Conveyor system

Pneumatic

Every pneumatic system uses pipes or ducts called transport lines that carry a mixture of materials and a stream of air. These materials are free flowing powdery materials like cement and fly ash. Products are moved through tubes by air pressure. Pneumatic conveyors are either carrier systems or dilute-phase systems; carrier systems simply push items from one entry point to one exit point, such as the money-exchanging pneumatic tubes used at a bank drive-through window. Dilute-phase systems use push-pull pressure to guide materials through various entry and exit points. Air compressors or blowers can be used to generate the air flow. Three systems used to generate high-velocity air stream: 

1.Suction or vacuum systems, utilizing a vacuum created in the pipeline to draw the material with the surrounding air. The system operated at a low pressure, which is practically 0.4–0.5 atm below atmosphere, and is utilized mainly in conveying light free flowing materials.

2.Pressure-type systems, in which a positive pressure is used to push material from one point to the next. The system is ideal for conveying material from one loading point to a number of unloading points. It operates at a pressure of 6 atm and upwards.

3.Combination systems, in which a suction system is used to convey material from a number of loading points and a pressure system is employed to deliver it to a number of unloading points.

Vibrating

A vibrating conveyor is a machine with a solid conveying surface which is turned up on the side to form a trough. They are used extensively in food-grade applications to convey dry bulk solids[1] where sanitation, washdown, and low maintenance are essential. Vibrating conveyors are also suitable for harsh, very hot, dirty, or corrosive environments. They can be used to convey newly-cast metal parts which may reach upwards of 1,500 °F (820 °C). Due to the fixed nature of the conveying pans vibrating conveyors can also perform tasks such as sorting, screening, classifying and orienting parts. Vibrating conveyors have been built to convey material at angles exceeding 45° from horizontal using special pan shapes. Flat pans will convey most materials at a 5° incline from horizontal line. 

Flexible

The flexible conveyor is based on a conveyor beam in aluminum or stainless steel, with low-friction slide rails guiding a plastic multi-flexing chain. Products to be conveyed travel directly on the conveyor, or on pallets/carriers. These conveyors can be worked around obstacles and keep production lines flowing. They are made at varying levels and can work in multiple environments. They are used in food packaging, case packing, and pharmaceutical industries and also in large retail stores such as Wal-Mart and Kmart. 

Spiral

Like vertical conveyors, spiral conveyors raise and lower materials to different levels of a facility. In contrast, spiral conveyors are able to transport material loads in a continuous flow. A helical spiral or screw rotates within a sealed tube and the speed makes the product in the conveyor rotate with the screw. The tumbling effect provides a homogeneous mix of particles in the conveyor, which is essential when feeding pre-mixed ingredients and maintaining mixing integrity. Industries that require a higher output of materials - food and beverage, retail case packaging, pharmaceuticals - typically incorporate these conveyors into their systems over standard vertical conveyors due to their ability to facilitate high throughput. Most spiral conveyors also have a lower angle of incline or decline (11 degrees or less) to prevent sliding and tumbling during operation. 

Vertical

Main article: Vertical conveyor

Vertical conveyors, also commonly referred to as freight lifts and material lifts, are conveyor systems used to raise or lower materials to different levels of a facility during the handling process. Examples of these conveyors applied in the industrial assembly process include transporting materials to different floors. While similar in look to freight elevators, vertical conveyors are not equipped to transport people, only materials. 

Vertical lift conveyors contain two adjacent, parallel conveyors for simultaneous upward movement of adjacent surfaces of the parallel conveyors. One of the conveyors normally has spaced apart flights (pans) for transporting bulk food items. The dual conveyors rotate in opposite directions, but are operated from one gear box to ensure equal belt speed. One of the conveyors is pivotally hinged to the other conveyor for swinging the attached conveyor away from the remaining conveyor for access to the facing surfaces of the parallel conveyors.[2] Vertical lift conveyors can be manually or automatically loaded and controlled.[3] Almost all vertical conveyors can be systematically integrated with horizontal conveyors, since both of these conveyor systems work in tandem to create a cohesive material handling assembly line. 

Vertical conveyor with forks

Like spiral conveyors, vertical conveyors that use forks can transport material loads in a continuous flow. With these forks the load can be taken from one horizontal conveyor and put down on another horizontal conveyor on a different level. By adding more forks, more products can be lifted at the same time. Conventional vertical conveyors must have input and output of material loads moving in the same direction. By using forks many combinations of different input- and output- levels in different directions are possible. A vertical conveyor with forks can even be used as a vertical sorter. Compared to a spiral conveyor a vertical conveyor - with or without forks - takes up less space. 

Vertical reciprocating conveyors (or VRC) are another type of unit handling system. Typical applications include moving unit loads between floor levels, working with multiple accumulation conveyors, and interfacing overhead conveyors line. Common material to be conveyed includes pallets, sacks, custom fixtures or product racks and more.

Motorized Drive Roller (MDR)

Motorized Drive Roller (MDR) conveyor utilize drive rollers that have a Brushless DC (BLDC) motor embedded within a conveyor roller tube. A single motorized roller tube is then mechanically linked to a small number of non-powered rollers to create a controllable zone of powered conveyor. A linear collection of these individually powered zones are arranged end to end to form a line of contiguous conveyor. The mechanical performance (torque, speed, efficiency, etc.) of drive rollers equipped with BLDC motors is right in the range of that needed for roller conveyor zones when they need to convey general use carton boxes of the size and weight seen in typical modern warehouse and distribution applications. A typical motorized roller conveyor zone can handle carton items weighing up to approximately 35 kg (75 lbs.). Because each zone can be individually controlled, this style of conveyor lends itself to network based distributed control systems and as such the technology is very often used as Zero Pressure Accumulation (ZPA) conveyor.The same motor technology has also been applied to higher gear reduction ratios such that pallet handling conveyors can be built with 24VDC Motorized Drive Rollers that can convey loads in the 500 kg to 1000 kg range (1000 to 2000 lbs)

There are many types of conveyor systems and roller conveyor equipment manufacturers world-wide and each can offer variations to this basic concept that either increases performance (and cost) or even reduces performance (and cost). Because roller conveyor equipment can economically handle cartons that are in the physical size range of mail and on-line order shipments; roller conveyor equipment and systems that utilize this technology have been growing steadily in number over the last 20 years because of the popularity of internet based shopping. The technology has grown to the level that the Conveyor Equipment Manufacturer's Association (CEMA) has separate and distinct guidelines for its application

Here are some advantages to MDR conveyor versus conventional (AC gearmotor driven) conveyor

• Less noise than conventional AC gearmotor driven conveyor

• Less power consumption over time compared to AC gearmotor driven conveyor and pneumatic devices

• Safer for operating and maintenance personnel compared to AC gearmotor

These advantages often make MDR conveyor a popular choice for conveyors in acilities, as well as general operations where operator ergonomics and safety are considerations. 

Heavy-duty roller

Heavy-duty roller conveyors are used for moving items that weigh at least 500 pounds (230 kg). This type of conveyor makes the handling of such heavy equipment/products easier and more time effective. Many of the heavy duty roller conveyors can move as fast as 75 feet per minute (23 m/min). 

Other types of heavy-duty roller conveyors are gravity roller conveyors, chain-driven live roller conveyors, pallet accumulation conveyors, multi-strand chain conveyors, and chain and roller transfers. 

Gravity roller conveyors are easy to use and are used in many different types of industries such as automotive and retail. 

Chain-driven live roller conveyors are used for single or bi-directional material handling. Large, heavy loads are moved by chain driven live roller conveyors. 

Pallet accumulation conveyors are powered through a mechanical clutch. This is used instead of individually powered and controlled sections of conveyors. 

Multi-strand chain conveyors are used for double-pitch roller chains. Products that cannot be moved on traditional roller conveyors can be moved by a multi-strand chain conveyor. 

Chain and roller conveyors are short runs of two or more strands of double-pitch chain conveyors built into a chain-driven line roller conveyor. These pop up under the load and move the load off of the conveyor.