CPM 2 belt or 3 belt unit. Vector or Servo motor. Consult factory for high rate applications.

2. Start Stop Induction


Slide 35

Equipment Application: Induction


First, lets review a Single Line Induction. These systems typically contain the following equipment: 1. 2. 3. 4. 5. 6. Power Roller Skew Live Roller Accumulation Brake / Induction Belt Scanner Belt (optional) In-motion scale (optional) Sorter

The typical single line induction system will use either: Speed Space Induction or Stop Start Induction

Slide 36

Equipment Application: Induction


Speed Determination for Stop/Start Induction:
Brake Belt Speed Based on required case ft./minute Rate Carton / 12 x CPM = Brake Belt Speed At this speed the rate carton will be back to back on the brake belt and moving at required case rate. The induction unit will constant-run with rate cartons or longer-than-rate cartons. The induction unit will stop/start to establish sorter gaps only when running shorter-than-rate cartons. Recommend 120 fpm maximum speed for the brake belt. At higher speeds the stop/start operation may tip over tall or high center-ofgravity cartons. Induct Belt Speed Calculated as a ratio to the Brake Belt Speed (See Chart). Select a ratio that will pull a speed gap of 6 to 9 for the shortest carton. The gap is for photo eyes and for carton stopping distance before the curve. Induct Belt Brake Belt

Slide 37

Equipment Application: Induction


System Speed Selection:
1. Power Roller Skew Speed 10% Faster than accumulation Speed Control to prevent accumulating on this section Induction Accumulation Speed Use singulation, when possible LRPE photo eye preferred. Induction Speeds Select the induction unit based upon required case rate and case size range, both length and height (tall cartons may tip if started too abruptly) 4. Scanner Belt Select a speed between the induction belt speed and the sorter belt speed. Sorter Belt Select a speed based upon the required case rate from the sorter speed charts. General rule speed changes from induction belt to sorter belt should be in increments of no more than 80 to 100 fpm. Speed increments higher can cause cartons to tip over, or rotate, effecting sort action. Tip sometimes you will need a constant-run belt on both sides of the in-motion scale. It depends on conveyor speeds, product size range, weight range, and required weight accuracy.

2.

5.

3.

Slide 38

Equipment Application: Induction


Determine Speeds. Example 1. low rate single line induction:
Design Rate: Case length: Design Minimum Maximum 25 cpm

1.

Accumulation Speed
((24 carton / 12) x 25 cpm) / .5 CFPM factor = 100 fpm 100 FPM x 1.1 = 110 fpm Brake Belt Speed 25 x (24/ 12) = 50 fpm Choose closest standard speed (See chart on left) 60 FPM is closest standard speed Induction Belt Speed 60 FPM belt is available only with a 2:1 ratio (see chart on left) Induction belt speed is 120 fpm In this case Sorter will run 310 fpm 120 fpm + ((310 fpm 120 fpm) / 2) = 215 fpm Next Standard Belt Speed is 220 fpm

2. 3.

Powered Roller Skew Speed


Induction Speed

24 9 30

4.

Scanner Belt

Slide 39

Equipment Application: Induction


Determine Speeds. Example 2. medium rate single line induction:
Design Rate: Case length: Design Minimum Maximum 45 cpm 24 9 30

1. Accumulation Speed
((24 carton /12) x 45 cpm) / .5 CFMP factor = 180 FPM 180 FPM x 1.1 = 200 fpm Brake Belt Speed 45 cpm x 24 carton / 12 = 90 fpm 90 fpm is a standard speed. Induction Belt Speed 90 fpm belt is available with a 2:1 ratio (See Chart on Left) Induction belt speed is 180 fpm

2. Powered Roller Skew Speed


3. Induction Speed

4. Scanner Belt
In this case Sorter will run 350 fpm 180 fpm + ((350 fpm 180 fpm) / 2) = 265 fpm Next Standard Belt Speed is 280 fpm

Slide 40

Equipment Application: Induction


Determine Speeds. Example 3. high rate single line induction:
Design Rate: Case length: Design Minimum Maximum 60 cpm 24 9 30

1. Accumulation Speed
((24 carton /12) x 60 cpm) / .5 CFPM factor = 240 fpm 240 fpm x 1.1 = 270 fpm

2. Powered Roller Skew Speed

Live Roller Accumulation 3. Induction Speed Brake Belt Speed is ineffective at this 60 cpm x 24 carton / 12 = 120 fpm speed. Use as a blow 120 fpm is a standard speed. through induction lane at Induction Belt Speed lower speeds if possible. 120 fpm belt is available with
a 1.5:1 ratio (see chart on left) Induction belt speed is 180 fpm

4. Scanner Belt
In this case Sorter will run 220 fpm 180 fpm + ((220 fpm 180 fpm ) / 2) = 200 fpm 200 fpm is a standard speed.

Slide 41

Equipment Application: Induction


Determine Speeds. Example 4. high rate single line induction :
Design Rate: Case length: Design Minimum Maximum 70 cpm 24 9 30

1. Accumulation Speed
((24 carton /12) x 70 cpm) / .5 CFPM factor = 280 fpm 280 fpm x 1.1 = 310 fpm Brake Belt Speed 70 cpm x 24 carton / 12 = 140 fpm Choose Closest Standard Speed (see chart on left) 150 fpm is closest standard speed Induction Belt Speed 150 fpm belt is available with a 1.5 : 1 ratio (see chart on left) Induction belt speed is 220 fpm

2. Powered Roller Skew Speed


3. Induction Speed
Live Roller Accumulation is ineffective at this speed. Use as a blow-through induction lane at lower speeds if possible.

4. Scanner Belt Speed


In this case Sorter will run 300 fpm 220 fpm + ((300 fpm 220 fpm)/2) = 260 fpm 260 fpm is a standard speed.

Slide 42

Equipment Application: High Speed Low Inertia Induction Belts


Dynamic Induction
Uses slow-down / speed-up control over induction belts to release cartons onto sorter. Creates consistent gaps between cartons. Multiple belt Multiple line High Speed Induction Low Inertia mechanical system Controlled Acceleration - .4g Modular Approach VFD or Servo control Dynamic, On the Fly Gapping

New Servo Induction Belt Design Modular Construction Use a two-belt or a three-belt unit to provide the required speed control Single Line induction Dual Line Induction Multiple Belts

Slide 43

Equipment Application: High Speed Low Inertia Induction Belts


Dynamic Induction Units Vector and Servo Motor Uses variable speed and variable accel/decel to create accurate, consistent gap between cartons.

Approximate Rate Based Upon: 18 Rate Carton 12 Minimum 36 Maximum

110-120 CPM

160-180 CPM

180-250+ CPM

Minimum carton size is important - having an extremely short minimum carton will add a third belt to most induction systems!

Slide 44

Equipment Application: High Speed Induction Belts


Application/Design Considerations for High Rate
1. Inductions should be designed for the rate speed plus 10%. The engineering factor accounts for mechanical losses such as: Variations in belt speed during accel and decel Variations in carton movement at transfer points Variations in carton location along the merge verti-belt And electrical losses such as : Conservative allowance for carton merging 2. Acceleration and deceleration of the belts is limited to 1G to reduce the incidence of tipping cartons. This is based on a square box where the length is equal to the height and the center of gravity is at the halflength point of the box, and in the lower 1/3 of the height. 3. First Belt, Belt #1, Should run at the design case Ft./Min. Last Belt, Belt #3, should run at the same speed as the sorter. 4. For Rule of Thumb, each belt should have no more than 100 FPM increase.

Slide 45

Equipment Application: High Speed Induction Belts


Example. 100 cpm system What speed to run the induction accumulation conveyor?
Contract Rate 100 cpm Design Rate = 100 cpm contract rate x 1.10 eng. factor = 110 cpm Rate Carton 21 Long 1. 2. (21 Long Carton / 12 ) x 110 cpm = 193 Case Ft./Min. 193 Case Ft./Min. / .5 Singulation Factor = 386 fpm Belt Speed.
Contract Rate Carton Size: Design Min. Max. Sorter Induction 100 CPM 21 12 36 Shoe Single Line

Problem: 386 fpm exceeds allowable accumulation speed! Solution 1: Reduce the Rate Carton to 12! (If only it was that easy!) Solution 2: Change the layout to a dual line induction. This will cut the rate in half and get the accumulation speed down to allowable limits. Solution 3: Use slug mode to allow blow-through from the accumulator.

Slide 46

Equipment Application: High Speed Induction Belts


Example. 80 cpm system, Dual Line Induction Determine Induction Belt Speeds
1. Determine Belt #1 Speed
80 cpm x 1.15 eng. factor = 92 cpm Design Rate 92 cpm / 2 lines = 46 cpm Per Line Design Rate 46 x 24/12 = 92 Case Ft./Min. = 92 fpm Belt Speed

Contract Rate Carton Size: Design Min. Max. Sorter Induction

80 CPM 24 12 36 Shoe Dual Line

Note: 1. 2. 3. 4. Two Stage Belt required at 42 CPM The speeds are relatively low. The sort rate and the infeed line rates are relatively low. Is the product relatively stable?

2.

Determine Sorter Speed


92 cpm x (24 + 18 Gap)/12 = 322 fpm Remember: Sorter Speed equals Last Belt Speed

3.

Determine number of intermediate belts


100 fpm + 100 fpm = 200 fpm (Belt #2) 200 fpm + 100 fpm = 300 fpm (Close Enough to sorter speed)

4.

Induction Configuration:

100 fpm

200 fpm

200 fpm

300 fpm

320 fpm

Slide 47

Equipment Application: In-Motion Weight Scales


Used For Check Weighing Cases must be metered one carton at a time onto scale For high rate (40 to 70 cpm) or high accuracy weights, the belt feeding into-the-scale and outof-the-scale should be constant-running belts at the same speed as the scale.

Sorter Slave Belt 250 fpm

Sorter Belt 250 fpm

Belt Curve Tangent 250 fpm

Scale 250 fpm

Scan Belt 250 fpm

Induct Belt 240/120 fpm

Slide 48

Equipment Application: Induction


The Index Belt Induction
The Index Belt Induction
Uses multiple belts to stage pre-gapped cartons. The cartons are slug-released directly onto the sorter induction belts. Only minor re-gapping is required before the sorter.

Commonly called a wedge merge. Advantages of this induction method: High sorter rate, 250+ cpm (limited to 150 cpm for both-side sorting) Multiple infeed lines Slower induction and accumulation belt speeds which reduces the amount of carton jams and sideby-sides

Slide 49

Equipment Application: Induction


The Index Belt Induction
Typically the sorter rate is roughly apportioned to each infeed line so that no line has more than 1/4 of the sorter rate Lower rates on each accumulation line means lower belt speeds. Lower belt speeds means fewer carton jams and fewer carton side-by-sides. Which results in fewer sorter no-reads. Cartons are pre-positioned on the Index Staging Belts, spaced at the required sorter gapping. The cartons are slug released onto the Sawtooth Merge Final sorter gapping is tweeked by the Gap Adjustement Belts This is a good induction design to consider for: High rate systems, 100 to 250 cpm. Systems with a wide range of carton sizes and widths and weights. Systems with multiple infeed lines.

Servo Gap Adjustment Belts Alignment Section

Scan Belt

Belt Sawtooth Merge

Vector Duty Index Staging Belts

Sorter

Vector Duty Brake Spacer Belts

Accumulation lines Slide 50

Equipment Application: Induction Sort Rates, 80-150 CPM


The Metered Release Induction
Typically the sorter rate is apportioned to each infeed line so that no line has more than 1/2 of the sorter rate. (1/3rd is better than ) No high-speed induction accumulation line means fewer carton jams and fewer carton side-by-sides. Which results in fewer sorter no-reads. Cartons are slug released onto the Brake/Spacer belt. Brake belt speed equals required sorter case-feet-per-minute. Spacer belt speed pulls the required sorter carton gap based on the spec carton length. Skewed roller alignment section provides a limited accumulation function. Final sorter gapping is tweeked by the Gap Adjustment Belts (Vector or Servo depending on system rate) A problem can occur when inducting a long slug of short cartons - a rate spike that will overwhelm the sorter induction. Count or Meter the release at the brake/spacer belt to limit the release rate to the maximum sorter rate. Alignment Section w / skatewheel guard rail Vector Motor Gap Adjustment Belts Scanner Belt Belt Sawtooth Merge

Inverter Duty Brake Spacer Belts

Sorter

Accumulation lines

Slide 51

Equipment Application 4. Sortation Sorting It Out


1. Accumulation

2. Central Merge 3. Induction 4. Sortation 5. Recirculation

6. After-sort Lines

Slide 52