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Conveyors, while simplistic in function, are constituted of a multitude of mechanical parts that enable durable, stable, and efficient movement. Much like a car, in its most basic form, a material-handling conveyor uses a motor (engine) and gearbox (transmission) to provide power in a continuous motion.
If you’re considering a conveyor unit or system in your facility, understanding its critical components and operations can assist in routine maintenance, repairs, upgrades, and future system integrations. Each part plays an important role, and grasping the mechanical basics can help you identify when continuous improvement situations occur within a conveyor system.
A belt is one of the most common applications of conveyance technology. A multi-layered rubber (or similar material) sheeting surrounds the “carcass” or the core of the belt. The carcass is constructed from tightly woven fabric, intertwined with each other within the top and bottom covers of the belt. Belts are wound around the head and tail pulleys on the conveyor bed, powered by the motor. Belts are created in a multitude of materials, sizes, and functions, covering a wide range of material handling applications.
Tip: Conveyor belts are extremely durable, but when rips and tears occur, splicing and vulcanization are relatively simple methods to repair the material.
Rollers are elongated cylinders attached via bearings across a conveyor bed using gravity and low-horsepower motors to move product. Items are propelled forward from spinning roller to roller, or across a belt that is threaded over a bed of rollers.
O-rings or O-bands are rubber-based circular bands that are routed in channels on rollers. O-rings allow multiple rollers to spin, keeping constant and stable movement forward as the product passes the section. Without O-rings, a roller would only move as the product skates over it. With O-rings, rollers in front of the package spin with the previous section, ensuring the package does not stop or jam.
Tip: It’s easy to diagnose when an O-ring has failed. Simply search for any rollers that are not spinning when the conveyor section is operating. A single broken O-ring won’t bring a system to a halt, but multiple non-spinning rollers could cause trouble. Fortunately, O-rings are inexpensive and easy to replace.
Conveyor belts are routed through a bed structure via a pulley system to drive movement forward. Pulleys provide stable motion by maintaining belt tension, tracking, traction, and direction. Each pulley in a conveyor bed provides a different function based on its location.
Pulleys are mainly only used for belted conveyors, although some manufacturers do have chain-routed pulleys for live (continuously moving) roller applications.
The engine of the conveyor, an electric motor (or gearmotor) generates energy for the gearbox, providing power to the moving components of the unit. Placed at the discharge end, or center of the conveyor, motors can vary in size, shape, and horsepower. For a single unit, a 2hp or 3hp motor provides adequate power, while faster conveyor systems (like a sorter) require larger, more powerful motors.
Conveyor motors come in various types and sizes, depending on the specific application and conveyor configuration. Motors can be AC (alternating current) or DC (direct current) and can have different power ratings, speed capabilities, and torque outputs. Conveyor motors are typically connected to the gearbox or the conveyor pulley or roller, and their speed and direction can be controlled through a variable frequency drive (VFD) or other speed control devices.
In addition to their power and durability, conveyor motors are also known for their low maintenance requirements and ease of use. They can be easily installed, repaired, or replaced, minimizing downtime and improving overall efficiency. Conveyor motors are also energy-efficient, reducing energy consumption and costs while maintaining high-performance levels.
Also known simply as a sensor, conveyors use photo eyes to complete functions based on the status captured when product moves on a unit. As a package travels throughout a conveyor system, it passes a multitude of sensors attached to the bed sides that track its movement. This tells the conveyor control module when to stop, go, or redirect the package(s), based on the information provided by every photo eye in a system. This avoids jams and blockages and maintains efficient product flow. Photo-eyes are categorized via their sensing ability and are manufactured either as through-beam sensors, retro-reflective sensors, and diffuse reflective sensors.
A few notable manufacturers of photo-eyes include but are not limited to:
Bearings play a critical role in the smooth operation of conveyor systems. Serving as the mechanical interface between moving parts, bearings provide support, reduce friction, and facilitate the motion of the conveyor belt. They are typically mounted on conveyor rollers, pulleys, and other rotating components, allowing them to rotate freely while minimizing wear and tear. Bearings enable the efficient and reliable movement of the conveyor belt, helping to transport materials smoothly and consistently.
Properly functioning bearings are essential for preventing belt misalignment, reducing downtime, and extending the overall lifespan of the conveyor system. With their crucial role in ensuring reliable and smooth conveyor operation, high-quality bearings are a key component in maintaining the performance and productivity of conveyor systems.
Brakes are an important safety feature in conveyor systems, providing control and stability during operation. These mechanical devices are designed to halt or slow down the movement of the conveyor belt or specific conveyor components. Brakes can be applied in various ways, including drum brakes, disc brakes, and caliper brakes, depending on the specific conveyor system’s requirements.
One of the key benefits of brakes in a conveyor system is enhanced safety. They can prevent conveyor belt slippage, which may occur during sudden stops or in emergency situations, reducing the risk of accidents or injuries. Brakes also allow for precise control over the conveyor’s speed, direction, and positioning, helping to avoid damage to materials, equipment, or personnel.
In addition to safety, brakes also provide operational flexibility. They allow for smooth and controlled stops, starts, and changes in direction, which can optimize the conveyor system’s performance. Brakes enable the conveyor to handle varying loads, inclines, or declines, ensuring consistent and reliable operation.
Guardrails and supports are crucial components of a conveyor system, providing stability, safety, and structural integrity. Guardrails, typically installed along the sides of the conveyor, serve as a physical barrier to prevent materials from falling off the conveyor belt or interfering with surrounding equipment or personnel. They help to contain and guide the materials being transported, ensuring that they stay on the conveyor and do not pose a hazard to the surrounding environment.
Supports, on the other hand, are used to provide structural stability and maintain proper alignment of the conveyor belt. They are usually positioned underneath the conveyor belt and provide support to the conveyor frame, rollers, and other components. Supports are designed to withstand the weight of the conveyor system, the materials being transported, and any additional loads or impacts that may occur during operation.
Guardrails and supports are typically made of durable materials, such as steel or aluminum, to provide strength and durability to the conveyor system. They are often adjustable and customizable to accommodate different conveyor configurations, heights, and widths. Guardrails and supports may also be equipped with additional features, such as guide rails, brackets, or brackets, to ensure proper alignment, prevent material spillage, and optimize conveyor performance.
A gearbox is a critical component in a conveyor system, serving as a mechanical power transmission device that controls the speed and torque of the conveyor belt. It is typically connected to the motor and the conveyor pulley or roller, and its main function is to convert the rotational speed and torque from the motor to the desired speed and torque for the conveyor belt.
Gearboxes contain a set of gears with different sizes and arrangements, which determine the gear ratio and subsequently the output speed of the conveyor belt. The gear ratio can be adjusted to suit the specific requirements of the conveyor system, allowing for precise control over the belt speed, direction, and performance. Gearboxes can be configured with various gear types, including:
Gearboxes also provide torque multiplication, allowing the motor to generate higher torque at the conveyor pulley or roller, which is essential for overcoming the resistance and friction of the conveyor belt and the materials being transported. This enables the conveyor system to handle heavy loads, inclines, or declines, while maintaining the desired belt speed and performance.
Gearboxes play a crucial role in protecting the motor and the conveyor system. They can absorb shocks and vibrations, smooth out the power transmission, and prevent excessive wear on the motor and other conveyor components. Gearboxes also provide safety features, such as overload protection, by using clutches, brakes, or other mechanisms to prevent damage to the motor or the conveyor system in case of excessive loads or sudden stops.
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Need help with your conveyor system? Century Conveyor Systems Inc. has over 40 years of conveyor service experience and boasts a full department of maintenance technicians and equipment experts. Learn more about our extensive capabilities at our On-site Conveyor Service page.
A conveyor system is a fast and efficient mechanical handling apparatus for automatically transporting loads and materials within an area. This system minimizes human error, lowers workplace risks and reduces labor costs — among other benefits. They are useful in helping to move bulky or heavy items from one point to another. A conveyor system may use a belt, wheels, rollers, or a chain to transport objects.
Typically, conveyor systems consist of a belt stretched across two or more pulleys. The belt forms a closed loop around the pulleys so it can continually rotate. One pulley, known as the drive pulley, drives or tows the belt, moving items from one location to another.
The most common conveyor system designs use a rotor to power the drive pulley and belt. The belt remains attached to the rotor through the friction between the two surfaces. For the belt to move effectively, both the drive pulley and idler must run in the same direction, either clockwise or counterclockwise.
While conventional conveyor systems such as moving walkways and grocery store conveyors are straight, sometimes, the unit needs to turn to deliver the items to the proper location. For the turns, there are unique cone-shaped wheels or rotors which allow the belt to follow a bend or twist without getting tangled.
The main purpose of a conveyor system is to move objects from one location to another. The design allows for movement of objects that are too heavy or too bulky for humans to carry by hand.
Conveyor systems save time when transporting items from one location to another. As they can be inclined to span multiple levels, they make it simpler to move items up and down floors, a task that, when performed manually by humans, causes physical strain. Inclined belts can automatically unload material, eliminating the need for someone to be on the opposite end to receive pieces.
You can probably imagine a large warehouse filled with conveyors using belts and rollers to move boxes and other heavy equipment, but this is just one of several types of conveyor systems. You’ll also find conveyor systems in airports, where they’re used to transport luggage. Other examples include escalators and ski lifts. These apparatuses still use a belt or chain and pulleys to move heavy items from one point to another.
There are many types of conveyor systems, including:
Each type of conveyor serves a specific purpose. For example, a slat conveyor, made from slats or plates instead of a belt, is designed for moving heavy materials. The materials conveyed by a slat system are typically too large or heavy for traditional belt movement.
An escalator is an example of a chain-driven conveyor system. Instead of having a pulley system that pulls items along, the chain conveyor uses a towing system that pulls the steps in an upward or downward motion.
Ski lifts are an example of an overhead conveyor. These units use an electric track inclined to pull the chairs up or down the mountainside. Like an escalator, these systems use a chain-driven towing system.
There are three main parts of a conveyor system: the belt support, the pulley and the drive unit. Each component plays an essential role in the conveyor unit’s operation. While all conveyor systems contain these parts, designs vary in the construction materials and where each component is located.
Belt support is the component that ensures the belt moves smoothly. If the support unit is not firm, the belt sags when workers place a heavy object on top, and the sagging causes the belt not to move smoothly or swiftly as it should. The use of a firm support unit keeps the belt taut and running efficiently.
The pulley system is an external component used to control the belt movement. Each unit has at least two pulleys, one that operates under power and an idle one. More complex conveyor systems may have additional rotors throughout the frame.
The drive unit allows the system to move. The unit contains a counter bearing that keeps the parts moving efficiently. This unit also allows for the belt to move in reverse and manage the repeated adjustments in direction for some systems. Some conveyor systems are manually operated. These systems still use a drive unit; however, it is not motorized.
A conveyor more or less acts as a central nervous system for operations that receive, handle, store, distribute, manufacture or ship products. Selecting the right conveyor system can be challenging for warehouse managers and other stakeholders due to the several conveyor types and hundreds of possible configurations to choose from.
Also, there are several factors to consider when trying to identify and purchase the ideal conveyor system for your warehousing or distribution facility. You should simultaneously consider both product and process requirements.
First off, an ideal conveyor system must be:
Installing the wrong conveyor system will quickly undermine a warehouse’s operational efficiency, leading to higher cost and lower customer satisfaction, eventually stripping the business of its competitive advantage.
Without further ado, let’s explore factors to consider when evaluating and selecting the right conveyor system for your operation.
Essentially, a conveyor system is used to move items between functional areas of a distribution facility. As such, the type of item(s) to be moved will determine the design, dimensions and type of conveyor system to be installed.
When searching for the best conveyor system for your facility, answering the following questions will help you ascertain design and configuration requirements and help you calculate things like horsepower and belt pull for individual conveyors:
Factors such as product weight, dimensions and fragility will greatly impact your decision process. The dimensions of the items in your facility will determine conveyor width, guide rail specifications and roller centers, while the weight of the products will decide roller gauge, roller diameter and motor sizing requirements.
Process requirements cover factors governing how the conveyor should move and the unique conditions of the operating environment. These considerations include:
Your conveyor system should be able to handle your facility’s average transfer rate as well as periods of peak demand due to seasonal fluctuations. The number of products you need to transport per hour (or per minute) will determine conveyor length and speed.
Also, certain kinds of conveyors are ideal for certain products. A large plastic chain conveyor is best used for transferring plastic-footed pallets, while a chain-driven roller conveyor is best suited for wooden pallets. Also, the former is best used for moving smaller boxes or totes than the latter.
The point where items are transferred to and from the conveyor is a critical one. Most conveyors use side to side transfers, powered transfers, dead plates, gravity rollers, etc. to facilitate this. Products with a smaller footprint may require a powered transfer, while larger and longer products may need gravity rollers.
For modern warehouses, manual transfer operations are unable to keep up with throughput levels required for speedy order fulfillment cost-efficiently. A conveyor system increases productivity, improves ergonomics, reduces product damage and makes for better access to materials and fewer workplace hazards.
However, the lifetime cost of purchasing, installing and maintaining such systems may be high for small and medium-size operations. It can range from the hundreds of thousands of dollars to millions, depending on factors such as:
Current estimates show that a Belt Curve AC and a Roller Curve AC conveyor cost approximately $5,243 and $2,686 per linear foot — under the following assumptions:
Note: This is just the upfront cost of the conveyor equipment. Aside from installation costs, you’ll also need to factor in the cost of restructuring your warehouse space to accommodate the conveyor system. The installation process itself could take a while and would affect order fulfillment and other warehousing activities. Lastly, operating and maintenance costs per year would likely exceed the initial purchase and installation costs.
If you’re considering a conveyor system, consider your budget, the speed at which you need to complete your work, space and other constraints, and of course, your loading and unloading plans. For instance, conveyor systems aren’t portable and they require substantial changes to your infrastructure. However, other practical and more affordable solutions exist to automate (and improve) your warehouse operations.
Download our white paper, 7 Reasons Why Warehouse Robots Beat Traditional Automation, to learn more about how warehouse robots like Chuck are a smarter, more cost-effective solution compared to traditional automation solutions like conveyor systems. We can also discuss the solution that’s right for you. Contact us today.
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