NEWS: conveyor system adds speed and ease to sorting

Conveyor system adds speed and ease to sorting
by: Celia Johnson

1 July 2007 (Food & Packaging )
Volume 00, Issue 00
© Copyright 2007. Reed Business Information Limited. All rights reserved.

Industrial Conveying Australia (ICA) and FKI Logistex have released the UniSort XV, a straight-line sliding-shoe sortation conveyor designed to maximise transport capabilities and space within the logistics and transport sector.

With a maximum speed of 3m/s (250 cartons per minute), the conveyor transports items on round tubes or flat slats guided by a track under the sorter bed that are interrupted at predetermined points by electrical solenoid divert switches to divert the required package.

According to the company, high operating efficiency is obtained by measuring the length of each individual item at induction and allocating the correct conveyer length.

credits: factiva

article available at:

http://ezproxy.tp.edu.sg:2056/aa/default.aspx?napc=S&fcpil=en&_XFORMSTATE=AEp7MTp7Mjp7MTA6MCw4OjAsOTpbezQ6IiBDb252ZXlvciBzeXN0ZW0gYWRkcyBzcGVlZCBhbmQgZWFzZSB0byBzb3J0aW5nICAgIiw1OjIyLDc6ImZ1ZHBhayIsOUgKAAYwOiJGVURQQUswMDIwMDcwNzEwZTM3MTBAAAABOCIsMjp7MDoiQXJ0aWNsZSIsMawPAU5ld3MpTAAPImRpc3Rkb2M6YXJjaGl2ZS9BvAACRG9jOjrdBC87kAEIIjE2MDYifV0sMjogHjEBfXAIBjE6MCwxNzoxLGwmcQEyYQI2cwAzOjJ4IAQsMTU6MCw3ZAKcAwgyOjAsMTk6MH19fREAAHABAAA%3d

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Guidelines for Safe Operations and Maintenance of Conveyors

Conveyor safety generally begins with sound design that is practical and avoids foreseeable dangers and hazards. Diligence in safety considerations must be applied during the course of manufacture, installation and establishment of operating and maintenance policies and procedures.

Generally, the accidents that cause personal injury in connection with a belt conveyor are not the result of faulty design or component failure. It has been found that most accidents are caused by human carelessness, negligence, or lack of training in operations and awareness of possible hazard.




Thus, these are the guidelines for safe operation and maintenance that an operating personnel should follow to minimize accidents in the workplace;

1. At a time close to completion of installation, all personnel and supervisors should be given a complete indoctrination in the use of the system and all of its equipment. Field inspection and classroom techniques are two valuable types of training.

2. A formal safety training program for operations, maintenance, and supervisory personnel will go a long way toward establishing and maintaining the highest standards of safety in the work place.

3. Concurrent with completion of the installation and the trial runs of all belt conveyors and associated equipment, a “Safety Checkup” is recommended. The checkup should include all mechanical and electrical operating equipment, plus the structures, walkways, ladders, stairs, head rooms, and access ways. It is at this time that a detailed physical inspection of the facility and the installed conveyor equipment will often reveal the need for additional guarding, safety devices, and warning signs.

4. At no time should the conveyors be used to handle material other than that originally specified. Capacity and belt speed design ratings should not be exceeded.

5. Only trained personnel should be allowed to operate the conveyor system. They should have complete knowledge of conveyor operation, electrical controls, safety and warning devices, and the capacity and performance limitations of the systems.

6. The locations and operation of all emergency control and safety devices should be made known to all personnel. Surrounding areas should be kept free of obstructions or materials that could impede ready access and a clear view of such safety equipment at all times.

7. A program should be established to provide frequent inspection of all equipment. Guards, safety devices, and warning signs should be maintained in their proper positions and in good working order. Only competent and properly trained and authorized persons should adjust or work on safety devices.

8. A “walking inspection” of a belt conveyor system is a good means by which well-trained maintenance personnel can often detect potential problems from any unusual sounds made by such components as idlers, pulleys, shafts, bearings, drives, belts, and belt splices.

9. Hands and feet should never come in contact with any conveyor component, and no one should be allowed to ride on a moving or operable conveyor. Poling at or prodding material on the belt or any component of a moving conveyor should be prohibited. Contact with, or work on, a conveyor must occur only while the equipment is stopped, with the electrical control locked off.
10. No person should be allowed to ride on, step on, or cross over a moving conveyors, nor to walk or climb on conveyor structures, without using the walkways, stairs, ladders, and crossovers provided.

11. Good housekeeping in a prerequisite for safe conditions. All areas around a conveyor, and particularly those surrounding drives, walkways, safety devices, and control stations, should be kept free of debris and obstacles, including inactive or unused equipment, components, wiring, and obsolete or non-applicable warning signs or posted instructions.

12. Any conveyor found to be in an unsafe condition for operation, or one that does not have all guards and safety devices in excellent condition, should not be used unless adequate supplementary safety devices are installed.

13. All persons should be barred by appropriate means from entering an area where falling material may present a hazard. Warning signs and barricades can be used.

14. First-class maintenance is a prerequisite for the safest operation of conveyors. Maintenance, including lubrications, should be performed with the conveyor stopped and locked out. Special lubricating equipment, lube extensions, pipes, and the like can be installed so as to permit lubrication of an operating conveyor without any foreseeable hazards.

15. Good lighting contributes to a safe working environment.

16. During the life of a belt conveyor system, its operational conditions and environment may require changes. There should be a continuing effort to detect and treat promptly any new possible safety hazards associated with these changes. If such a hazard cannot be readily eliminated, warning signs, barricades, or posted instructions should be installed.

With the increasing use of belt conveyors in the transportation of bulk materials, the number and severity of accidents have been reduced. When conveyors are used as a means of transport in the place of vehicular units, such as railcars and trucks, the problem of traffic related accidents is minimized. Also, environmentally related health problems can be easily limited by the elimination of dust hazards. Indeed, belt conveyors have substantially reduced the hazards present in practically any other method of bulk materials handling. The further reduction in number and severity of accidents will be a direct result of applying and enforcing the safe practices of design, installation, operation, and maintenance.

credits to: Belt conveyors for bulk materials, 3rd edition
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Conveyor Features

the conveyor systems are often customized according to the needs of the warehouse and the distribution center.

some of the various conveyor features would be as follows:

conveyors can be installed with end-pushers, which would change the direction of the container's travel.

some even have case turners, which would automatically turn the boxes or whatever containers are loaded on the conveyors.

credits: customconveyors of youtube

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Economical Benefits of Conveyors

Conveyors have attained a dominant position in the warehousing function, especially on transportation due to such inherent advantages as their economy and safety of operation, reliability, versatility, and practicall unlimited range of functions aside from their normal purpose of providing a continuous flow of material between operations. Furthermore, their conformity to environmental requirements has given conveyors the incentive to be the option for material handling equipments.

Here are some of the economical benefits provided by the conveyor system:

1. Variety of materials handled

The materials carried by conveyors can range from very fine, dusty chemicals to large, lumpy ore stone, coal or pulpwood logs. They are carried with minimum degradation as they are on stationary position on the belt of the conveyors.

With the use of rubber belts, conveyors are highly resistant to corrosion and abrasion. thus, maintenance costs are comparatively low when handling materials such as alumina and sinter.

2. Continuous operations

Conveyors operate continuously without loss of time for loading and unloading or empty return trips. Scheduling is easier and dispatching is almost unnecessary. They provide continuous flow of materials while avoiding confusion, delays, and safety hazards in congested aread. In addition, the costs per ton has decreased dramatically as the annual ton handled increases.

3. Adaptability to path of travel

The conveyor system provides the means of transporting materials through the shortest distance betwee the require loading and unloading points. They are weather protected and can be provided with structures which prevent the escape of dust to the surrounding atmosphere.

4. Accuracy

The movement of the goods on the conveyors can be scheduled in the most concise manner; and even more interesting is the services performed on the goods. While being transported through the conveyors, materials can also be weihed accurately and continuously or they can be sorted, picked, or sprayed. In many cases, such operations are performed on the goods when they are being transported to increase warehouse efficiency.

5. Reliability and Availability

Conveyors are operated at the touch of a button at any time of the day; shift after shift. They can also be housed so that both they and the material being transported are protected from elements that would impede the movement of trucks and certain other means of transportation.

6. Safety

Just few personnels are required to operate the conveyor system and thy are exposed to fewer hazards. Materials are contained on the belt and personnel are not endangered by falling lumps or the malfunction of huge unwieldy transport vehicles. Furthermore, conveyors offer less hazards to careless personnel than is inherent in other means of transporting bulk materials.

Not only is the employee safety improved, but the equipment itself too. Conveyors can be protected from overload and malfunction by built-in mechanical and electrical safety devices.

7. Low labor costs

The labor hours per ton required to operate the conveyor system is the fewest amongst all the methods of transporting materials. It is highly automated, incurs low operating costs, and provides higher return on investment.

Most functions of the system can be monitored from a central control panel or controlled by a computer requiring a minimum number of operating personnel to inspect the equipment and report conditions that may need maintenance.

8. Low power costs

Because conveyors are operated by electric power, they are less affected by the pries, shortages, and other limitations of liquid fuel. They consume power only when they are used and there is no need for empty return trips or idling in line for the next load.

9. Low maintenance costs

Maintaining conveyors can be extremely low, as surprising as it may sound. Extensive support systems associated with truck haulage are not required. Component parts are usually housed and have very long life compared with that of motor vehicles.

Usually, they only need scheduled inspections and lubrications an any repais or replacements can be anticipated. Thus, unscheduled downtime is avoided.

Parts are small ad accessible so replacements can be made on the site quickly and with minimal service equipment. In addition, adequate inventories of spare parts can be maintained at a alow cost and also require very little storage space.

10. Environmental advantages

The conveyor system is environmentally more acceptable than other means of transporting materials as they do not pollute the air nor deafen the ears. They operate quietly and do not contaminate the air with dust or hydrocarbons.

taken from: Belt Conveyors for Bulk Materials, Third Edition

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Economic Considerations

the costs incurred in using conveyors can be categorized to:

1. Operating costs

- this includes the maintenance costs, wages of the operators, inspections costs etc.
- the expenses incurred for the operation of the conveyor/s.

2. Capital costs

- this includes the actual investment required on the conveyors, the changes/improvements in the warehouse (to make space for the conveyors) etc.
- the initial cost incurred for the purchase and installment of the conveyor/s.

taken from: Conveyor Belt Technology Volume I/86 (Reihard H. Wohlbier, editor-in-chief)

personal note: although the investment cost incurred in the installment of the conveyor system might be very significant, it provides long term improvements and economical benefits that will justify the need for the conveyor system. this is something that we will elaborate further.

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Types of conveyors

These are the types of conveyor:

1. Chute Conveyor

Unit/Bulk + On-Floor + Accumulate

Inexpensive

Used to link two handling devices

Used to provide accumulation in shipping areas

Used to convey items between floors

Difficult to control position of the items

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2. Wheel Conveyor

Unit + On-Floor + Accumulate

Uses a series of skatewheels mounted on a shaft (or axle), where spacing of the wheels is dependent on the load being transported

Slope for gravity movement depends on load weight

More economical than the roller conveyor

For light-duty applications

Flexible, expandable versions available

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3. Roller Conveyor

Unit + On-Floor + Accumulate

May be powered (or live) or nonpowered (or gravity)

Materials must have a rigid riding surface

Minimum of three rollers must support smallest loads at all times

Tapered rollers on curves used to maintain load orientation

3(a) Gravity Roller Conveyor

Alternative to wheel conveyor

For heavy-duty applications

Slope for gravity movement depends on load weight

For accumulating loads

3(b) Live (Powered) Roller Conveyor

Belt or chain driven

Force-sensitive transmission can be used to disengage rollers for accumulation

For accumulating loads and merging/sorting operations

Provides limited incline movement capabilities

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4. Chain Conveyor

Unit + In-/On-Floor + No Accumulate

Uses one or more endless chains on which loads are carried directly

Parallel chain configuration used to transport pallets

Vertical chain conveyor used for continuous high-frequency vertical transfers (cf. vertical conveyor used for low-frequency intermittent transfers)

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5. Slat Conveyor

Unit + In-/On-Floor + No Accumulate

Uses discretely spaced slats connected to a chain

Unit being transported retains its position (like a belt conveyor)

Orientation and placement of the load is controlled

Used for heavy loads or loads that might damage a belt

Bottling and canning plants use flat chain or slat conveyors because of wet conditions, temperature, and cleanliness requirements

Tilt slat conveyor used for sortation

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6. Flat Belt Conveyor

Unit + On-Floor + No Accumulate

For transporting light- and medium-weight loads between operations, departments, levels, and buildings

When an incline or decline is required

Provides considerable control over the orientation and placement of the load.

No smooth accumulation, merging, and sorting on the belt

The belt is roller or slider bed supported; the slider bed is used for small and irregularly shaped items

In 1957, B.F. Goodrich, Co. patented the Möbius strip for conveying hot or abrasive substances in order to have "both" sides wear equally

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7. Magnetic Belt Conveyor

Bulk + On-Floor

A steel belt and either a magnetic slider bed or a magnetic pulley is used

To transport ferrous materials vertically, upside down, and around corners

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8. Troughed Belt Conveyor

Bulk + On-Floor

Used to transport bulk materials

When loaded, the belt conforms to the shape of the troughed rollers and idlers

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9. Bucket Conveyor

Bulk + On-Floor

Used to move bulk materials in a vertical or inclined path

Buckets are attached to a cable, chain, or belt

Buckets are automatically unloaded at the end of the conveyor run

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10. Vibrating Conveyor

Bulk + On-Floor

Consists of a trough, bed, or tube

Vibrates at a relatively high frequency and small amplitude in order to convey individual units of products or bulk material

Can be used to convey almost all granular, free-flowing materials

An Oscillating Conveyor is similar in construction, but vibrates at a lower frequency and larger amplitude (not as gentle) in order to convey larger objects such as hot castings

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11. Screw Conveyor

Bulk + On-Floor

Consists of a tube or U-shaped stationary trough through which a shaft-mounted helix revolves to push loose material forward in a horizontal or inclined direction

One of the most widely used conveyors in the processing industry

Many applications in agricultural and chemical processing

Water screw developed circa 250 BC by Archimedes

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12. Pneumatic Conveyor

Bulk/Unit + Overhead

Can be used for both bulk and unit movement of materials

Air pressure is used to convey materials through a system of vertical and horizontal tubes

Major advantages are that material is completely enclosed and it is easy to implement turns and vertical moves

12(a) Dilute-Phase Pneumatic Conveyor

Moves a mixture of air and solid

Push (positive pressure) systems push material from one entry point to several discharge points

Pull (negative pressure or vacuum) systems move material from several entry points to one discharge point

Push-pull systems are combinations with multiple entry and discharge points

12(b) Carrier-System Pneumatic Conveyor

Carriers are used to transport items or paperwork (e.g., money from drive-in stalls at banks)

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13. Vertical Conveyor

Unit + On-Floor + No Accumulate

Used for low-frequency intermittent vertical transfers (cf. vertical chain conveyor can be used for continuous high-frequency vertical transfers

13(a) Vertical Lift Conveyor

Carrier used to raise or lower a load to different levels of a facility (e.g., different floors and/or mezzanines)

Differs from a freight elevator in that it is not designed or certified to carry people

Can be manually or automatically loaded and/or controlled and can interface with horizontal conveyors

13(b) Reciprocating Vertical Conveyor

Utilizes gravity-actuated carrier to lowering loads, where the load overcomes the magnitude of a counterweight

Can only be used to lower a load

Alternative to a chute conveyor for vertical "drops" when load is fragile and/or space is limited

Can be manually or automatically loaded and/or controlled and can interface with horizontal conveyors

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14. Cart-On-Track Conveyor

Unit + In-Floor + Accumulate

Used to transport carts along a track

Carts are transported by a rotating tube

Connected to each cart is a drive wheel that rests on the tube and that is used to vary the speed of the cart (by varying the angle of contact between the drive wheel and the tube)

Carts are independently controlled

Accumulation can be achieved by maintaining the drive wheel parallel to the tube

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15. Tow Conveyor

Unit + In-Floor + Accumulate

Uses towline to provide power to wheeled carriers such as trucks, dollies, or carts that move along the floor

Used for fixed-path travel of carriers (each of which has variable path capabilities when disengaged from the towline)

Towline can be located either overhead, flush with the floor, or in the floor

Selector-pin or pusher-dog arrangements can be used to allow automatic switching (power or spur lines)

Generally used when long distance and high frequency moves are required

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16. Trolley Conveyor

Unit + Overhead + No Accumulate

Uses a series of trolleys supported from or within an overhead track

Trolleys are equally spaced in a closed loop path and are suspended from a chain

Carriers are used to carry multiple units of product

Does not provide for accumulation

Commonly used in processing, assembly, packaging, and storage operations

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17. Power-and-Free Conveyor

Unit + Overhead/On-Floor + Accumulate

Similar to trolley conveyor due to use of discretely spaced carriers transported by an overhead chain; however, the power-and-free conveyor uses two tracks: one powered and the other nonpowered (or free)

Carriers can be disengaged from the power chain and accumulated or switched onto spurs

Termed an Inverted Power-and-Free Conveyor when tracks are located on the floor

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18. Monorail

Unit + Overhead + Accumulate

Overhead single track (i.e., mono-rail) or track network on which one or more carriers ride

Carriers: powered (electrically or pneumatically) or nonpowered

Carrier can range from a simple hook to a hoist to an intelligent-vehicle-like device

Single-carrier, single-track monorail similar to bridge or gantry crane

Multi-carrier, track network monorail similar to both a trolley conveyor, except that the carriers operate independently and the track need not be in a closed loop, and a fixed-path automatic guided vehicle (AGV) system, except that it operates overhead

Termed an Automated Electrified Monorail (AEM) system when it has similar control characteristics as an AGV system

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19. Sortation Conveyor

Unit + On-Floor/Overhead

Sortation conveyors are used for merging, identifying, inducting, and separating products to be conveyed to specific destinations

19(a) Sortation Conveyor: Diverter

Stationary or movable arms that deflect, push, or pull a product to desired destination

Since they do not come in contact with the conveyor, they can be used with almost any flat surface conveyor

Usually hydraulically or pneumatically operated, but also can be motor driven

Simple and low cost

19(b) Sortation Conveyor: Pop-Up Device

One or more rows of powered rollers or wheels or chains that pop up above surface of conveyor to lift product and guide it off conveyor at an angle; wheels are lowered when products not required to be diverted

Only capable of sorting flat-bottomed items

Pop-up rollers are generally faster than pop-up wheels

19(c) Sortation Conveyor: Sliding Shoe Sorter

Sliding shoe sorter (a.k.a. moving slat sorter) uses series of diverter slats that slide across the horizontal surface to engage product and guide it off conveyor

Slats move from side to side as product flows in order to divert the product to either side

Gentle and gradual handling of products

19(d) Sortation Conveyor: Tilting Device

Trays or slats provide combined sorting mechanism and product transporter

Can accommodate elevation changes

Tilt tray sorters usually designed in continuous loops with a compact layout and recirculation of products not sorted the first time

Tilt slat sorters carry products on flat-surface slat conveyor and can handle wider variety of products compared to tilt tray

19(e) Sortation Conveyor: Cross-Belt Transfer Device

Either continuous loop, where individual carriages are linked together to form an endless loop, or train style (asynchronous), where a small number of carriers tied together with potential for several trains running track simultaneously

Each carriage equipped with small belt conveyor, called the cell, that is mounted perpendicular to direction of travel of loop and discharges product at appropriate destination

Automatically separates single line of products into multiple in-line discharge lines

credits to: http://www.ise.ncsu.edu/kay/mhetax/index.htm

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Definition of Conveyor

After covering the general issues related to MHE, we are now moving on to the main focus of our blog: CONVEYORS.

and what better way to start than to define it?

Conveyor: a horizontal, inclined or vertical device for moving or transporting bulk materials or objects in a path predetermined by the design of the device and having points of loading and discharge fixed, or selective; included are skip hoists, vertical reciprocating and inclined reciprocating conveyors; typical exceptions are those devices known as industrial trucks, tractors and trailers, tiering machines (truck type), cranes, monorail cranes, hoists, power and hand shovels, power scoops, bucket drag lines, any conveyor designed to carry people, and highway or rail vehicles.

taken from: Conveyor Terms and Definitions, Fifth Edition (R. R. Babel, Chairman)

Conveyor system: is a common piece of mechanical handling equipment that moves materials from one location to another. Conveyors are especially useful in applications involving the transportation of heavy or bulky materials. Conveyor systems allow quick and efficient transportation for a wide variety of materials, which make them very popular in the material handling and packaging industries. Many kinds of conveying systems are available, and are used according to the various needs of different industries.

Conveyor systems are used widespread across a range of industries due to the numerous benefits they provide.

Conveyors are able to safely transport materials from one level to another, which when done by human labor would be strenuous and expensive. They can be installed almost anywhere, and are much safer than using a forklift or other machine to move materials. They can move loads of all shapes, sizes and weights. Also, many have advanced safety features that help prevent accidents. There are a variety of options available for running conveying systems, including the hydraulic, mechanical and fully automated systems, which are equipped to fit individual needs.

Conveyor systems are commonly used in many industries, including the automotive, agricultural, computer, electronic, food processing, aerospace, pharmaceutical, chemical, bottling and canning, print finishing and packaging. Although a wide variety of materials can be conveyed, some of the most common include food items such as beans and nuts, bottles and cans, automotive components, scrap metal, pills and powders, wood and furniture and grain and animal feed. Many factors are important in the accurate selection of a conveyor system. It is important to know how the conveyor system will be used beforehand. Some individual areas that are helpful to consider are the required conveyor operations, such as transportation, accumulation and sorting, the material sizes, weights and shapes and where the loading and pickup points need to be.

credits: wikipedia.org

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