Basics of Conveyor Engineering Hardware

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BASICS OF CONVEYOR ENGINEERING HARDWARE

BY

MIKE COLEMAN
INTERLAKE CONVEYOR SPECIALIST

NA 94 FORUM

ABSTRACT

In the conveyor business there is never a perfect solution, only partial answers to the solution,
and that is the reason for this seminarto familiarize you with the different types of equipment
available, and their application.

GATHER FACTS

Certain questions must first be answered before you can even begin to conceptualize that
conveyor system. An overall objective must first be set, and a basic understanding of the type of
system is important. A few examples of the type of systems are warehousing,

receiving,
packaging, shipping, production (both flexible, and progressive). It is also important to consider
the size, shape, and age of the building, and possible future expansions. Environmental
conditions must also be taken into account like temperature, and humidity.

Additional information should include, sales forecasts, combined with production capabilities,
keeping in mind the need for flexibility since manufacturing is ever changing in this world
economy.

But the most important thing to remember when considering a conveyor system is the KISS
principle, for often times we get carried away with the equipment options, and before you know
it, we have lost the true objective of the system, with over design, and expensive features. Future

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considerations must also be taken into account early on, so your system must be adaptable, and
flexible for a phase-in expansion.

Once you have an overall picture, or sequence of operations, then specific questions must be
asked. Load Characteristics are vital, and include the size, shape, weight, and material to be
conveyed. The footprint is important for it is what the conveyor will see, and will help determine
the best type of equipment to use. Rate of flow is important for it will determine the speed that
the conveyor needs to run, and product orientation if you are interfacing with automated
equipment, and or need to incorporate accumulation of products.

Now that you have a general layout, combined with the specific information of your system, you
can begin to specify the type of equipment required.

EQUIPMENT APPLICATION

There are multiple functions for each type of conveyor. It is now a question of applying the best-
suited equipment, while staying within your budget.

GRAVITY

Gravity conveyor is your least expensive equipment, and is suitable for most manual
applications. It is often used to pass orders from picking zones, or for staging material to
shipping, packaging, or inspection. Since it is non-powered, it is safe and easy to work with. If
the conveyor is to be pitched, it is important to know the weight of the product, for a heavy
carton will build up more momentum than a lighter carton.

It is also important to know how the conveyor is being loaded, for there is a wide range of
capacities. Hand loading applications would require a lighter gage material than fork truck
loading due to less shock. Also take into account the side frames for a structural member may be
needed to resist impact.

POWERED CONVEYOR

There are many types, and styles, but they all have one objective, and that is to move the product
from one point to another as efficiently as possible. From the application chart, you can see that
belt conveyors have a broad range of usage. They are the least expensive type of powered
conveyor due to the limited number of bearings required. Horizontal belts can handle most
product shapes, and weights. There are two types, a slider bed, and a roller bed. A slider bed is a
steel sheet that the belt rides over and a roller bed is just as the name implies.

A slider bed is most often used for small lightweight products, where a roller bed is used for
heavier products with longer runs. Belt pull is the limiting factor, and should be determined by
your conveyor supplier.

An incline/decline belt conveyor is used to move product from one elevation to another. A ruff
top belt is usually supplied, which grips the product, and prevents it from freewheeling or
sliding. It is important to know the maximum incline angle to prevent product tumbling.

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LIVE ROLLER CONVEYOR

Live Roller conveyor is the next conveyor of choice, and covers a wide range of application. It is
used mostly in areas where product accumulation or staging is important. Live Roller conveyor
comes in many styles. They are, belt driven, cable drive, and shaft driven. Each has it's own
advantages, and disadvantages, in regards to usage and flexibility.

Belt driven live roller (BDLR) is where the carrying rollers (rollers holding the product) are
powered by a belt. This belt is wedged between the carrying rollers and the pressure rollers. The
pressure rollers can be adjusted up or down to increase or decrease the driving force. Another set
of rollers is required for this conveyor but is not shown, and that is the return rollers used to
return the belt to its starting position. Most BDLRs are used for medium to heavy-duty
application, where significant driving force is required, such as through merges, divert arms, and
pallet handling applications.

A shaft driven live roller (Lines shaft) is the carrying rollers are individually powered by an
elastomeric belt, which is driven off a main shaft. This type of conveyor is used mostly in light to
medium duty applications, and lends itself to multiple accessories powered by a single drive.

Cable driven live roller is similar to lineshaft, except the carrying rollers are powered by a steel
cable that are able to snake around through the curves, and straight sections. It is also a light to
medium duty conveyor.

Live roller conveyors lend themselves better for accumulation applications both zero pressure,
and minimum pressure because the power source can be dropped out of a zone, or adjusted to
limit the amount of driving force required to move the product while at the same time maintain
product flow throughout.

CHAIN DRIVEN LIVE ROLLER CONVEYOR

Chain Driven Live Roller (CDLR) is used for heavy-duty applications, and comes in both
transport and accumulation models. Like any powered roller conveyor the footprint is important
to provide smooth roller to roller flow, so if the pallet has bottom slats, it is a good idea to have
them running length wise or perpendicular to the rollers.

This type of conveyor is powered by a series of chains that is connected progressively to each
roller, or by a single chain that runs the length of the conveyor. The progressive roller to roller
requires two sprockets welded to each roller, where a single chain only requires one sprocket.
Each has its application, but the heavier the load the more chain pull is required which would
dictate one over the other.

Due to the heavy loads being transported, a fork truck is often required, consequently, a
structural frame and heavy gage roller is often required to withstand the abuse factor. Also, a toe
in or toe out frame configuration may be needed to mount the rollers high opposite the chain
guard to allow ease of loading and unloading. Roller capacity can run as high as 1200 lbs each so
we are talking heavy stuff here.

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SUMMARY

This paper should provide a better understanding of the type of equipment available and the
primary application. As you have noticed, different types of equipment can be used for the same
application; but remember the future and this ever changing world market, for your system today
needs to be flexible, changeable and simple. It is a major investment that you should not
outgrow.

EXHIBITS

Gravity Conveyor

Gravity roller conveyors provide one of the most versatile and economical means of moving
portable applications. Gravity conveyors can quickly move large quantities of items in virtually
any direction with a minimum of effort and expense. Gravity conveyors move product in two
ways: on a pitch, utilizing the natural flow of gravity or on a level line where conveyance of the
item in accomplished by pushing.

Gravity, or non-powered roller conveyors, is ideal for moving most unit loads that have a firm,
flat bottom surface. They can be used in both permanent and portable applications. To select the
proper equipment for the required application, the following steps must be considered.

1. Load Characteristics
2. Conditions and Bearing Selection
3. Roller Center Spacing
4. Roller Capacity
5. Width and Settings
6. Frame Requirement
7. Support Capacity
8. Conveyor Pitch
9. Support Heights and Quantities

Load Characteristics

The single most important consideration to insure your system reliability is known as the
footprint, which is the bottom surface of the load that is to be conveyed. The load bottom must
be firm and free of projections, which could prevent smooth travel over rollers. A slipsheet
could provide the necessary rigidity. If at this step, all load characteristics are not favorable, do
not proceed. Consider a power conveyor.

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Conditions and Bearing Selection

Bearings

OPEN DRY BEARING
Open dry bearings offer the least resistance to turning of all bearing types. They are constructed
with an outer shield, which is fixed to the stationary inner race of the bearing and does not touch
any rotating part. Manufactured with a light oil lubricant, the open dry bearing gives satisfactory
results in most normally clean, dry, indoor applications.

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DUST PROTECTED BEARINGS
Dust protected bearings, non-lubricated, have the same easy rolling action as a plain bearing
because the dust shield is a non-contact type seal. The shield, which is fit to the stationary inner
race does not touch any rotating parts of the bearing. In a reasonably moisture free environment,
excellent results are achieved with absolutely no lubrication.

FACTORY LUBRICATED BEARINGS
The lubricated bearings are similar in construction to the dust protected incorporating the same
dust shield arrangement with an additional rear grease seal.
The factory-lubricated bearings are recommended for all powered roller applications, both for
live roller and belt conveyor applications. Caution should be used in applying this construction in
areas where excessive grit or dust exists, as there are no means provided for regreasing these
bearings as there are with pressure-lubricated construction.

PRESSURE LUBRICATED BEARINGS
The pressure-lubricated bearings are similar in construction to the factory-lubricated bearings:
however, requiring in application the necessity of drilling the hex axle for grease fittings for
delivery of grease to internal parts of the bearing. Grease delivered under pressure to the interior
of the bearings forces out old grease, thereby producing a new effective seal. The advantages of
the re-greasable feature are obvious when considering application in extremely dirty
environments.

Determine Roller Center Spacing

A MINIMUM OF THREE ROLLERS MUST SUPPORT THE SMALLEST UNIT LOAD.

Divide the minimum package length you anticipate conveying in your system by three (or the
number of rollers needed) to arrive at the roller center-to-center distance. Choose a roller section
with roller centers the same or less than this figure.

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Determine Roller Capacity

Roller capacity is determined by dividing the weight of the heaviest load by the minimum
number of rollers that will carry the load at any single moment.

Determine Width & Settings Straight Sections

STRAIGHT SECTIONS
If your application consists only of straight conveyor sections, the recommended conveyor width
is: Conveyor Width = Package Width + 2 inches

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Determine Frame Requirement

To extend the life of the conveyor or to avoid damage from overloading, it is best to be on the
safe side in calculating frame capacity. Allow for extra loading. In many cases conveyors are
subjected to greater abuse and loads than they were intended for. Frame requirements should be
carefully calculated. Locating supports on closer centers is one way to increase frame capacities.
In doing this, compare the cost of an increased frame to the number of extra supports to see
which method is most economically feasible. When figuring capacities, include the weight of the
conveyor section and be sure to check the capacities of each type of frame against the total load.

FORMULA:

Live Load: Multiply Number of Loads in 10-0 Long Section x Weight of Each Load
+
Dead Load: Multiply Number of Rollers in 10-0 Long Section x Weight on Each Roller

= Total Load

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DETERMINE SUPPORT CAPACITY: The supports to be selected must have a load carrying
capacity equal to or greater than the maximum loading condition and weight of section itself.

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Powered Conveyor

Belt Conveyors Types and Applications
Being the most versatile of power conveyor, belt conveyors are the most frequently used. One
reason for the versatility is the work surface belt, which can handle loads of almost any shape
and over a moving platform for process or production work. Belt conveyors are also one of the
least expensive power conveyors.

Slider Bed
The belt slides over a continuous metal bed, which is attached between the tops of the conveyor
channel frames. Because support for the entire belt surface is provided, the belt friction (30%
friction coefficient) is increased, thus limiting loads to 52 lbs. per sq. ft. or less. Operation is
quiet and the bed offers a no-sag, no bump surface.

Slider bed conveyors are excellent for production work where small parts of varying sizes and
shapes must be carried or assembled. The surface remains constantly flat.

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Roller Bed
The belt rolls over rollers rather than a metal bed. Friction is greatly reduced thus smaller motors
and drives can be used. For light loads, one roller is sufficient under each load but for heavier
loads and inclines, two or more rollers should be used. (See your conveyor supplier for specific
roller capacities.)

Inclines and Declines

When elevation must be changed, incline or decline belt conveyors are used at a maximum 300
angle.

This rule can only be used for evenly weighted loads! A vertical line dropped from the exact
center of the load (center of gravity) should fall within the center one third of the bottom of the
load. Outside of this area the load would be unstable. If the weight within the carton is off center
or unevenly distributed, do not use this rule! Testing may be necessary to determine the center of
gravity and exact incline.

Example: A package is 28L x 20H x 12W
X = L/H
X = 28/20 = 1.4 Maximum incline angle = 25 degrees

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Handy Incline Table

This chart is also to be used only with evenly weighted loads. Divide carton length by carton
height to find: X = L/H

On the table, the degree of include next to your value of X will be the maximum incline
guideline you should use.

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Belt Driven Live Roller Curves

Belt driven curves are used with live roller conveyor. However, their use does have some
limitations, such as it can be used for transportation only and cannot accumulate. Pressure rollers
are not used in curves. In their place, sheaves along the inner frame (smaller radii) are used to
guide a V-Belt and apply belt pressure to the carrying rollers. The carrying rolls thru the curve
are tapered to keep loads properly aligned. There is a maximum 400 lb. limit of distributed load
per curve. Powered curves generally operate faster than straight conveyors to keep loads
separated and from bumping each other.

CHAIN DRIVEN LIVE ROLLER CONVEYOR

Chain driven live roller conveyors utilize a roller bed for the carrying space. They provide
controlled movement of a great variety of commodities from the lightest to the heaviest loads.
Unit loads travel directly on the roller surface.

The positive drive afforded by chain on sprockets makes chain driven live roller conveyor the
choice for heavy loads (pallets. etc.) and for conveyors used in applications where heat, dirt, oil,
grease or other contaminants may cause belt damage. Two sprockets are welded to each roller
and individual loops of chain connect rollers in a staggered pattern. The driving chain or chains
are at one end of the rollers and are shielded or guarded. This driving arrangement is desirable
for heavy loads and for applications, which require frequent stopping or reversing.

The path is usually level, but can be slightly inclined or declined, limited by the coefficient of
friction between the rollers and the load. Because the drive is positive, there is no slippage: all
rollers turn at the same speed. Both straight sections and curves are available.

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