HANDLING MACHINES

Application Notes: Roller Conveyor

Machine purpose
To move isolated loads of sufficient size with minimum friction but with very small changes of level. Optimized flow for gain in time and/or personnel. Production, assembly, erection, packing and conditioning lines, work-station supply, transport, handling, distribution, storage, intermediate storage, accumulation storage, sorting, order preparation, picking, shipping, heating and cooling of elements.

Theory of operation

A roller conveyor is used for routing isolated loads (pallets, containers, boxes, cartons, others). The rollers are driven by flat or cylindrical belts or by chains. The machine can accommodate switches. Rail and air freight in-feed, automatic postal package sorting, hospital logistics, transport and storage of documents and files, transfer of television sets on assembly line, routing of orders to shipping point, sorting of cartons by customer and round, weighing and labeling station, dynamic carton stock, manual work-station, food product packaging line (deep-frozen foods) and storage of books, handling of bags and containers, reception of pallets (docks), deep freezing by blowing red berries and peas, automobile body conveying, preparation of orders for mail order sales. Pallet conveyor, pressureless accumulation conveyor. Roller conveyor, roller table, heavy conveyor, light conveyor.

Several examples of use

Names of machines related to application Names used

Rollers Stopper Guiding strand

Drive motor

Drive chain

Detection, identification Control Flat angle iron feet for attaching to floor

2003 Schneider Electric

All rights reserved. Doc. # 0105DB0301

HANDLING MACHINES

Main types

Conveyor with plastic, steel or aluminum rollers, free or motorized roller conveyor, telescopic roller conveyor, roller conveyor for heavy loads, roller conveyor, 2-chain roller conveyor, fixed and flexible curves, taper roller curve, inclined roller conveyor. Conveyor belt, belt conveyor, belt curve, chain conveyor (parallel or supporting), telescopic roller or belt conveyor, flexible conveyor, turntable, turn-over, elevator, chain transfer, belt transfer. Generally roller conveyors are located indoors. However, for agro-food applications, it can operate at negative temperatures (-40C) with high relative humidity or harsh environments (dust, corrosive agents). Washing with a jet (or a high pressure jet) with or without detergents is a practice that imposes a specific choice of material. Some applications call for electrostatic discharging of the conveyed parts. For a system, the electrical cabinet is generally isolated. For an isolated machine, the electric equipment must be designed to allow for the environment and if necessary for explosive atmosphere. Guides, guide strand, guide disk, link attachment, stop or buffer, stopper, pneumatic stop, retracting lock, brake roller for mobile conveyor, flat angle foot for floor attachment, conveyor-turntable link, stepper feed, roller or motor, disengagable, self-driven rollers, brake roller, brake plate, switch, automatic linear switch, automatic angle switch, parallel single output grouper, pusher, selection pusher, centering pusher, pushing shoe, pop-up, turn-over finger, bin orientation device (pivot), automatic empty bin stacker, gate, weight control unit (static or dynamic), gauge tester, load identification (bar or magnetic code), test bench, electro-zinc finish or stainless steel for agro-food, anti-static belt, blower, fan, air conditioner, flow control software, PC, printer. Conveyors of all types, chain or belt transfer at 45 or 90, transfer truck, turntable, turntable with transfer, shuttle, turn-over, vertical, multiple level elevator, continuous vertical elevator, elevator table, scissors elevator table, elevator platform, transfer elevator, distribution cart (with or without friction wheel drive mechanism), wire guided cart, magazine, empty pallet magazine, transtorage, rotary storage. Assembly, sorting, weighing, grading, counting, identification, packing, conditioning, palletizing, deepfreezing, treatment, painting, baking.

Other typical machines or family

Situation in environment

Associated systems

Upstream and downstream machines

Related professions

Table position, D1 Shipping of specific products Automatic palletizing Process control and display station (if necessary). Process cabinet

Passage of load, D1 Jamming, D3

E
Turn- Roller table conveyor Belt Transfer

Distribution box or cabinet

E
Chain transfer

Load counting, D2 Positioning of load for stoppage, D5 Identification of the load, D6 Lack of product, D4 Package return defective labeling Incoming products from all production sources

Machine located within a process

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Electrical equipment associated with conveyor

Item D D D E E E E E E E E E/M1 E/M1 E/M1 E E E/M1 E E E E E E D1 D2 D2 D3 D2 D2 D2 E E E E E E E E E E E E E E E E E E E E E E E E E Functions Distribution Mobile electric distribution of roller conveyor General distribution Mechanical protection of distribution Equipment Mechanical protection of equipment and control Attaching electrical equipment Routing cables Distributing power Connecting cables Control power supply Power control Roller conveyor energizing Movement supply and safety cut-off Starting motor(s) (if possible on load) Changing motor running direction Changing motor speed Energizing variable speed controller power Brake release control Positioning the load Protection Protecting motor(s) against short-circuits Protecting motor(s) against overloads Protecting the brake(s) Protecting control power supply transformer Lighting circuit, 220 V outlet and control circuit Protecting and monitoring network and motor Detection Top and bottom table position Passage of load (presence, absence) Load counting Jamming on conveyor Product run-out Positioning of load for stoppage Load identification (automatic sorting) Opening of electric equipment access door Signalling (dialogue) Voltage presence on roller conveyor Energizing roller conveyor Roller conveyor in motion Displaying coded messages, conveyor status Displaying plain messages: maintenance, production Displaying process, exchanges underway Resetting roller conveyor Process supervision Control (dialog) Starting and stopping roller conveyor Emergency stop Selecting automatic or manual modes Manual rotation control (maintenance) Selecting desired speed direction Resetting roller conveyor after fault Sending variable speed controller setpoint Processing Start order sequence Time delays Power adaptation Switching variable speed controller setpoints Positioning of load Flow and stock management Isolated machine Machine integrated into a process Monitoring of emergency stop buttons Solutions* KN, KS C60, NS, Masterpact, GS1, FA, KA, LA AA, AM, ACM AA, AM, ACM, ACP, LG., XAP, DE8-B AM3, AM1, DZ6, LG. AK2-G, AK2-L, LG. AB3, AK5 AB1, DB6, DZ5, ABS, ABE, LG., 9080G 9070T/TF LS1D, GS1, Vario, NS, Compact, LG., FA, KA LC1, LP1, LU LC1, LC3, LD1, ATV6, LG., LU, ATV28/11 LC2, LG8, LU, ATV28/11 LC1, ATV6, LU LC1, LU LC1, LU MSP, AV28/11 LS1D, GS1, GV2M-L, GV., LB1L, NS, LG., LU LRD, LT3, GV2M-P, GV7, LB1L, LG., ATV28/11 GV2, LU DF6, GB2RT, GB2CB, C60, GV. DF6, GB2CB, C60, Vigi C60, GV2 RH328AP, SM21, EM9T Q. x 1 1 1 x x x x 1 1 1 1 1 x 1 1 1 1 1 1 1 3 x x x x x x x x 1 1 1 1 x 1 1 1 1 1, 2 1 1 x 2, 1 1 1 x 1 x x 1 x x x 1
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XC, XS, XU depending on load type, XCW XC, XS, XU depending on load type, XCW XC, XS, XU depending on load type, XCW XC, XU depending on load type, XCW XC, XU depending on load type, XCW XGV, XC, XS, XU, XGS, XCW XC XB4B XB4B XVB, audible signalling unit XBLA, XB4B XBT TSX, XBT-N/G XB4B XBT XB4B XB2B, XA2B, Vario, XY2C, XB4B, XALD XB4B XAD, XBT, XB4B, 9001K XAD, XBT, XB4B XB4B SZ1RV, XBT, XB4B CAD, LA1, RU, RX, RH, micro TSX RE4, RE5, LAD, Twido, micro TSX RU, RX, RH LA1, RU, RX, RH, Twido, microTSX TSX7, micro TSX TSX7, micro TSX, XBT-N/G micro TSX, Momentum micro TSX, XBT-N/G XPS-A

*refer to general catalog for complete details.

HANDLING MACHINES

Criteria for choice of machine user Critical points to be solved by manufacturer/know-how

Mechanical Guidance of loads, loss of adhesion of loads during acceleration, noise, transportation of fragile products, transportation of atypical shaped products. Electric Detection of jamming and anomalies, detection in difficult environments (cold: mist), identification of products, synchronization with other conveyors, positioning of loads, speed of logic control components in automatic sorting application (load follow-up). Motor dimensioning 90% of light roller conveyors (<5 lb.) use a range of motors with power from 1/3 hp to 3/4 hp. Conveyor belts for the same loads require power ranging from 1 hp to 4 hp (high speed table). The weight of the loads (influencing the choice of material and the diameter of the rollers): ultra light, <4 lbs. ; light, <110 lbs.; medium, <220 lbs.; heavy up to 2 T. Size and shape of loads. Speed of movement of loads : 3.2 feet/min to 393 feet/min The length of the conveyor: up to several miles; generally in lengths of 20 to 32 feet. Conveyor width 4 inch to 6.5 feet. Conveyor height. Topology, logistics and transit conditions. Environment/Applications : steel grades (stainless), route, accumulation, load identification, etc.

Cost of roller conveyor

A roller conveyor for light loads (<220 lbs.), 20 feet long, costs $46K before tax. A system can cost between $500K and $30 million. A roller conveyor is cheaper than a belt conveyor (belt guidance). The mechanism is simpler and the drive power is reduced compared to a conveyor belt of the same capacity. The belt conveyor becomes essential as soon as elevation is necessary.

CE marking
Low voltage directive 73/23/CEE of 19/2/73, amended by directive 93/68/CEE of 22/7/93. Safety This machine is covered by machine directive No 89/392/CEE, amended. Generally, this is one of the elements in an automated installation for which safety is incorporated. When this machine is accessible to the personnel, it is necessary to install emergency stop devices every 30 feet or trip wire emergency stop switches monitored by a Preventa module. EMC (electromagnetic compatibility) 89/336/CEE + amendments. When a variable speed controller is used, the radio perturbations must be attenuated by VW3A input filters, if necessary with VW3A line coils or SinWave active compensators (MG) to reduce harmonic current. Schneider services consulting, training, research assistance, checks and measurements on site. It is advisable to use interference supressors for contactors (LA4).

Several application references in Europe

Germany: Mannesmann Demag Austria : Belgium : Denmark: Spain : Finland : France : Savoye, Samovie, Sydel, Atecmi, Matflex, NTS , Manumeca, Greece : Italy: Conveyors, Peem, Papa, Montini Norway: Netherlands: Caljan Portugal: Sweden: Switzerland: UK : Shuttle worth

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Roller Conveyor

Motor Starter Detection

main functions (...) optional

M2 M2 D2 M1 M2 M3

product that may be critical

D1

M2 M3 M2 D3 M2

Mark
M1

Qty
1

Motor starter function

Forward/backward movement of the chain conveyor on load: avoiding mechanical shocks, stopping at foreseen position.

Recommended product
ATV28 ATV11 Type ATV28/11 starter with two running directions, low and high speed with acceleration, and deceleration ramp times. P<1.5kW / 2 hp. Type ATV28/11 starter with two running directions, low and high speed with acceleration and deceleration ramp times. P<1.5kW / 2 hp. The reverse motion is used during maintenance operations. P<1.5kW / 2 hp. U-Line control

Remarks
The changing from low to high speed with acceleration and delay or detection of the table position. @ 460 / 575 VAC ------@ 115 / 230 VAC The changing from low to high speed can be realized by a time delay or detection of the table position. @ 460 / 575 VAC ------@ 115 / 230 VAC Standard motor switching with overload protection Provide solid state overload protection and communications capability.

>1 M2

Forward/backward movement of the pallet on the conveyor elements.

ATV28 --------ATV11

2 M3

Lifting/lowering of chain transfer

LC2 LU

Mark
D1

Qty 2
per element

Detection needs

Recommended product
Type XS1 inductive proximity sensor, diameter 12 mm, XCK angular position switch with roller lever. Type XUL photo-electric sensor with background suppression.

Remarks
Alternative: cylinder mounted sensors XS7-V12 on PADE cylinders.

Detecting the top and bottom position XS of the table to authorize: or the arrival or the exit of the pallet, XC the backward or forward movement of the pallet on the arrival and exit conveyor. Detecting the pallet position on the arrival and exit conveyor. XU

>1 D2
per element

For more precise sensing a thru-beam system should be used, For brilliant materials a sensor with background suppression or a polarized reflex sensor should be used. Generally the sensors are mounted between the rollers and detect towards the top.

2 D3

per element

Detecting the passage and presence of the pallet on the table.

XU

Type XUL photo-electric sensor with background suppression.

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HANDLING MACHINES

Roller Conveyor

Motor Starter Detection

main functions (...) optional

M2 M1 M2 V2

product that may be critical

D3 V M1 D2 D4 M2 D1

Mark
M1

Qty
1
per element

Motor starter function

Recommended product
Starter with one running direction, P < 0.75 kW / 1 hp. Type ATV28/11 starter with two running directions with variable speed, P < 3 kW / 4 hp. The reverse motion is used during maintenance operations.

Remarks
See M3

Forward movement of products on the LC1 ------product separation element. LU Forward/backward movement of products on the conveyor elements. ATV-28 ------ATV-11

1 M2
per element

The conveyor rotation speed can depend on the jamming detection and only initiate the stopping of the conveyor after the time delay is elapsed. @ 460 / 575 VAC ------@ 115 / 230 VAC

Mark
D1

Qty 2
per stopper

Detection needs
Detecting the top and bottom position of the table to authorize: the arrival or the exit of products. Detecting the product position on the arrival and exit conveyor.

Recommended product
XS or XC XU Type XS1 inductive proximity sensor, diameter 12 mm. XCM angular position switch with roller lever. Type XUL photo-electric sensor with reflex system. Type XU photo-electric sensor with standard or delayed reflex system.

Remarks
Alternative: cylinder mounted sensors XS7-V12 on PADE cylinders. Generally the sensors are mounted between the rollers and detect towards the top. For a more precise sensing a thru-beam system should be used. For brilliant materials a sensor with background suppression or a polarised reflex sensor should be used.

>1 D2
per stopper

1 D3
per element

Detecting a product jamming after the XU switching.

1 D4

per element

Detecting a product jamming before the switching.

XU

Type XU photo-electric sensor with background suppression.

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