What is the Conveyor system?
A conveyor system provides rapid and efficient movement of loads and materials with a completely mechanical device for handling. Conveyor systems may consist of a belt, wheels, rollers or chains to transport the items.
A conveyor system is a very common piece of mechanical handling equipment that moves materials from Point A to Point B. Conveyors are particularly useful for heavy or bulky items.
Quickly and efficiently able to move a number of different types of materials, these systems are used in virtually all industries related to the material handling and packaging; even consumer markets have practical uses for conveyor systems as they are quite prevalent in grocery stores and airports delivering the last leg of product/bag delivery to the customer.
Conveyors are available in a variety of types and applications may vary between industries. There are also chain conveyors (either floor or overhead). Chain systems consist of I-Beam, enclosed tracks, towline, power & free and hand pushed trolleys.
This system not only reduces human error, and management of operations (therefore reducing occupational health and safety risks) and operational costs, but are also practical for moving bulky or heavy items from defined points.
How do conveyor systems Work?
Conveyor systems generally utilize a conveyor belt stretched between multiple pulleys with a closed loop formed around the pulleys to allow the belt to be continuously rotating.
One of the pulleys, the drive pulley, powers or tugs the conveyor belt, and therefore moves the associated items from one point to another.
The most common conveyor system design operates with a rotor that powers the drive pulley and belt through friction between the drive pulley and the belt and friction between the rotor and the drive pulley.
In order for the belt to rotate correctly the drive pulley and idler must go in the same rotational direction, either clockwise or counterclockwise.
Also, while conventional conveyor systems with moving walkways and grocery store conveyor systems may operate in straight lines, frequently th conveyor system is required to move to provide the proper delivery of items.
In order to allow for turns, specialized cone-shaped wheels/ rotors that allow the belt motion to follow a bend / twist without entangling.
Benefits of using a conveyor system
- Can effectively and safely move items from one level to another via an elevated conveyor system
- Can be installed in most cases and typically provide value and safety as they automate the process, provide failsafe’s, and have safeguarding devices
- Conveyor systems can move large amounts of items in various shapes, sizes, and weights
- Conveyor systems provide excellent safety features that limit accidents and injuries while increases throughput and efficiency to the system
- Conveyor systems can run in many ways, by hydraulic, mechanical, and fully automated systems that fit the business’ needs
Types of conveyor systems
As touched on briefly earlier there are a variety of conveyor systems that can be used and which conveyor you use or buy depends on what you want the conveyor system to do – for example, it would not make much sense to use a roller conveyor to get people to walk faster between two different terminals at an airport, that would be best served with a belt conveyor system.
1. Belt Conveyors
Belt conveyors are the most prevalent and simplest conveyor and will have variable speeds. Belt conveyors utilize a moving belt on a structural steel frame that supports the belt and material.
If the support is provided from a stationary structure under the belt, this is called sliding style. When rollers are used to support the belt with a small distance between the rollers, this is called a roller belt style.
Advantages:
- One of the cheapest conveyors
- Simple and easy to use
- Can have changes in elevation
- Can be loaded from any place along the belt
Disadvantages:
- Simplicity denotes severe limitations in features.
- Belt systems can be problematic to clean and typically do not deliver great outcomes.
- Sticky materials can get stuck on the belt and transfer to the return side, the rolls, idlers and pulleys.
2. Gravity Roller Conveyors
Gravity roller conveyors consist of a fixed number of rollers that are spaced evenly apart and connected to a side frame.
Where the rollers are positioned provides an intended location for materials to be placed to be moved. If a gravity roller conveyor is inclined or has an angle of attack, materials will move through the effects of gravity.
While pieces of different sizes can be loaded onto a gravity roller conveyor, operators should be mindful of oversized materials running into smaller ones. Shipping company’s use gravity roller conveyors to load and unload trucks.
Advantages:
- Gravity can be utilized for transportation of the product across a decline.
- No power means less costs and a greener outcome.
- Highly modular and can be used for many purposes.
- Relatively low maintenance.
Disadvantages:
- Products may end up being damaged when moved by gravity
- Heavy and therefore not very portable
- No control of conveyor speed
3. Chain Conveyors
Chain conveyors may have two or more sets of chains, which make contact with the bottoms of the items to be moved, and these materials rest upon the chains under transport.
Chain driven conveyors are ideally suited for items with uneven bottom surfaces or for items that are very heavy. Items with a heavy frame can have pallets placed directly on them. Because of the types of items chain conveyors move they have slow operating speeds.
4. Motorized Roller Conveyors
Motorized roller conveyors are fitted with motors, located with the conveyor frame, to drive evenly spaced rollers.
A motorized roller conveyor is comparable to a gravity conveyor, except that it contains motors. The number of motors will depend upon both the load to be moved and the design of the system.
The connection between the rollers can be chain or a belt. In some systems there is a sensor that starts and stops the motor to prevent pieces from getting packed together.
5. Slat Conveyors
Slat conveyors share the same design features as chain conveyors, including flat slats attached to the chain. In some ways they also function like belt conveyors, where the belt was replaced by slats.
Slats have a very smooth surface that does not damage or harm items being conveyed and are very useful for assembly applications. Slat conveyors can also be robotically automated to load and unload parts due to the smooth surface and the absence of protrusions on the surface of the slats.
6. Overhead Trolley Systems
Overhead, trolley track systems have manual or motor capabilities for movement. Using an enclosed track or “I” beam allows cart systems to elevate and move parts through finishing operations, drying booths or supplying assembly lines.
7. Monorail Conveyors
Monorail conveying systems consist of carriers that transport materials and are perfect for long distances. The rails are suspended from the structure of the building and are energized by signaling lines from the conductor lines that supply power through the mounting rails.
Monorail conveyors make use of overhead space over the production area. In some application designs, the carriers lower to the production level and then rise up and away.
8. Power and Free Conveyors
Power-and-free conveying systems are specifically designed to move parts through the manufacturing and assembly process. The items are assembled in the individual workstation style. The items being assembled move from workstation to workstation.
They stop at each workstation to be worked on and leave the workstation and then move on. Power-and-free systems are a special overhead conveying system.
9. Inverted Conveyors
Inverted conveyors are mounted on the floor and may be used as power and free conveyors. These generally have a drive system that does not involve a belt or chain.
10. Paternoster Conveyors
Paternoster conveyors are a vertical type of conveying system using equal spacing of load carriers that are linked together by a continuous loop chain drive. They are sometimes referred to as platform conveyors.
11. Chute Conveyors
Chute conveyors have an even flat surface of wood, metal or plastic on an incline in a frame, and can be straight, spiral or circular. The material is slid down the surface to move it from one elevation to another.
12. Screw Conveyors
Screw conveyors are designed to move bulk materials such as grains, chips and loose materials. The screw conveyor consists of a rotating helicoid, which is placed on a shaft, and is contained within a pipe.
Screw conveyors are also known as augers, helix conveyor systems, and spiral conveyors. The blades provide a helix movement to the material, which moves the material upward.
13. Pneumatic Conveyors
Pneumatic conveyors move bulk materials using a pressurized gas to transport the bulk material in a closed pipeline. As pressure builds in the pipe, powders or granular materials are lifted and transported through the pipe.
14. Vibratory Conveyors
A vibratory conveyor relies on vibration to transport materials along a conveying trough, and it is designed to move agricultural products like grains, solids, vegetables being harvested in a field, and quarried rock.
The motioning and agitation moves the products either gently or quickly through the use of cycles of vibration. Each form of vibratory conveyor has a design that serves its specific function; the designs for mining conveyors are radically different than those designed for harvesting and food production.
FAQs
What is the most common conveyor system?
A belt conveyor, also called a conveyor belt, is a fairly simple conveyor with limited features mainly used to move bulk materials such as sand, salt and grain. Its simplicity makes it easy to use and also makes it one of the most common types of conveyors.
What is conveyor system design?
In simple terms, a conveyor system is a piece of equipment designed to efficiently move goods, ingredients or materials from one location to another. An intelligently designed conveyor system can improve production outputs, reduce the need for manual handling, increase factory space and even lower operational costs.
How important is the conveyor system?
Conveyor Systems Help Automating Human Operations
Likewise, they are installed to automate the transportation of products or goods around your workplace. Thus, reducing the length and complexity of task completion for your workforce. Meanwhile, the amount of time saved will ensure a higher level of productivity.
Where is conveyor used?
The applications of a conveyor system in manufacturing can include being used on a car manufacturing line, a production line for electrical goods, and a food production line for baked food. The way a conveyor is used in this environment is by moving the product from one point to the next.
What are the three types of conveyors?
There are several types of conveyor systems, including belt, roller, overhead, and pneumatic conveyors. Each type has unique characteristics and uses across different industries.
What is the basic conveyor system?
The most common type of conveyor, in its most basic form, is an end drive belt conveyor; such as one sees in the grocery store check-out. This consists of a frame with a driven pulley or drum on one end, and an idler pulley or drum on the other end; with an endless belt looped around both pulleys and frame.