Conveyor Technology Case Studies
Vacuum conveyor for transporting coffee capsules
During the production of coffee capsules, it is crucial to transport them out of the filling system securely to prevent tipping. A multi-gripper on a linear axis discharges 16 capsules in 2 rows, completing a cycle in 2.4 seconds. To clear the storage position, the capsules need to be moved 860 mm within 0.9 seconds. Additionally, a straight section of the track functions as an unloading station for random sampling, facilitated by an air blast. At the end of the conveying path, a 90° rotation is necessary to transfer the capsules to the subsequent customer conveyor.
An optimal solution was devised using a pair of interconnected belt conveyors. The loading area employs a GUF-P 2000 belt conveyor with a vacuum function, directly linked to the filling system. The belt conveyor remains stationary as capsule packages are placed on it. In order to index the capsules 860 mm in 0.9 seconds, a servo motor was designed with a speed of approx. 75 m/min and an acceleration of approx. 3 m/s². Constant vacuum within the conveyor frame and rows of holes in the belt prevent capsule tilting or slipping. Following the random sampling process, capsules are transferred to the second conveyor for further processing, which operates continuously without a vacuum function. A rolling knife edge at the discharge end of the vacuum conveyor ensures smooth capsule transfer. Both conveyors are equipped with side rails tailored to the product’s geometry.
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Cooling conveyor system for a robot welding cell
The welded components need to undergo a cooling process during transportation to the subsequent station within a robot welding facility, allowing for subsequent slag removal. The products require approximately four minutes cooling time. This necessitates a conveyor system capable of transporting the products across both straight and curved sections. The placement of products on the cooling line is handled by a robot, while manual removal occurs at the end of the cooling line. Additionally, the design must ensure access to the interior of the plant for maintenance purposes, with the access area capable of being opened twice daily. The welding seam temperature will briefly reach 800 °C, and the products weigh between six to eight kilograms. The welding system achieves a throughput of two units per minute, and the conveyor must be resilient to the abrasive conditions
The cooling line is constructed using multiple SBF-P flat top chain conveyors, featuring both curved and straight sections. A durable steel chain, designed to withstand the brief high temperatures of welding seams, serves as the transportation medium. With a conveyor speed of 5 m/min and the track layout, the welded components have ample time to cool down to an appropriate temperature. The ergonomic conveyor height of 800 mm facilitates easy removal of parts by workers at the end of the line. For access to the system’s interior, a foldable GUF-P 2000, equipped with a wire mesh belt for transportation, can be effortlessly swivelled upwards by 90° using handles.
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Interlinking transportation for canisters using a conveyor bridge
Two machining stations within the plastic canister production process require interlinking. The challenge lies in managing spatial limitations: Empty canisters must traverse a curve and pass another machine, ultimately returning to the original feed height at the discharge point for accumulation. The transportation of canisters occurs in an upright position and transversely to the conveying direction, with the requirement that their alignment remains consistent at the end of the system as it was at the entry point. Each canister weighs approximately two kilograms. It is crucial for the interlink to operate reliably in a two-shift operation. Furthermore, additional spatial constraints regarding the length and height of the interlink must be taken into account.
A transportation system is constructed using the mk modular construction kit. A KMF-P 2040 curved modular belt conveyor is used to feed the products in, enabling seamless transport of canisters without the need for complicated stops and turns. For the incline, two ZRF-P 2040 timing belt conveyors with a longitudinally grooved timing belt are employed, set at an upward incline of approximately 30°. The canisters move between these two lines, and the high friction of the timing belt, along with gentle clamping, ensures upward transportation. Precise synchronization of the two timing belt conveyor lines is achieved using a closed-loop controller, eliminating any offset. A GUF-P 2000 belt conveyor functions as the bridge, while two additional timing belt conveyors facilitate the downward transport of canisters. A discharge and removal station utilizes an additional belt conveyor with an end stop. The entire framework is constructed using the mk profile construction kit.
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TÜV test rig for baby strollers
Testing baby strollers involves simulating various ground conditions using standardised obstacles. The conveyor belt’s speed should be adjustable, reaching up to 10 km/h (170 m/min), equivalent to a moderate jogging pace. The maximum total load for testing is 150 kg.
The GUF-P 2004 belt conveyor was equipped with a timing belt drive and balanced rollers. A wire hook connection ensures easy belt change. Standardised obstacles were screwed onto the belt. To mitigate intense vibrations resulting from the cleats, the conveyor belt was supported on metal vibration buffers. Magnetic pull switches were implemented to provide a shutdown safety feature.
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Fast transportation of cylindrical battery cells in battery pack production
Cylindrical battery cells, each with a diameter of 46mm (height ranging from 80 to 120 mm) and weighing 0.3 kg per unit, are delivered to the goods-in department of an automotive manufacturer for battery pack production. In this department, robots batch-deliver the cells to the assembly process, arranging them on a belt conveyor.
On this conveyor, the DMC code of each cell needs to be scanned. Additionally, the cells undergo a cleaning process, visual inspection, and electrical testing to identify and separate defective units. Subsequently, the cells, now in an upright position, face a height difference of approximately 2500 mm to progress to the next processing stage in a position-oriented manner.
The transportation of these goods should be pallet-free, ensuring smooth flow, maximum throughput, and high process reliability.
The Versaflex A06 flat top chain conveyor system proves to be an optimal choice for the secure transportation of vertically oriented battery cells. In the horizontal segments, side rails with a 48 mm clearance effectively maintain the cells in an upright position, ensuring their proper alignment for subsequent process steps.
For inclined transport, a clamping conveyor, also referred to as a double-grip conveyor, emerges as the most effective solution. Two Versaflex A06 conveying tracks positioned directly opposite each other utilize flexible cams to laterally clamp the cells, facilitating their vertical transport to another level. The conveyor ascends rapidly and smoothly to a height of 3400 mm.
Operating at a speed of 480 mm/s (28 m/min), equivalent to a cycle time of 0.1 seconds per unit or a throughput of 600 cells per minute, the conveyor system covers a total conveying path length of approximately 20 m, including the horizontal sections before and after the incline. The utilization of a clamping device allows for bridging a substantial height difference over a relatively short distance through a steep incline.
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Automation line for motor assembly
Motor blocks and cylinder heads are manufactured and assembled at an automobile manufacturer. Various motor components need to be flexibly supplied for mounting on the main line so that they can be subsequently assembled. There is no interim storage on the assembly line, meaning that production occurs just in time, which requires a certain degree of flexibility. Zones for walking and driving must remain clear with a relatively low flow rate.
Meeting the specified requirements, a solution utilising Automated Guided Vehicles (AGVs) along with suitable mobile racks and load handling equipment proved optimal. mk provided mobile racks designed to be coupled and towed by the AGVs, allowing flexible transportation to various stations. Driven roller conveyors serve as load handling equipment on the racks, facilitating the transport of motor components onto the AGVs and subsequent lines at the stations. In one instance, a roller conveyor with divided rollers and a centre guide was engineered for the specific product. Friction wheels, attached to both the roller conveyor and the corresponding station, drive the roller conveyors, eliminating the need for a dedicated motor and ensuring they are not reliant on the AGV’s battery supply.
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