Belt Conveyor System

7/26/2019 Belt Conveyor System

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Belt Conveyor System

Design Manual


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UPDATE

Foreword

Whilst the utmost care is taken to ensure the accuracy of the data and designdetails contained herein, they are provided on the understanding that the companyshall under no circumstances be liable for any injuries, expenses or other losseswhich may in any way be attributable to the use, or adoption, of such data and/or

design details.

AE Conveyors reserves the right to alter or amend, without prior notices, data anddesign details specified herein.

Any comments regarding this document or requests for further copies should beaddressed to AE Conveyors.

The purpose of this document is to explain the function of the components and themanner in which they should be applied and selected.

Importance of the manual

Version StatusVersion

date

Sections

affectedComments Changed by

1.0First

release23.02.2011 All Initial version Azuwan


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ContentsSection

Product Introduction......................................................................... 1

Technical Descriptions..................................................................... 2

Accessories...................................................................................... 3

Product Application ........................................................................ 4

References....................................................................................... 5


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THIS PAGE IS INTENTIONALLY LEFT BLANK


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Section 1 Product Introduction

Contents

Heading Page

1 Warnings, Cautions & Notes ................................................ 6

2 Product Improvements .......................................................... 6

3 Trademarks............................................................................ 6

4 Technical Queries.................................................................. 6

5 Abbreviations......................................................................... 7

6 Principles of Powered Roller Conveyor................................. 8

7 Selling Features..................................................................... 8

8 Module Overview................................................................... 8

9 Range of Modules ................................................................. 9

9.1 Level Belt............................................................................ 9

9.2 Live Roller & Accumaflow................................................... 9

9.3 Incline................................................................................. 10

9.4 Metering Belt ...................................................................... 10

9.5 Booster............................................................................... 11

9.6 Blade Stops........................................................................ 11

9.7 Roller Stops........................................................................ 11


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1 Warnings, Cautions & Notes

Warnings, Cautions and Notes are used in themain body of text and are used to emphasiseimportant points. The instructions contained withinthese highlighted areas must be adhered to.

WARNING

WARNINGS CALL ATTENTION TOINSTRUCTIONS, WHICH MUST BEFOLLOWED PRECISELY TO AVOIDINCREASING THE RISK OF INJURYOR DEATH. BE SURE TO ACTUPON EVERY ITEM LABELLED INTHIS WAY

CAUTIONS CALL ATTENTION TOINSTRUCTIONS WHICH MUST BE

FOLLOWED PRECISELY IN ORDERTO AVOID DAMAGE TO THEPRODUCT, THE PROCESS, OR IT'SENVIRONMENT.

CAUTION

2 Product Improvements

It is the policy of AE Conveyors, to be ever mindfulof improvements in product design, materials andconstruction. Consequently, this document isissued on an unrestricted basis with theunderstanding that the information presented may

be subject to amendment or change.

3 Trademarks

Throughout this manual trademark names are used

Rather than put a trademark symbol (TM

) in everyoccurrence of a trademark name, the author statesthat the names are used only in an editorial fashion,and to the benefit of the trademark owner with nointention of infringement of the trademark.


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5 Abbreviations

AC Alternating CurrentAPR Adjustable Pallet RackingBB Back to Back dimensions (measured

between inside faces of side channels)BDMS Bright Drawn MiId Steel.BS British StandardBZP Bright Zinc PlatedCE Communaute EuropeenecSt CentistrokesDC Direct CurrentDTGP Dust Tight Grease Packet (Bearing)ECA Electronics Corporation of America

ERW Electrically Resistance WeldedFIFO First-In, First-OutFILO First-In, Last-OutFLT Fork Lift TruckF/min Feet per minuteFWR Full Width RollerHp HorsepowerHPT Hand Pallet Truckid Inside diameterISO International Standards Organisationkg KilogramkW KilowattLH Left Hand

M/min Metres per minutemm MillimetreNm Newton metreod Outside diameterPBR Push Back RackPEC Photo-Electric CellPLC Programmable Logic Controllerpsi Pounds per square inchPS Proximity SensorRH Right HandRHS Rolled Hollow SectionRSA Rolled Steel AngleRSC Rolled Steel Channel

RTV Retractable Trip ValveSAE Society of Automotive EngineersSEMA Storage Equipment Manufacturers AssociationSUS Saybolt Universal Seconds (Lubrication)SWG Standard Wire GaugeSWL Safe Working LoadT/L Taper LockTOR Top of Roller (Height)TOC Top of Chain (Height)TTR Twin Track RollerVG Viscosity Grade (ISO Lubricant Reference)WW Working Width (Dimension)


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7 Selling Features

The main selling features (those that distinguishit from other package conveyors) are:

Accumulating goods at a loading bay.

Move goods whilst picking.

Low maintenance costs and high reliability.

Wide range of load weights or sizes.

Low noise operation

Designed for application where improved loadcontrol and speed of operation are importantfactors.

8 Module Overview

Level Belt

Live Roller & Accumaflow

Incline Metering Belt

Booster

Blade Stops

Roller Stops

Error! Reference source not found.

6 Principles of Powered RollerConveyor

Belt conveyor is a package handling conveyorsystem for use with a wide range of load weightsor sizes up to 60kg per metre of belt. They areparticularly useful when a conveyor is required tocarry fragile loads.

The system consists of a number of standardmodules, level belt, Incline/decline belt, live roller,Accumaflow, booster and metering belt.

The conveyor operates on a principle of drivingan endless belt through a series of rollers anddrive unit.

Level, incline, decline, metering and booster beltsall use a BB - 50mm wide belt.

Live roller and Accumaflow use a 150mm widebelt, which drives a number of rollers within thebed section.

The belt conveyor system has the capability of asingle drive unit powering up to 30 metres ofconveyor.


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9 Range of Modules

9.1 Level Belt

9.2 Live Roller & Accumaflow


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9.3 Incline

9.4 Metering Belt


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9.5 Booster

9.6 Blade Stops

9.7 Roller Stops


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Section 2 Technical Descriptions

Contents

Heading Page

1 Intended Use..................................................................................... 18

2 Incorrect Use..................................................................................... 18

3 Level Belt - Centre Drive................................................................... 20

3.1 Fixed Speeds............................................................................... 20

3.2 Available Lengths......................................................................... 203.3 Roller Pitch (Roller Bed Only).......................................................20

3.4 Belt............................................................................................... 20

4 Level Belt End Drum Drive............................................................. 21

4.1 Belt............................................................................................... 21

4.2 Fixed Speeds................................................................................21

4.3 Available Lengths......................................................................... 21

4.4 Roller Pitch (Roller Bed Only)...................................................... 21

5 Incline Belt......................................................................................... 22

5.1 Angle of Incline............................................................................. 22

5.2 Height (Lift)................................................................................... 22

5.3 Fixed Speeds............................................................................... 22


5.5 Incline Sections............................................................................ 22

6 Feeder Bed Assembly................................................................ 23

6.1 Description .................................................................................. 23

6.2 Feeder Lengths............................................................................ 23

6.3 Belt............................................................................................... 23

6.4 Assembly...................................................................................... 24

6.5 End Terminals.............................................................................. 24

6.6 Feeder Unit .................................................................................. 24

7 Incline Section............................................................................... 25

7.1 Description .................................................................................. 25


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Heading Page

7.2 Centre Drive Unit.......................................................................... 25

7.3 Braked Motors.............................................................................. 25

7.4 Belt .............................................................................................. 25

8 Top Curve Bed Assembly ................................................................ 26

8.1 Description .................................................................................. 26

8.2 Bed Section.................................................................................. 26

8.3 End Terminals.............................................................................. 27

9 Booster Conveyor ............................................................................ 28

9.1 Description .................................................................................. 28

9.2 End Drum Drive........................................................................... 28

9.3 Angle of Incline............................................................................. 28

9.4 Fixed Speeds ...............................................................................29



9.7 Belt .............................................................................................. 29

10 Live Roller Centre Drive................................................................. 30

10.1 Fixed Speeds .............................................................................. 30


10.3 Roller Pitch................................................................................... 30

10.4 Belt .............................................................................................. 30

11 Live Roller End Drum Drive............................................................ 31

11.1 Fixed Speeds ...............................................................................31


11.3 Roller Pitch................................................................................... 31

11.4 Belt .............................................................................................. 31

12 Accumaflow Centre Drive.............................................................. 32

12.1 Fixed Speeds ...............................................................................32


12.3 Roller Pitch................................................................................... 32

12.4 Belt .............................................................................................. 32

13 Accumaflow End Drum Drive......................................................... 33


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Heading Page

13.1 Fixed Speeds ...............................................................................33


13.3 Roller Pitch................................................................................... 33

13.4 Belt .............................................................................................. 33

14 Metering Belt .................................................................................... 34

14.1 Fast Belt....................................................................................... 34

14.2 Brake Belt..................................................................................... 34

14.3 Speeds ........................................................................................ 34

15 End Terminal Unit.............................................................................. 35

15.1 Available Widths........................................................................... 35

16 End Terminal Unit (Square Nose)..................................................... 36

17 Live Roller/Accumaflow End Terminal Unit....................................... 37

18 End Terminal Unit (Round Nose)...................................................... 38

19 Centre Drive Unit............................................................................... 40

19.1 Description ...................................................................................40

19.2 Motors...........................................................................................40

19.3 Fixed Speeds ...............................................................................40

19.4 Chain Drive .................................................................................. 40


19.6 Snubs and Tension Rollers.......................................................... 41

19.7 Drive Pulley.................................................................................. 41

19.8 Guarding ...................................................................................... 41

20 High Speed Centre Drive Unit........................................................... 43

20.1 Description ...................................................................................43

20.2 Motors...........................................................................................43

20.3 Fixed Speeds ...............................................................................43

20.4 Pulley Drive.................................................................................. 43


21 End Drum Drive................................................................................. 46

21.1 Description ...................................................................................46


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Heading Page

21.2 Motor Unit..................................................................................... 46

21.3 Fixed Speeds ............................................................................... 46

21.4 Snub Roller .................................................................................. 46

22 Metering Belt Drive Unit ................................................................... 48

22.1 Dive Unit....................................................................................... 48

22.2 Pulleys.......................................................................................... 48

22.3 Speeds ........................................................................................ 48

22.4 Chain Drive .................................................................................. 48

22.5 Available Widths.......................................................................... 48

23 Feeder Unit ...................................................................................... 50

23.1 Feeder Unit .................................................................................. 50

23.2 Snub Roller .................................................................................. 50


24 Top Curve Unit ................................................................................. 52

24.1 Description .................................................................................. 52


24.3 Angle of Incline............................................................................. 52

24.4 Snub Roller .................................................................................. 52

25 Tensioners......................................................................................... 54

25.1 Underslung Tensioner.................................................................. 54

25.2 Integral Tensioner ....................................................................... 54

25.3 Lengths ........................................................................................ 54


25.5 Facia ............................................................................................ 5426 Bed Sections .................................................................................... 57

26.1 Mono Bed..................................................................................... 57



26.4 Rollers ......................................................................................... 57

26.5 Roller Bed .................................................................................... 58



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Heading Page


26.8 Rollers ......................................................................................... 58

26.9 Live Roller ....................................................................................59



26.12 Rollers ......................................................................................... 5926.13 Accumaflow.................................................................................. 60



26.16 Rollers ......................................................................................... 60

26.17 Line Pressure............................................................................... 60


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WARNING

WARNING

THE BELT RANGE OF POWERCONVEYORS IS DESIGNED FORPACKAGE HANDLING, (I.E. TO BELOADED BY HAND) AND SHOULDNOT UNDER NORMALCONDITIONS BE LOADED BYHAND BEYOND 25KG PER LOAD

2 Incorrect Use

The belt ranges of conveyors are not suitable forhandling products or chemicals of an aggressivenature (e.g. acids).

The conveyor operates on the principle of beingable to drive a belt from a single motor drive unitup to a variable length depending upon load (drive

unit can power up to 333 kg maximum).

Choose from a range of level belt, incline belt, orbelt driven roller conveyors to suit yourapplication. Level belt conveyors and belt drivenroller conveyors are for the horizontaltransportation of items and assembly lineoperations. Incline belt conveyors are used todeliver packages or boxes from one floor toanother and when fitted with a reversing controlcan operate in either direction.

Belt speeds available are 9, 14, 18, 24, 30, 42, 52,

58, 72 and 85 metres per minute.

BELT CONVEYORS ARE NOT

SUITABLE TO BE WALKED UPON.

DOING SO MAY RESULT IN SEVERE

PERSONAL INJURY. PERSONNELGATES OR STEP OVER GANTRYS

SHOULD BE USED WHEN

CROSSING A CONVEYOR

1 Intended Use

Belt conveyor is a package handling conveyorsystem for use with dry cardboard packages /boxes, plastic based products or tote bins up to amaximum weight of 60kg per metre. Ideal forhandling fragile loads or a wide range of loadweight or sizes and is designed for applicationswhere improved load control and speed ofoperation are important factors.


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3 Level Belt - Centre Drive

Fig. DM2.1 Level Belt Centre Drive

As can be seen from the illustration the conveyorconsists of 3 basic units:-

Centre Drive Unit

End Terminal Unit

Bed Sections (Mono Bed & Roller Bed)

Refer to the dedicated sections for detailedtechnical information on the above units.

The drive and tension unit can be mountedbeneath any 1.0 (Mono Bed), 1.5, 2.0, 2.5 or 3.0metre bed section. The shortest standard overallconveyor length including the two end terminalunits, (each 250mm long) is 1.5 metres (MonoBed) or 2.0 metres (Roller Bed). Standardintermediate bed sections of 1.0 (Mono Bed only),1.5, 2.0, 2.5 and 3.0 metre are available.

3.1 Fixed Speeds

9, 14, 18, 24, 30, 42, 52, 58, 72 and 85metres/minute

3.2 Available LengthsOverall conveyor lengths of 2.0, 2.5, 3.0, 3.5, 4.0,

4.5, 5.0 metre etc., in 0.5 metre increments to 30metres

3.3 Roller Pitch (Roller Bed Only)250mm Pitch

3.4 BeltThe standard transmission belt is a 2-plypolyester backed, PVC top coated belt 3mm thickBelt width is BB - 50mm


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4 Level Belt End Drum Drive

Fig. DM2.2 - Level Belt (End Drum Drive)

End Terminal Unit

Underslung Tensioner



The end drum drive is mounted at one end of theconveyor and an end terminal at the other. Anunderslung tensioner is mounted beneath theconveyor bed to accommodate belt tensioning.The shortest standard overall conveyor lengthincluding the end terminal and end drive unit,(each 250mm long) is 1.5 metres (Mono Bed) or

2.0 metres (Roller Bed). Standard intermediatebed sections of 1.0 (Mono Bed only), 1.5, 2.0, 2.5and 3.0 metre are available

4.1 Belt

The standard transmission belt is a 2-plypolyester uncoated transparent low-noiseunderside, hard black PVC top coated belt 2.2 0.20mm thick

Belt width is BB - 50mm.

4.2 Fixed Speeds

15, 18 and 21 metres/minute

4.3 Available Lengths

Overall conveyor lengths of 2.0, 2.5, 3.0, 3.5, 4.0,metre etc., in 0.5 metre increments to a maximumof 10 metres.

4.4 Roller Pitch (Roller Bed Only)

250mm Pitch


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5 Incline Belt

Fig. DM2.3 - Incline Belt


Centre Drive Unit (Braked)

End Terminal Units


Top Curve Bed Assembly

Feeder Bed Assembly


Inclined belt conveyors are used to deliver

packages or boxes from one floor to another andwhen fitted with a reversing control can operate ineither direction. They can be used as stand-alone units or as integrated elements of aconveyor system.

5.1 Angle of Incline

Angles available: fully adjustable between 0

o

up to30

o

.

5.2 Height (Lift)

The difference in height between the feeder andtop curve sections is referred to as the lift. Inclinedbelt conveyors come in 1.5m to 6m lifts, in 0.25mincrements. The dimension between the floor andthe top of the feeder section belt is termed as theinfeed height, whereas the dimension to the topcurve belt is termed outfeed height.

5.3 Fixed Speeds



250mm Pitch

5.5 Incline Sections

A complete incline belt conveyor is made up fromthree separate sections: Feeder, Inclined Belt andTop Curve. The following pages outline thecharacteristics of each section.


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6 Feeder Bed Assembly

Fig. DM2.4 - Feeder Bed Assembly

6.1 Description

A short, level length of belt conveyor that preventsthe trailing edge of loads from bumping acrossrollers as the leading edge climbs the inclined beltIt comprises of an end terminal unit, a tension unitand a feeder unit. This unit is split into two halvesone half connected to the level portion, the next(which is adjustable in angle) connects to theInclined Belt. A normal smooth top belt travels

along the length of the feeder section, returningback underneath.

The feeder unit can be adjusted for any angle upto 30, there is no handing of the feeder thereforethe chain guard can be positioned on the sidemost convenient on site.

An integral or underslung tension unit is fitted tothe feeder section to allow belt tensioning.

6.2 Feeder Lengths

1000mm (300 500BB), 1500mm and 2000mm

6.3 Belt

The standard transmission belt is a 2-plypolyester uncoated transparent low-noiseunderside, hard black PVC top coated belt 2.20.20mm thick

Belt width is BB - 50mm.


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Fig. DM2.5 Feeder Bed Assembly Lengths

6.4 Assembly

The feeder bed assembly is assembled with atensioned vulcanised belt and only requiresbolting to the bed section of the incline.

Sprockets/pulleys are installed on the side of thefeeder unit as shown in the above figure. If yourequire the sprockets/pulleys to be installed on theopposite side (access for maintenance due toobstructions) please state when ordering theassembly.

6.5 End Terminals

Two types of end terminals are available and can

be ordered for each length of assembly.

1. Round Nose:

2. Square Nose:

6.6 Feeder Unit

Two types of feeder unit are available and can beordered for each length of assembly.

1. Feeder unit with sprocket and chains

2. Feeder unit with pulleys and timing belt


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7 Incline Section

7.3 Braked Motors

The centre drive unit must be fitted with an

electromagnetic braked motor. These are fittedto prevent overrun on a declined belt or run backon an inclined belt when the electrical power isremoved. The brakes are made with a frictiondisc on the extended motor shaft. When thecurrent is off, it is held stationary by a pressureplate under heavy coil spring tension. When thecurrent is on, electro magnets retract thepressure plate and compress the springs so thatthe disc can turn freely without a drag on themotor. Adjustment for tension and wear is madevia an external lever.

7.4 BeltThe incline section uses a high grip 2-plypolyester belt, which has a black longitudinalgroove profile top surface, and a transparentfabric finish underside belt 3.1 0.20mm thick.The belt must be installed with the fabric surfacefacing downwards. The belt joint may bevulcanised or fitted with the standard hookfasteners (as Level Belt Conveyors).

Belt width is BB - 50mm

Fig. DM2.6 Incline Section

7.1 Description

The actual part of the conveyor that allows the

load to gain height, travelling on a high grip belt.This section is made up of a number of bedsections (available in standard sizes), connectedto the feeder section via the second half of theactual feeder unit, and to the top curve sectionvia the first half of the top curve unit. The bedsections are joined together using splice plates.

7.2 Centre Drive Unit

A centre drive is attached beneath the bedsections, through which the returning load-carrying belt is threaded, providing motive powerfor the conveyor. This drive is transferred to theseparate belt on the feeder section by use of a


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8 Top Curve Bed Assembly

Fig. DM2.7 - Top Curve Assembly

8.1 Description

Top Curve Section is used to bring the load backto a level attitude after completing the transitionfrom an inclined position. The top curve sectioncomprises of a top curve unit connected to an endterminal unit identical to that found at the feedersection. The top curve unit itself is adjustable inangle between 0 and 30 and comprises of twohalves similar to the feeder unit. However, unlikethe feeder section, this does not have a separateload-carrying belt. In this instance, the belttravelling up the inclined section is extendedaround the top curve bed assembly, returningdown to the drive unit.

8.2 Bed Section

A bed section is fitted in between the Top Curveand the End Terminal when using a top curvelength of 990mm or above. The bed section canbe either roller bed or mono bed.


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Fig. DM2.8 Top Curve Bed AssemblyLengths

8.3 End Terminals

Two types of end terminals are available and canbe ordered for each length of assembly.

1. Round Nose:

2. Square Nose:


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9 Booster Conveyor

Fig. DM2.9 - Booster Conveyor


Centre Drive Unit or End Drum Drive

End Terminal Unit



9.1 Description

The booster conveyor is a level belt inclined at anangle of 15 with the addition of a bottom and topcoupling unit.

These units assist the transfer of packages ontoand off the booster conveyor with the aid of a 35dia. pop out roller. Primarily booster conveyorsare used to regain height lost in a gravity run,they can only be used as inclines.

Boosters may be driven using a centre drive unit,positioned below the conveyor (see illustration),or an end drum drive.

9.2 End Drum DriveThe end drum drive is mounted at the top end ofthe conveyor and an end terminal at the otherwhen using an end drum drive. An underslungtensioner is mounted beneath the conveyor bedto accommodate belt tensioning.


15 Degrees


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Fig. DM2.10 - Booster Conveyor (keyDimensions)

9.4 Fixed Speeds

Centre Drive 9, 14, 18, 24, 30, 42, 52, 58, 72 and85 metres/minute

End Drum Drive 15, 18 and 21 metres/minute


Overall conveyor lengths of up to a maximum of6.0 metres at 0.5m increments. (refer to tableopposite for available lengths)


250mm Pitch

9.7 Belt



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10 Live Roller Centre Drive

Fig. DM2.11 - Live Roller (Centre Drive)

Live roller conveyors consist of a roller bed drivenby a belt operating on the underside of the rollers.Therefore, the belt will always travel in theopposite direction to the required package flow.The live roller conveyor consists mainly of threebasic modules: -

Centre Drive Unit

End Terminal Unit

Bed Sections


The drive and tension unit can be mountedbeneath any 1.5, 2.0, 2.5 or 3.0 metre bedsection. The shortest standard overall conveyorlength including the two end terminal units, (each250mm long) is 2.0 metres. Standardintermediate bed

10.1 Fixed Speeds



Overall conveyor lengths of 2.0, 2.5, 3.0, 3.5, 4.0,4.5, 5.0 metre etc., in 0.5 metre increments to 30

metres

10.3 Roller Pitch

83, 125 and 250mm Pitch

10.4 Belt


Belt width is 150mm


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11 Live Roller End Drum Drive

Fig. DM2.12 - Live Roller (End Drum Drive)

Live roller conveyors consist of a roller bed drivenby a belt operating on the underside of the rollers.

Therefore, the belt will always travel in theopposite direction to the required package flow.The live roller conveyor consists mainly of fourbasic modules: -

End Drum Drive

End Terminal Unit


Bed Sections


The end drum drive is mounted at the back of theconveyor and an end terminal at the front inrelation to the direction of travel (refer to abovefigure). An underslung tensioner is mountedbeneath the conveyor bed to accommodate belttensioning. The shortest standard overallconveyor length including the end terminal andend drive unit, (each 250mm long) is 2.0 metres.Standard intermediate bed sections of 1.5, 2.0,2.5 and 3.0 metre are available.

11.1 Fixed Speeds



Overall conveyor lengths of 2.0, 2.5, 3.0, 3.5, 4.0,metre etc., in 0.5 metre increments to a maximum

of 10 metres.

11.3 Roller Pitch

83, 125 and 250mm Pitch

11.4 Belt


Belt width is 150mm


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12 Accumaflow Centre Drive

Fig. DM2.13 - Accumaflow (Centre Drive)

In all aspects, the Accumaflow Conveyor isidentical to Live Roller except for the bed section.Refer to bed section details for principle of

operation. The end terminal unit is a live roller unitand does not have any accumulation feature. TheAccumaflow conveyor consists mainly of threebasic modules: -

Centre Drive Unit

End Drum Drive

Bed Sections


The drive and tension unit can be mounted

beneath any 1.5, 2.0, 2.5 or 3.0 metre bed sectionThe shortest standard overall conveyor lengthincluding the two end terminal units, (each250mm long) is 2.0 metres. Standardintermediate bed sections of 1.5, 2.0, 2.5 and 3.0metre are available.

12.1 Fixed Speeds



Overall conveyor lengths of 2.0, 2.5, 3.0, 3.5, 4.0,4.5, 5.0 metre etc., in 0.5 metre increments to 30metres

12.3 Roller Pitch83 and 167mm Pitch

12.4 Belt


Belt width is 150mm


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13 Accumaflow End Drum Drive

Fig. DM2.14 - Accumaflow (End Drum Drive)

In all aspects, the Accumaflow Conveyor isidentical to Live Roller except for the bed section.Refer to bed section details for principle ofoperation (refer to above figure). The end

terminal unit is a live roller unit and does not haveany accumulation feature. The Accumaflowconveyor consists mainly of four basic modules: -

End Drum Drive

End Terminal Unit


Bed Sections


The end drum drive is mounted at the back of the

conveyor and an end terminal at the front inrelation to the direction of travel. An underslungtensioner is mounted beneath the conveyor bed toaccommodate belt tensioning. The shorteststandard overall conveyor length including the endterminal and end drive unit, (each 250mm long) is2.0 metres. Standard intermediate bed sectionsof 1.5, 2.0, 2.5 and 3.0 metre are available

13.1 Fixed Speeds



Overall conveyor lengths of 2.0, 2.5, 3.0, 3.5, 4.0,metre etc., in 0.5 metre increments to a maximumof 10 metres.

13.3 Roller Pitch

83 and 167mm Pitch

13.4 Belt


Belt width is 150mm


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14 Metering Belt

Fig. DM2.15 - Metering Belt


Metering Belt Drive Unit

End Terminal Unit

Tensioners

Bed Sections (Mono bed only)


A complete metering belt conveyor is made upfrom two separate sections: Brake Belt and FastBelt. As these names suggest, there are twospeeds to this conveyor, which are achievedusing a single drive unit. This drive unit providesmotive power to the end of each section via achain and sprockets of different sizes, resulting ina speed increase. This feature has the effect ofseparating loads that are travelling nose to tail

across the conveyor. This is enhanced by the useof two different belt types, one with higher gripcharacteristics than the other.

There are various overall lengths of metering beltsavailable, giving different fast and slow belt lengthcombinations. Each combination is constructed ofa number of standard units: End Terminal units ateach end a Drive Unit in the centre, TensionUnit(s) and Bed sections. Standard bed sectionsof 1.0, 1.5, 2.0, 2.5 and 3.0 metres are available.

14.1 Fast Belt

The fast belt is 1.0m (300BB to 500BB) or 1.5m(600BB & 800BB) in length, achieved byconnecting a Tension Unit (500mm or 1000mm)between the End Terminal Unit (250mm) and onehalf of the Drive Unit (500mm / 2). It is fitted witha standard transmission belt 2-ply polyester

uncoated transparent low-noise underside, hardblack PVC top coated belt 2.2 0.20mm thick

14.2 Brake Belt

The brake can be a minimum length of 1.0m(300BB to 500BB) or 1.5m (600BB & 800BB),constructed identically to the fast belt. Otherlengths, in 0.5m increments up to 4.5m, areachieved by connecting a bed section(s) betweenthe End Terminal Unit and the other half of theDrive Unit. All length configurations above 1.5mhave an underslung Tension Unit designed to bebolted below the bed section(s). It is fitted with a

The standard high grip profile belt is a 2-plypolyester belt with a black longitudinal grooveprofile top surface, and a transparent fabric finishunderside belt 3.1 0.20mm thick. The belt mustbe installed with the fabric surface facingdownwards.

14.3 Speeds

Brake Belt -9, 14, 18.5, 24 and 27.5metres/minute

Fast Belt- 14, 21, 27.5, 35 and 40metres/minute


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15 End Terminal Unit

Fig. DM2.16 - End Terminal Unit

As can be seen from the illustration End Terminalunits come in three basic units:-

End Terminal Unit (Square Nose)

End Terminal Unit (Round Nose)

Live Roller/Accumaflow End Terminal Unit

In all cases, the end terminal unit consists of a75mm diameter terminal pulley, which is the samecomponent as used on the centre drive/tensionunit and a 50mm diameter snubbing roller. Thissnubbing roller has a wall thickness of. 3.2mmand is fitted with a precision bearing. Thesnubbing roller provides a tracking facility viaadjusting brackets.

15.1 Available Widths

300, 400, 450, 500, 600 and 800BB

Refer to the following pages for detaileddimensions for each type of end terminal shownin the above illustration.


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16 End Terminal Unit (Square Nose)

Bolted to each end of the conveyor length on thefollowing conveyors:-

Level Belt

Booster Belt

Metering Belt

Incline/Decline Belt

Fig. DM2.17 - End Terminal Unit (Square Nose)- Key Dimensions


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17 Live Roller/Accumaflow EndTerminal Unit

Bolted to each end of the conveyor length on thefollowing conveyors:

Live Roller

Accumaflow

Fig. DM2.18 - Live Roller/Accumaflow EndTerminal Unit - Key Dimensions


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18 End Terminal Unit (Round Nose)

Bolted to the end of a belt conveyor system on thefollowing conveyors:

Level Belt

Incline / Decline Belt

Fig. DM2.19 - End Terminal Unit (Round Nose)- Key Dimensions


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19 Centre Drive Unit

Fig. DM2.20 - Centre Drive Unit

19.1 Description

A centre drive is attached beneath the bedsections, through which the returning load-carrying belt is threaded, providing motive powerfor the conveyor. Either a 0.75 kW, 1.5 kW or1.5kW high speed motor is used with in linehelical spur gear box. The geared motor unitgives an output speed of 43rpm and is coupled tothe drive pulley via a precision chain drive. InclineBelt Conveyors: in addition, are fitted with anelectromagnetic braked motor. These are fitted toprevent overrun on a declined belt or run back onan inclined belt.

19.2 Motors

The motors used are suitable for an electrical

supply of 415 volts, 3 phase, 50 Hertz. It is veryimportant to obtain full details of the customerssupply especially overseas where not only is thevoltage different but it can also be 60 Hertz. Inaddition, the working conditions are also importantRefer to application section.

19.3 Fixed Speeds

The following speeds are available for both0.75kW and 1.5kW.

9, 14, 18, 24 and 30 metres/minute

These speeds are achieved by changing thesprockets on the geared motor and headshaft.For speeds outside this range, it is necessary tochange the geared motor. If this is the case, theDesign Department at Gainsborough should beconsulted. For sprocket combinations refer toTable. DM2.1

19.4 Chain Drive

This is a 1/2" pitch duplex transmission chain.


300, 400, 450, 500, 600 and 800BB


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19.6 Snubs and Tension Rollers

The 75mm diameter rollers have precisionbearings pressed in to each end for a 30mmdiameter fixed shaft to pass through. The tensionpulley is adjustable in its position and has 360mmof adjustment.

19.7 Drive Pulley

The 230mm effective diameter (723mmcircumference) pulley has a crowned outersurface to assist belt tracking and is lagged toensure maximum transmission of power to the

belt. The pulley together with an integral 35mmdiameter shaft revolves in precision bearingsfixed to the drive side plates.

Table. DM2.1

19.8 Guarding

Chain Guard -This is a one-piece guard, which fitsover the driving chain totally enclosing all theworking, parts.

Bearing Guard -Fitted on the opposite side to thechain guard giving protection from rotating shafts.

For dimensions for removal of guards refer to Fig.DM2.21 - Centre Drive Unit - Key Dimensions


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Fig. DM2.21 - Centre Drive Unit - KeyDimensions


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20 High Speed Centre Drive Unit

Fig. DM2.22 High Speed Centre Drive Unit

20.1 Description

High speed drive units use a timing belt drivesystem rather than a sprocket and chain. Otherthan the drive system the centre drive is Identical

to the standard drive unit with only a 1.5kWgeared motor option. The geared motor unit givesan output speed of 124 rpm and is coupled to thedrive pulley via a timing belt drive.

20.2 Motors

The motors used are suitable for an electricalsupply of 415 volts, 3 phase, 50 Hertz. It is veryimportant to obtain full details of the customerssupply especially overseas where not only is thevoltage different but it can also be 60 Hertz. Inaddition, the working conditions are also importantRefer to application section.

20.3 Fixed Speeds

The following speeds are available for 1.5kW.

42, 52, 58, 72 and 85 metres/minute

These speeds are achieved by changing thepulleys on the geared motor and headshaft. Forspeeds outside this range, it is necessary tochange the geared motor. If this is the case, theDesign Department at Gainsborough should beconsulted. For pulley combinations refer to TableDM2.2

20.4 Pulley Drive

14mm pitch x 20mm wide Polychain sprockets.


300, 400, 450, 500, 600 and 800BB


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Table. DM2.2


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Fig. DM2.23 High Speed Centre Drive Unit -Key Dimensions


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21 End Drum Drive

Fig. DM2.24 - End Drum Drive

21.1 Description

The end drive is of a bolted construction

incorporating underguarding and finger guards.

21.2 Motor Unit

0.18 kW motorised drum, which is crowned toassist with belt tracking.

21.3 Fixed Speeds

The following speeds are available:


21.4 Snub Roller

Roller Tube: 50mm dia 3.2mm wall thickness,

mild steel tube zinc plated

Bearing: Precision

Axle: 11mm A/F hexagonal steel bar.Axle is sprung loaded both ends.


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Fig. DM2.25 - End Drum Drive - KeyDimensions

Fig. DM2.26 - End Drum Drive (Live Roller) -Key Dimensions


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22 Metering Belt Drive Unit

Fig. DM2.27 - Metering Belt Drive Unit

22.1 Dive Unit

A 0.75kW geared motor drives both brake belt

and fast belt. For applications with up to 20stop/starts per min, a brake motor is fitted. Forapplications above 20 stop/starts per min, pleaseconsult engineering department

22.2 Pulleys

The drive unit is fitted with two 75mm diameterlagged drive pulleys

22.3 Speeds

Belt speeds given are based on the use of 17T

and 25T sprockets on pulleys (refer to Fig.Metering Belt Drive Unit - Key Dimensions). Thisratio will generate a small (50% of load length)gap between loads, which may be detected byphotoelectric cell arranged at the delivery end.

There is a single motor rating available: 0.75kW,with five speeds: See table below

22.4 Chain Drive

This is a 1/2" pitch duplex transmission chain.


300, 400, 450, 500, 600 and 800BB


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Fig. DM2.28 - Metering Belt Drive Unit - KeyDimensions


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23 Feeder Unit

Fig. DM2.29 - Feeder Unit

23.1 Feeder Unit

23.1.1 Chain and Sprockets

The unit consists of two 75mm diameter drivepulleys whose shafts run in bearings mounted onthe feeder side plates. A 17 Tooth duplexsprocket is fitted to each shaft and a duplex chaindrive transmits the power from the belt driving thepulley on the inclined section to the feeder pulley,giving drive to the feeder belt.

23.1.3 Angle

The feeder unit can be adjusted for any angle up

to 30, there is no handing of the feeder thereforethe chain guard can be positioned on the sidemost convenient on site.

23.2 Snub Roller

50 diameter snub roller with a 3.2mm wallthickness and is fitted with precision bearings.


300, 400, 450, 500, 600 and 800BB

23.1.2 Timing Belt and Pulley

The unit consists of two 75mm diameter drivepulleys whose shafts run in bearings mounted onthe feeder side plates. A 32 Teeth timing beltpulley is fitted to each shaft and an 8M timing beltdrive transmits the power from the belt driving thepulley on the inclined section to the feeder pulley,giving drive to the feeder belt.


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Fig. DM2.30 - Feeder Unit - Key Dimensions


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24 Top Curve Unit

Fig. DM2.31 - Top Curve Unit

24.1 Description

Having conveyed packages from a horizontalplane and up an incline, it is desirable to bring theconveyor back to the horizontal plane again andfor this reason, a top curve is used. The unit,which is bolted to the last bed section, is madefrom two pairs of side plates, which in turn locates4 bed and 2 return rollers. The side plates arehinged in the middle to allow for angularadjustment up to 30. On one side, the rollers aremounted in adjustable brackets to allow fortracking. The top curve is bolted directly to an endterminal unit (490mm only) or a bed section of

varying length (500, 1000, 1500mm).


300, 400, 450, 500, 600 and 800BB


Angles available: up to 30o

.

24.4 Snub Roller6 off 50 diameter snub roller with a 3.2mm wallthickness and are fitted with precision bearings.

Roller Dimensions

4 top snub rollers are BB - 112mm

2 bottom snub roller are BB - 3mm


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Fig. DM2.32 - Top Curve Unit - Key Dimensions


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25 Tensioners

Fig. DM2.33 - Tension Units

25.1 Underslung Tensioner

This unit is 500mm long and available in standardBack to Back. It comprises of two 90mm deep

channels with four 80mm diameter tension rollers,2 fixed and 2 adjustable giving a maximum belttensioning of 208mm. The unit is fixedunderneath the conveyor bed section to thebottom flange of the channel with 8 off M8 x20mm Hex Head Setscrews.

25.2 Integral Tensioner

The horizontal feeder of an incline conveyor hasan integral tension unit 500mm long on 300, 400,450 and 500mm wide conveyors. The unitcomprises of two 180mm deep channels with four80mm diameter tension rollers 2 fixed and 2

adjustable giving a maximum belt tensioning of208mm. The tensioner is bolted between thepower feeder and an end terminal unit refer to FigDM2.35 - Integral Tension Unit - Key Dimensions

600BB & 800BB feeder sections use theunderslung tensioners mounted beneath a1000mm frame.

25.3 Lengths

500mm long (Integral unit for 300 to 500BB feedersections)

500mm long (Underslung unit for 300 to 800BB)


300, 400, 450, 500, 600 and 800BB

25.5 Facia

The underslung tensioner accepts standard 90mmdeep facia. The integral tensioner is finished offwith standard 140mm deep facia.


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Fig. DM2.34 - Underslung Tension Unit - KeyDimension


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Fig. DM2.35 - Integral Tension Unit - KeyDimensions


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26 Bed Sections

26.4 Rollers

Return Rollers

Roller Tube: 35mm dia 1.2mm wall thickness,mild steel tube zinc plated

Bearing: Precision


Fig. DM2.36 - Monobed Panel - Bed Section

26.1 Mono Bed

Conveyor frames are made from cold formed90mm x 35mm x 2.5mm thick painted steelchannels. Monobed panels are 500mm long andare made from 1.6mm thick zinc plated steel, andare fitted within the frames. Return rollers are35mm diameter x 1.2mm wall thickness withprecision bearings. They are placed in theconveyor every 1000mm.


Standard bed lengths of 1.0, 1.5, 2.0, 2.5 and 3.0metres.


300, 400, 450, 500, 600 and 800BB


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26.8 Rollers

Bed Rollers


Bearing: Precision


Return Rollers


Bearing: Precision


Fig. DM2.37 - Rollerbed - Bed Section

26.5 Roller Bed

Conveyor frames are made from cold-formed90mm x 35mm x 2.5mm thick painted steelchannels. The load bearing rollers are 50mmdiameter x 1.5mm wall thickness. These are fittedwith precision bearings and are rated at100kg/roller. They are placed in the conveyorevery 250mm pitch as standard. Return rollersare 35mm diameter x 1.2mm wall thickness withprecision bearings. They are placed in theconveyor every 1000mm.


Standard bed lengths of 1.5, 2.0, 2.5 and 3.0metres.


300, 400, 450, 500, 600 and 800BB


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Fig. DM2.38 - Live Roller - Bed Section

26.9 Live Roller

Conveyor frames are made from cold-formed140mm x 35mm x 2.5mm thick painted steel

channel sections with "pop out" slots punched at41.46mm pitch in the web and top flanges. Thebed rollers are 50mm diameter x 1.5mm wallthickness. These are fitted with precisionbearings and are rated at 100kg/roller. They areplaced in special pop out slots in the conveyor at83, 125 or 167mm pitch as standard.

The top strand of the belt rests on pressure rollerswhich are 35mm diameter x 1.2mm thickness withprecision bearings and are rated at 35kg/roller.Punched in the web of this section at 83mm pitchare holes for the pressure rollers. The pressure

roller holes are positioned at varying pitches referto Fig. DM2.38 - Live Roller - Bed Section

Return rollers, which are the same specificationas pressure rollers are fitted at 1000mm pitch.


Standard bed lengths of 1.5, 2.0, 2.5 and 3.0metres.


300, 400, 450, 500, 600 and 800BB

26.12 Rollers

Bed Rollers



Bearing: Precision


Pressure & Return Rollers


Bearing: Precision



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Fig. DM2.39 - Accumaflow - Bed Section

26.13 Accumaflow

Conveyor frames are made from cold formed140mm x 35mm x 2.5mm thick painted steelchannel sections with "sloped slots" cut out at83mm pitch in the web and top flanges. The bed

rollers are 50mm diameter x 1.5mm wallthickness and fitted with precision bearings andare rated at 100kg/roller. The roller axles are setin nylon collars, which ride on sloped steel slots inthe conveyor frame. When the forward motion ofa package is interrupted, the backward force ofthe belt causes the conveying rollers to travel upthe sloped slots. As the rollers move up theseslots a floating effect is created with the roller onlylightly touching the belt and producing a state ofequilibrium with pressure reduced to a minimum.The carrying rollers automatically resume theirnormal positive action position when the package

is allowed to flow forward.

The top strand of the belt rests on pressure rollerswhich are 35mm diameter x 1.2mm thickness withprecision bearings which are rated at 35kg/roller.Punched in the web of this section at 167mmpitch are slotted holes for the pressure rollers.The pressure rollers can be adjusted to vary theamount of drive by using the cam adjusters referto Fig. DM2.39 - Accumaflow - Bed Section

Return rollers, which are the same specificationas pressure rollers are fitted at 1000mm pitch


Standard bed lengths of 1.5, 2.0, 2.5 and 3.0

metres.


300, 400, 450, 500, 600 and 800BB

26.16 Rollers

Bed Rollers


Bearing: Precision


Pressure & Return Rollers



Bearing: Precision

Axle: 8mm A/F hexagonal steel bar.

26.17 Line Pressure

The line pressure of an accumulated package isin the range of 4% - 7% of its total.


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Section 3 Accessories

Contents

Heading Page

1 Roller Stop......................................................................................... 62

1.1 Roller Stop Operation.................................................................... 62

1.2 Roller Stop (pneumatic)................................................................. 62

1.3 Air Consumption............................................................................. 62

1.4 Available Widths............................................................................. 62

2 Blade Stop......................................................................................... 64

2.1 Blade Stop Operation..................................................................... 64

2.2 Blade Stop (pneumatic)................................................................. 64

2.3 Air Consumption............................................................................. 64

2.4 Available Widths............................................................................. 64

3 Splice Angles and Floor Fixing ......................................................... 66

4 Side Guides....................................................................................... 675 Facia.................................................................................................. 68

6 Photo Cell and Reflector Brackets.................................................... 69

6.1 Metal Shielded Type...................................................................... 69

6.2 Plastic Type.................................................................................... 70

6.3 PEC Angle Moulding...................................................................... 70

7 Encoder Kit........................................................................................ 72

8 Remote Emergency Stop................................................................. 73


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1 Roller Stop

1.3 Air Consumption

32 Bore x 50mm Stroke300 BB to 800 BB = 0.52 litres of free air percycle.


300, 400, 450, 500, 600 and 800mm.

Fig. DM3.1 - Roller Stop

1.1 Roller Stop Operation

The roller stop is intended to hold back a queue ofboxes.

The stop assembly features a failsafe normally upsystem of operation, by the use of an extendedspring located between the opposing link arm andinner side channel.

The roller stop is 50mm above roller height in theup position and level with roller height in the downposition.

1.2 Roller Stop (pneumatic)

Each stop assembly consists of two side channelsspaced apart by bolted crossties, the distancebetween the channels is variable to suit the

conveyor size, up to a maximum of 800mm back toback. The overall width of the stop assembly is60mm greater than the back to back dimension.The roller is fastened between two side plates andforms the lifting part of the stop. The pivot armmechanism comprises of a 20mm diameter brightdrawn mild steel shaft, together with link arms30mm x 12mm thick, drilled and pinned to the pivotshaft. This mechanism provides the link betweenthe lifting stop, the air, and an attachment point forthe extension spring.


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Fig. DM3.2 - Roller Stop (pneumatic) - KeyComponents

Fig. DM3.3 - Roller Stop (pneumatic) - KeyDimensions


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2 Blade Stop

Fig. DM3.4 - Blade Stop

2.1 Blade Stop Operation

The blade stop is intended to hold back a queue

of boxes and accumulate them.

The blade stop is 20mm above roller height in theup position and 15mm below in the down position.

2.2 Blade Stop (pneumatic)

The blade itself is a 3mm thick steel plate. Theblade is guided in two nylon blocks and is lifted bya double acting pneumatic cylinder.

2.3 Air Consumption

32mm Bore x 25mm Stroke300 BB to 800 BB = 0.26 litres of free air per cycle

2.4 Available Widths:

300, 400, 450, 500, 600 and 800mm.


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Fig. DM3.5 - Blade Stop - Key Components

Fig. DM3.6 - Blade Stop (pneumatic) - KeyDimensions


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3 Splice Angles and Floor Fixing On applications where it is not possible toposition a stand directly under a joint in theconveyor frames, a splice angle connector mustbe fitted. In any circumstances, the un-supportedspan of conveyor frames must not exceed 3metres.

Two splice angles will be required for each joint.

It is preferable to position a stand as near to thesplice angle as possible.

Fig. DM3.7 Splice Angle Location

Both Type 1 and Type 2 conveyor stands requiresecuring to the floor using an expandable Floor-Fixing Bolt.

Two M10 x 90 Floor Fixing Bolts are required foreach stand.

A hole that exceeds the length of the bolt by15mm should be drilled into the floor toaccommodate the fixing see Fig. DM3.8 - FixingStand to Floor.

Fig. DM3.8 - Fixing Stand to Floor


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4 Side Guides

Fig. DM3.10 - Side Guide Fixing Details

Each guide is 25.4mm x 25.4mm zinc platedsquare tube supplied in lengths of 3 metres.

Support brackets are clamped to the conveyorchannels at approximately 1.5 metre spacing. Theguide tubes are located in the brackets andsecured by locking screws.

Guide support brackets are available as single ordouble rail assemblies for 90 or 140 deepchannels. The single rail assembly positions theunderside of the guide tube 40mm above theTOR or TOB.

The double rail assembly positions the undersideof the guide tubes 40mm and 190mm above theTOR or TOB.

To further enhance the smooth lines of the guidesspecial plastic connectors and end caps areavailable.

For coding to order see Reference section.

Fig. DM3.9 Single Side Guide Location


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5 Facia This is an easily fitted accessory, made ofextruded PVC section, which may be added to theconveyor side channels (90mm or 140mm) to givea smooth and neat appearance.

The facia should be fitted after such items aspneumatics or photocells, as their brackets willdictate how lengths are cut.

For coding to order see Reference section.

Fig. DM3.11 Fitting the Facia


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6 Photo Cell and Reflector Brackets

There are two types of PEC/Reflector mountingavailable, metal shielded and plastic.

6.1 Metal Shielded Type

Designed to be used where personnel areworking or constantly passing the conveyor.

In order to protect the PEC, reflector and anypersonnel from catching or obstructing the units, aformed metal shroud is fitted to both the PEC and

reflector mounting brackets.

This shroud does limit the angular rotation (acrossthe conveyor) of the PEC and reflector to 45degrees from the perpendicular.

For codes to order see Reference section.

Fig. DM3.12 - PEC Bracket Assembly

Fig. DM3.13 - Reflector Bracket Assembly


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Fig. DM3.15 - PEC Bracket Assembly

Fig. DM3.16 - Reflector Bracket Assembly

Fig. DM3.14 - Location of PEC Angle Moulding

6.2 Plastic Type

The second type of PEC and Reflector mountingis intended to be used in areas where there isless personnel traffic or where large angular /vertical adjustment is required.

They are not shrouded and therefore are morevulnerable to damage or accidental misalignment.However, they are capable of being rotated muchfurther from the perpendicular than the metal type.

The PEC/Reflector is mounted on a clamp fitted

around a plastic tube. This tube is itself clampedin position by the lower plastic (nylon) moulding.The tube is prevented from rotating in the lowerclamp by a plastic location pip and a self-tappingscrew.

To detect very low height loads (down to 20mmhigh) the PEC can be mounted upside down ifnecessary.

6.3 PEC Angle Moulding

This accessory enable the plastic PEC bracket toaccept the photoelectric cell normally used on themetal shielded PEC bracket assembly.


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Fig. DM3.17 PEC Angle Moulding - Detail

Fig. DM3.18 - PEC Guard Assembly


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7 Encoder Kit

Fig. DM3.19 Encoder Kit Assembly

The encoder wheel is fitted with four metal strips,which are located on one side. When rotating theyare detected via a 18mm diameter proximitysensor mounted to a bracket. This then enables acontrol system to calculate accurate tracking andspeed of packages through a length of conveyor.


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8 Remote Emergency Stop

Fig. DM3.20 Remote Emergency Stop

As part of the safety circuit, running throughouteach system, emergency stop buttons can beinserted into the string at appropriate positions.

Remote Emergency Stop:This is a push buttonemergency stop requiring wiring on site to a motor

junction box nearby utilising the break-in facility.


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Section 4 Product Application

Contents

Heading Page

1 Belt Conveyor Application....................................................... 78

1.1 Below are some typical examples........................................ 78

1.2 Environment......................................................................... 78

2 Loads to be Conveyed............................................................ 79

3 Roller Pitch Selection.............................................................. 79

3.1 Live Roller/Accumaflow........................................................ 79

3.2 Level Belt and Booster Belt (roller bed only)........................ 79

3.3 Incline/Decline...................................................................... 79

3.4 Pitches Available.................................................................. 79

3.5 Minimum Load Sizes Live Roller/Accumaflow................... 80

3.6 Minimum Load Sizes Level Belt / Booster......................... 80

3.7 Conveyor Width Selection.................................................... 80

3.8 Conveyor Speed Selection................................................... 80

3.9 Centre Drive Unit.................................................................. 80

3.10 High Speed Centre Drive Unit.............................................. 80

4 Application of Level Belt Conveyor.......................................... 81

4.1 Level Belt Loadings.............................................................. 81

4.2 Spacing of Stands................................................................ 81

4.3 Mechanical Loading Level Belt - Centre Drive..................... 82

4.4 Mechanical Loading Level Belt - End Drum Drive................ 83

5 Application of Inclines/declines................................................ 84

5.1 Maximum Inclines and Declines........................................... 84

5.2 Load Stability........................................................................ 84

5.3 The following should be considered..................................... 84

5.4 Belt Considerations.............................................................. 86

6 Feeder and Top Curve Angle Positions................................... 87

7 Incline/Decline Loadings.......................................................... 89

7.1 Incline/Decline Structural Loadings...................................... 89


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Heading Page

7.2 Mechanical Loading............................................................. 89

8 Application of Accumaflow....................................................... 90

8.1 Loads.................................................................................... 90

8.2 Selection............................................................................... 90

9 Application of Live Roller......................................................... 90

9.1 Line Pressure ...................................................................... 90

9.2 Structural Loadings.............................................................. 91

9.3 Mechanical Loadings - Centre Drive.................................... 91

9.4 Mechanical Loadings - End Drum Drive............................... 92

10 Application of Metering Belts................................................... 93

10.1 Fast Belt Length .................................................................. 93

10.2 Brake Belt Length................................................................. 93

10.3 Stands ................................................................................. 93

10.4 Loadings............................................................................... 93

11 Horizontal Curve Tangents...................................................... 95

12 Special Loads.......................................................................... 95

12.1 Bag Handling........................................................................ 95

12.2 Tapered Containers.............................................................. 96

12.3 Runners................................................................................ 96

12.4 Partially Filled Containers..................................................... 96

12.5 Wire Baskets........................................................................ 96

12.6 Wooden Boxes..................................................................... 96

12.7 Loads with Uneven Weight Distribution................................ 96

12.8 Recessed Bottoms............................................................... 96

12.9 Bales or Bundles.................................................................. 96

13 Soft Starts and Inverters.......................................................... 97

13.1 Electronic Soft Start.............................................................. 97

13.2 `Motec` Frequency Inverter.................................................. 97

14 Incline Stand Selection............................................................ 98

14.1 Sideguides............................................................................ 100

14.2 Underguards......................................................................... 100


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Heading Page

14.3 Working Areas...................................................................... 100

14.4 Traffic Areas......................................................................... 100

14.5 Transport Areas.................................................................... 100

15 Accumulation .......................................................................... 101

15.1 Loads.................................................................................... 101

16 End Stops ............................................................................... 102

17 End Plates............................................................................... 102

18 System Design Considerations - Mechanical.......................... 103

18.1 Environment......................................................................... 103

18.2 Site Conditions .................................................................... 103

18.3 Product ................................................................................ 103

19 System Design Example ........................................................ 104

19.1 Application ........................................................................... 104

19.2 Deciding on Modules............................................................ 105

19.3 Deciding on Conveyor Width and Speed............................. 105

19.4 Accumaflow Section ............................................................ 106

19.5 Accumaflow Summary.......................................................... 106

19.6 Metering Belt Section........................................................... 106

19.7 Metering Belt Summary........................................................ 106

19.8 Incline Section ..................................................................... 106

19.9 Incline Summary................................................................... 107

19.10 Accessories.......................................................................... 108


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1 Belt Conveyor Application

The type of conveyor to be used in a particularinstallation is dictated by several factors. The typeof package, object or load to be conveyed; theoperation to be performed on the conveyor, if any;and the physical conditions surrounding theinstallation, all play a part in determining the kindof conveyor to be used. It is, of course, impossibleto formulate a standard that would permit properchoice of the type of conveyor best suited to aparticular problem, but the following generalitieswill help.

Use belt conveyors for any load whose shape orconstruction would not result in damage to thebelting.

1.1 Below are some typical examples.

Bottles

Christmas tree ornaments

Pieces of paper

Light bulbs

Fuses

Sticks of chewing gum

Individual packages of food products

Cartons of soap products Paper products

Canned goods

Radio and television cabinets

Belt conveyors, in addition to conveying fragileloads, will convey any load that would travel ongravity conveyor when vertical drop or gradientsare not available.

Belt conveyors are ideally suited to assembly lineoperations as they can be operated at almost anyspeed with equal success. They can be usedwhere speed of travel and spacing of loads must

be controlled.When vertical drop is desired for fragile loads, thebelt conveyor is usually the best solution as it cannegotiate steep declines with complete controlover the speed of the descending load.

The belt conveyor is the most commonly usedpower conveyor because of its versatility.Packages or objects of the smallest size andweighing grams, as well as large sizes can beconveyed with equal ease. Fragile loads can beconveyed successfully.

The conveyors can negotiate inclines or declinesup to 30 with ease. Almost always, the centre ofgravity of the package governs the maximumangle rather than the friction between the surfaceof the belt and the package.

Decline belt conveyors are frequently used inplace of gravity roller or wheel spirals and in placeof spiral chutes when fragile loads are to belowered, or when it is necessary for any reason tocontrol the speed of descending loads.

1.2 Environment

It is very important to obtain full details of thecustomers working conditions.

Examples

Volatile atmosphere - explosion proof motor.

Hot climate - tropical insulation, in this instance wemust know the temperature range, relativehumidity, if air-conditioned site, is salt present inthe atmosphere.

Please contact the engineering department for anyquires regarding special environments or workingconditions


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Fig. DM4.1 Calculating Required Pitch

3 Roller Pitch Selection

3.1 Live Roller/Accumaflow

(Fig DM4.1)

There must be at least 3 rollers under the loadbeing conveyed at any one time. Take theminimum load length and divide by 3 to give themaximum pitch of rollers required.

3.2 Level Belt and Booster Belt (roller bedonly)

The rollers on these conveyors need to be

spaced only close enough to keep the beltingfrom sagging unduly between the idler or carryingrollers. When conveying light loads weighing upto a few kgs, it is only necessary to space therollers at 250mm apart. (Loads as usuallyencountered in department stores and mail orderhouses are examples of the types of loads thatwill operate properly with rollers on 250mm pitch).

On heavy unit loads that are also short it isadvisable to always have at least two rollersunder a load on a booster or level belt conveyor.Loads above 15kg that are less than 500mm longrequire bed rollers spaced at equal or less thanhalf the load length.

2 Loads to be Conveyed

It is important to find out as much about the loadto be conveyed as possible. This is the first stepin successful conveyor design.

The details needed to be known are as follows:

Load Dimensions length, width and height.

Load Weight

The condition of the load must not result indamage to the belting.

Position of the Centre of Gravity in relation to theheight of the load. Is the load likely to topple whenrunning on an incline or decline?

3.3 Incline/Decline

On incline and decline conveyors, two rollersunder the loads are required to prevent "bobbing"and slip back on inclines or slip ahead ondeclines.

3.4 Pitches Available


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3.7 Conveyor Width Selection

Generally, the conveyor width should be selectedto be 50mm wider than the widest load beinghandled. This gives adequate working clearancebetween load and side guiding.

3.8 Conveyor Speed Selection

For general purposes, a speed of 18 metres perminute is adequate for most needs. This speedwould be used where loads have to be placed onor taken off the conveyor when in motion.

When a certain number of loads have to be

transported in a given time, the minimumconveyor speed can be calculated by using thefollowing formula.

(Length of longest load + gap required betweenloads (both in metres)) x loads per minute.

Example:

Longest Load = 500mm

Gap = 100mm

Loads per minute = 20

(0.5m + 0.1m) x 20 = 0.6 x 20 = 12m/min

Looking at the tables below the next standardspeed above 12m/min is 14. This gives ananswer of 14 metres per minute and is theminimum conveyor speed to be used.

3.9 Centre Drive Unit

3.5 Minimum Load Sizes LiveRoller/Accumaflow

3.6 Minimum Load Sizes Level Belt /

Booster

3.10 High Speed Centre Drive Unit


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4 Application of Level Belt Conveyor

4.1 Level Belt Loadings

4.1.1 Structural Loading Level Belt

The belt range of conveyors is designed forpackage handling, (i.e. to be loaded by hand) andshould not under normal conditions be loadedbeyond 60kg per metre.

4.2 Spacing of Stands

The spacing of stands is dependent on theloading on the conveyor or location of them (i.e.

around a centre drive unit). Fig. DM4.2 - StandSpacing Chart shows the maximum spanbetween stands for various conveyor loadings.

WARNING

On level belt conveyors the centredrive unit should be positioned at theback of the conveyor run when lookingat the package direction of travel.

THE BELT RANGE OF POWERCONVEYORS IS DESIGNED FORPACKAGE HANDLING, (I.E. TO BELOADED BY HAND) AND SHOULDNOT UNDER NORMAL CONDITIONSBE LOADED BY HAND BEYOND25KG PER LOAD.

Note

Fig. DM4.2 - Stand Spacing Chart


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4.3 Mechanical Loading Level Belt CentreDrive

The level belt range of conveyors is available witheither 0.75kW or 1.5kW motors and the loadcapability of specific conveyors can be read fromthe loading chart. The figures given on the chartare for both roller bed and mono bed conveyors.

Fig. DM4.3 - Level Belt (centre drive) Loading


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Fig. DM4.4 - Level Belt (end drum drive) Loading Chart

4.4 Mechanical Loading Level Belt - End DrumDrive

The belt range of conveyors is available in threespeeds and the load capability of specificconveyors can be read from the loading chart. Thefigures given on the chart are for both roller bedand mono bed conveyors.


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Table. DM4.1 - Type of Load

5 Application of Inclines/declines

5.1 Maximum Inclines and Declines

The maximum belt angle is a function of thecharacteristics of the load.

The condition of the load itself is the mostimportant consideration. For example, a woodenbox with a flat, rough bottom might negotiate a30 incline while a smooth oily tote box may slideat 20 both on the same belting. While the weightof the load has some effect on friction, theflatness and roughness of the load bottom are

usually the determining factors.

Since it is impractical to determine the exactdegree of roughness and/or "bulge" for every loadno precise engineering formula can be applied.We must therefore, rely on experience "averages"plus personal evaluation of the individual jobconditions.

The following recommendations should beconsidered as high averages when using thefollowing types of loads.

5.2 Load Stability

In many cases the stability of the load is thelimiting factor. For uniformly packed loads thecentre of gravity is close to the geometric centreof the load and can be located at the intersectionof diagonals drawn between opposite corners(refer to Fig. DM4.5 Load Stability). For non-uniform loading (T.V. sets, bottles etc.) the centreof gravity may have no relation to the shape ofthe load. It can be located by "balancing" the loadon each of its four bottom edges and noting theangle of stability in each direction.

Fig. DM4.5 Load Stability

It is well known that under static conditions a loadwill be stable if a perpendicular from its centre ofgravity falls within its base. Unfortunately, beltconveyors do not provide a static condition. Theymust stop and start quickly and a load must beable to absorb forces such as momentum andacceleration without rocking beyond its stabilitypoint resulting in tumbling or tipping.

5.3 The following should be considered.

A short, high load is vulnerable to tilting asmomentum is applied at the long lever arm fromits base to the centre of gravity.

High-speed will apply greater accelerating anddecelerating forces than a low speed unit. Also,the use of brakes will accentuate deceleratingaction.

The bottoms of most loads are not flat but slightlybulging. Some rocking can occur even onhorizontal conveyor beds.


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No precise measurement of all forces is practicaland we must rely on a "rule of thumb" and modifyit by judgement based on the individual jobconditions. The rule states that for reasonablestability under normal conditions, a perpendicularfrom the centre of gravity shall fall within thecentre 1/3 of the base. Thus, for a square load thetheoretical maximum angle is 18. For a goodpackage this could be increased to 20, and for apoor load, Should probably be reduced to 16.Refer to Fig. DM4.6 - Load Stability Check forIncline/Decline Conveyors

The spacing of intermediate section rollers affectsthe amount of "bobbing" or sway in transit. Thecloser the rollers the smoother the action. Monobed section provides the smoothest action.

The contents of loosely packed tote boxes canshift in transit, and change the calculated centreof gravity.

Fig. DM4.6 Load S

Belt Conveyor System

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