Conveyor Equipment Manufacturers Association · FOR CEMA REVIEW OF STD. 407-UNIT HANDLING SECTION- NOT AUTHORIZED FOR DISTRIBUTION-06/04/2018 CEMA Standard No. 407-2015 – Motor

THE VOICE OF THE CONVEYOR INDUSTRY OF THE AMERICAS

AGENDA OF THE CEMA ENGINEERING CONFERENCE UNIT HANDLING SECTION MEETING

Tuesday, June 26, 2018 – 8:00 am

1. Call to order

2. Review of the committee purpose The purpose of the Unit Handling committee is to prepare and govern CEMA publications and standards relative to Unit Handling conveyors. This is conducted in support of the CEMA organizational purpose of promoting standardization of design, safety, manufacture and application on a voluntary basis and in such manner as will not impede development of conveying equipment and component parts or lessen competition

3. Attendance and introductions

4. Review and approval of previous minutes (attached)

5. Old Business a) CEMA Standards for Unit Handling

1. ANSI/CEMA Std. No. 102 Conveyor Terms & Definitions – Status update from the subcommittee and Bulk Handling group inputs

2. CEMA 401 – 2003 (R2015) Roller Conveyors (Dan Modzeleski) 3. CEMA 402 – 2003 (R2015) Belt Conveyors (Ron Wagner) 4. CEMA 403 – 2003 (R2015) Belt Driven Live Roller Conveyors (Boyce Bonham) 5. CEMA 404 – 2003 (R2015) Chain Driven Live Roller Conveyors (Need steward) 6. CEMA 405 – 2003 (R2015) Slat Conveyors (Boyce Bonham) 7. CEMA 406 – 2003 (R2015) Line Shaft Driven Conveyors (Need steward) 8. CEMA 407 – 2015 Motor Driven Live Roller Conveyors (Randy Carlson) 9. CEMA 601 – 1995 Overhead Trolley Conveyors (Mike Wohletz)

b) Review documented Manufactures of equipment relative to each standard

1. CEMA 401 – Dematic, Honeywell Intelligrated, Hytrol, and Arrowhead 2. CEMA 402 – Honeywell Intelligrated, Dematic, Hytrol, Transnorm, Interoll,

Arrowhead, Bunting Magnetics, and Talos 3. CEMA 403 – Intelligrated, Dematic, and Hytrol 4. CEMA 404 – Dematic, Honeywell Intelligrated, Hytrol, and Arrowhead 5. CEMA 405 – Dematic, Honeywell Intelligrated, and Hytrol 6. CEMA 406 – Dematic, Honeywell Intelligrated, and Hytrol 7. CEMA 407 – Dematic, Honeywell Intelligrated, Hytrol, and Wynright 8. CEMA 601 – Companies involved??

Conveyor Equipment Manufacturers Association


c) CEMA Unit Safety Video – Status, inventory and sales

d) CEMA Application Guide for Unit Handling Conveyors, 2nd Edition ‐ Status, inventory and sales

e) Industry Standard Updates i. NFPA79 ii. others

f) MDR Safety Review Committee

i. Review work by sub‐committee, Randy Carlson

g) The Current Technology and Codes Associated to Motors – Presentation by Charlie Ritinski, Jim Alt and Stephanie Berry

d) Additional Conveyor Products under review for CEMA Standards – Updates

1. Extendible Conveyors i. Mike Hake will lead the investigation with assistance of Dan Modzeleski and

Bart Natoli 2. Loop Sorters

i. Rodney Mishmash will lead the investigation with assistance of Shawn Grubb and Randy Carlson

6. Election of a 2nd Vice Chair for Engineering Conference for the Unit Handling Section

7. New Business

a) Submit CEMA Std. No. 407 to consensus for ANSI Certification (Attached) b) CEMA Std. 601 – Review Proposal (Attached) c) CEMA Whitepaper – Volunteers needed (Sample attached)

8. Next Meeting – June 25, 2019, La Playa Hotel, Naples, FL

9. Adjourn

Ron Wagner, Chair


MINUTES OF THE CEMA ENGINEERING CONFERENCE UNIT HANDLING SECTION MEETING

Tuesday, June 27, 2017

1. Ron Wagner, called the meeting to order at 8:00 am

2. The committee purpose was read.

3. An attendance sheet was circulated. See list attached.

4. Reviewed minutes of 2016 meeting. The date was amended and minutes approved

5. Old Business

a. CEMA Standards for Unit Handling were reviewed for change. A general request was made for the stewards to review each standard for a 21st century look.

i. CEMA 102 – Terms and Definitions (Chris Maines, Intelligrated) 1. Work assigned during 2016 meeting to review and upgrade graphics

is still underway by Joe Pahlow, Arrowhead Conveyor Corp. and Brandy Lloyd, Hytrol Conveyor Company.

2. A secondary sub-committee was created to review for additional content updates such as required additions or deletions, or updated information. Sub-Committee: Raul Peña Longoria (chair), Dan Modzeleski & Rob Gruendel, Dematic; Boyce Bonham, Hytrol Conveyor Company; Charlie Ritinski, Sumitomo Machinery Corp.; Shawn Grubb, Intelligrated; Andy Eckerle, Bastian Solutions.

3. Ron Wagner from Intelligrated will coordinate with Edwin McDonald from Komatsu Mining Corp. for members and participation from the Bulk Handling group.

ii. CEMA 401 – 2003 (R2015) Roller Conveyors (Dan Modzeleski, Dematic) 1. No content changes required. 2. Steward changed from Mike McGettigan, Dematic to Dan Modzeleski,

Dematic. iii. CEMA 402 – 2003 (R2015) Belt Conveyors (Ron Wagner, Intelligrated)

1. No changes required. iv. CEMA 403 – 2003 (R2015) Belt Driven Live Roller Conveyors (Boyce Bonham,



Hytrol Conveyor Company) 1. No changes required.

v. CEMA 404 – 2003 (R2015) Chain Driven Live Roller Conveyors (Brandy Lloyd, Hytrol Conveyor Company)

1. Change the assigned steward from Chris Glenn, Hytrol Conveyor Company to Brandy Lloyd, Hytrol Conveyor Company.

vi. CEMA 405 – 2003 (R2015) Slat Conveyors (Boyce Bonham, Hytrol Conveyor Company)

1. No changes required. vii. CEMA 406 – 2003 (R2015) Line Shaft Driven Conveyors (Brandy Lloyd, Hytrol

Conveyor Company ) 1. Change the assigned steward from Chris Glenn, Hytrol Conveyor

Company to Brandy Lloyd, Hytrol Conveyor Company. viii. CEMA 407 – 2015 Motor Driven Live Roller Conveyors (Randy Carlson,

Dematic) 1. Added 407 to the review list

ix. CEMA 601 – 1995 Overhead Trolley Conveyors (Mike Wohletz, Automatic Systems, Inc.)

1. Added Mike Wohletz as steward. b. New Standards/Guides for Unit Handling

i. Design and Application of Personnel Barriers Adjacent to Elevated Unit Handling Conveyors (Dan Modzeleski, Dematic) See Attached Draft SBP-005

1. The SBP was approved at the Fall 2016 meeting. c. CEMA Unit Handling Safety Documents

i. Unit Handling Safety Video sub Committee report (Boyce Bonham, Hytrol Conveyor Company)

1. Boyce Bonham provided a status update of the project along with update from feedback of the Safety Committee meeting on 6/26/17. The ownership of the sub-committee is now with the safety committee.

d. Safety Documents Needed or Under Development i. A suggestion was presented in 2016 to associate the generic terms of

“Safety Yellow” and “Safety Orange” paint to a technical specification. The intent would be to have one common recognized definition to alleviate multiple definitions amongst member companies and customers. Sub-Committee: Bill Brungs, Intelligrated (chair); Dan Modzeleski, Dematic; Brandy Lloyd, Hytrol Conveyor Company; Don Suderman, Bunting Magnetics; Rodney Mishmash, Interroll.


1. Bill Brungs, lead of the sub-committee, provided a status update of the project along with update from feedback of the Safety Committee meeting on 6/26/17. The ownership of the sub-committee is now with the safety committee.

e. Controls Committee update (Rob Gruendel, Dematic) i. Rob provided an update of Controls Committee work.

f. CEMA Application Guide for Unit Handling Conveyors 2nd Edition (Chris Maines, Intelligrated)

i. Chris Maines provided an update as to status of the book. The book published in 2016.

g. Reviewed documented Manufactures of equipment relative to each standard 1. CEMA 401 – Dematic, Intelligrated, Hytrol, Arrowhead

a. Add Wynright, Bastian and Interroll 2. CEMA 402 - Intelligrated, Dematic, Hytrol, Transnorm, Interoll and

Arrowhead, Bunting magnetics, Talos a. Add Wynright and Bastian

3. CEMA 403 - Intelligrated, Dematic, Hytrol a. Add Wynright, Bastian and Arrowhead

4. CEMA 404 – Dematic, Intelligrated, Hytrol, Arrowhead a. No Change

5. CEMA 405 – Dematic, Intelligrated, Hytrol a. Add Wynright and Bastian

6. CEMA 406 – Dematic, Intelligrated, Hytrol a. No Change

7. CEMA 407 – Dematic, Intelligrated, Hytrol, Wymright a. Add Interroll, Bastian and Itoh

h. NFPA79 Updates i. Bill Brungs (Intelligrated) and Rob Gruendel (Dematic) provided a brief

overview of revision cycle. It was suggested that each member company review the standard and participate in the public review.

i. MDR Safety Review Committee i. The sub-committee reports to the Safety Committee.

6. New Business

a. Nomination of Unit Handling Chair and Vice Chair i. Chris Maines, Intelligrated; 2017 Vice Chair, will not be returning next year.

Both seats were required to be filled. There were no volunteers for the chair, and a nomination of Ron Wagner, Intelligrated; was made and


approved. The vice chair position nomination was Brandy Lloyd, Hytrol; which was approved.

b. CEMA Marketing whitepaper. The request was reviewed with committee. Boyce Bonham, Hytrol; and Dan Modzeleski, Dematic; will produce the white paper. The initial topic of the Safety Video will be explored, with more content possible.

c. The topic of ANSI standards and the review recycle was brought up for discussion relative to most members not understanding the process and timing.

i. Ron Wagner, Intelligrated; will coordinate through Phil Hannigan, CEMA; to determine if we can provide reference to the ANSI procedure, or provide a summary version.

d. Additional Conveyor Products were brought up for discussion to determine if CEMA standards would be appropriate.

i. Extendible Conveyors 1. Mike Hake, Transnorm System; will lead the investigation with the

assistance of Dan Modzeleski, Dematic and Bart Natoli, Habasit America.

ii. Loop Sorters 1. Rodney Mishmash, Interroll Corp.; will lead the investigation with the

assistance of Shawn Grubb, Intelligrated and Randy Carlson, Dematic. e. The current technology and codes associated to motors was brought up for

discussion. Many organizations are being asked by the customer base about technology being presented for public view.

i. A sub-committee was created to review and provide an update to the UH meeting next year. Sub-Committee: Charlie Ritinski, Sumitomo Machinery Corp.; Jim Alt, Nord; and Stephanie Berry, Stober Drives.

7. Next Meeting – June 26, 2018 – La Playa Hotel, Naples, FL

8. The meeting was adjourned.

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CEMA Standard No. 407 - 2015 Approved: September 16, 2015

CEMA Standard No. 407

Motor Driven Live Roller (MDR) Conveyors


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CEMA Standard No. 407-2015 – Motor Driven Live Roller (MDR) Conveyors

II

DISCLAIMER The information provided herein in advisory only. These recommendations provided by CEMA are general in nature and are not intended as a substitute for professional advice. Users should seek the advice, supervision and/or consultation of qualified engineers, safety consultants, and other qualified professionals. Any use of this publication, or any information contained herein, or any other CEMA publication is made with agreement and understanding that the user and the user’s company assume full responsibility for the designs, safety, specifications, suitability and adequacy of any conveyor system, system component, mechanical or electrical device designed or manufactured using this information. The user and user’s company understand and agree that CEMA, its member companies, its officers, agents and employees are not and shall not be liable in any manner under any theory of liability to anyone for reliance on or use of these recommendations. The user and the user’s companies agree to release, hold harmless and indemnify and defend CEMA, its member companies, successors, assigns, officers, agents and employees from any and all claims of liability, costs, fees (including attorney’s fees), or damages arising in any way out of the use of this information. CEMA and its member companies, successors, assigns, officers, agents and employees make no representations or warranties whatsoever, either expressed or implied, about the information contained herein, including, but not limited to, representations or warranties that the information and recommendations contained herein conform to any federal, state or local laws, regulations, guidelines or ordinances.

Conveyor Equipment Manufacturers Association 5672 Strand Ct., Suite 2

Naples, Florida 34110 - 3314 www.cemanet.org Copyright © 2015

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FOREWORD Motor Driven Live Roller (MDR) Conveyors – Conveyors which use individual motors and rollers as a carrying surface, or utilize a belt as a carrying medium – are used for the controlled movement of a great variety of regular or irregular shaped loads, from light and fragile to heavy and rugged unit loads.

The path may be horizontal, inclined or declined, limited by the stability of the load and the friction between the carrying surface and the load.

MDR conveyors typically can be set-up to the speed best suited for the work being performed, and in some cases variable speeds can be used. They are used where unit loads are allowed to accumulate, typically with no load to load contact, causing blocked line conditions, as a pace setter for assembly operation, for loading on and off, or for transportation.

The Unit Handling Conveyor Section of the Conveyor Equipment Manufacturers Association has the responsibility for maintenance of this standard. The purpose of this standard is to establish certain minimum standards for use in the design and application of motor driven live roller conveyors. For additional information relating to definitions and selection of common components, see current edition of ANSI/CEMA Standard No. 102, Conveyor Terms and Definitions. The illustrations throughout this book are schematic in nature and represent the general nature of a particular device. The illustrations are not intended to represent the recommended safety configurations since guarding has been omitted to permit clarity in showing the operational characteristics of the device. Refer to the current editions of ANSI/ASME B20.1, Safety Standard for Conveyors and Related Equipment; ANSI/ASME B15.1, Safety Standard for Mechanical Power Transmission Apparatus; and ANSI Z244.1, American National Safety Standards for Lock-out/Tag-out of Energy Sources - Minimum Safety Requirements; Title 29, Code of Federal Regulations (29 C.F.R.) Part 1910.147, The Control of Hazardous Energy (lock-out/tag-out); Title 29, Code of Federal Regulations (29 C.F.R.) Part 1910 Subpart O, Machinery and Machine Guarding. Consult ASME or ANSI for the latest editions.

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TABLE OF CONTENTS

Page Sections

1 Definitions 1 Typical cross section 3

2 Applications 5 Conveyor width 5 Speed and load 7 Conveyor bed 7 Straight beds 8 Inclined / declines conveyors 8 Slope 8 Nose-overs / power feeder 9 Curves 9 Transfer / diverters 9 Merge Spurs 10 Control options 10 Supports 11 Belting selection 11

3 Technical Data 12 Roller selection 12 Torque requirements 12 Speed requirements 13

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SAFETY NOTICE The Conveyor Equipment Manufacturers Association has developed Industry Standard Safety Labels for use on the conveying equipment of its member companies. The purpose of the labels is to identify common and uncommon hazards, conditions, and unsafe practices which can injure, or cause the death of, the unwary or inattentive person who is working at or around conveying equipment. The labels are available for sale to member companies and non-member companies. A full description of the labels, their purpose, and guidelines on where to place the labels on typical equipment, has been published in CEMA’s Safety Label Brochure No. 201. The Brochure is available for purchase by members and non-members of the Association. Safety Labels and Safety Label Placement Guidelines, originally published in the Brochure, are also available free on the CEMA Web Site at http://www.cemanet.org/safety-labels-2/ Please Note: Should any of the safety labels supplied by the equipment manufacturer become unreadable for any reason, the equipment USER is then responsible for replacement and location of these safety labels. Replacement labels and placement guidelines can be obtained by contacting your equipment supplier or CEMA.

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SECTION 1 - DEFINITIONS Conveyor, Width - The dimension inside to inside (BF) of frame rails. Frame, Conveyor - The structural member which supports the machinery components of a conveyor. Guide Rails - Members paralleling the path of a conveyor and limiting the product on the conveyor to movement in a defined path. Hand - The right hand or left hand of a conveyor is determined by facing the direction in which the material is flowing. Horizontal Curve - A conveyor section used to change the direction of travel. The curved radius is measured to the inside face of the inside frame rail. The hand of the curve is determined by facing in the direction of the unit load and visually observing the unit load travel. Right hand curves transport unit loads to the right and left hand curves to the left. Pop - Out Roller - A special load carrying roller mounted in such a manner as to pop out when foreign objects are introduced between the belt and the roller. Roller Bed - A bed utilizing a series of rollers and channels used to support a conveyed load. Slider Bed - A stationary surface used to support a conveyed load. Roller; Carrier - A cylindrical member with internal bearings mounted on a non-rotating shaft. Carrying Rollers - A series of rollers used to support a conveyed load. Snub Roller - Any roller used to increase the arc of contact between a belt and drive or tail pulley. Tracking training - The process of adjusting conveyor components and loading conditions in a manner which will correct any tendency of the belt to run other than centrally. Motorized Roller (or Drive Roller) - A roller similar to a carrying roller but contains an internal motor that turns the external tube when the axle is captured in the frame. Drive Bands or Belts (round) - Elastic bands made from a round plastic, typically urethane, and are approximately 3/16 – 1/4 inches in diameter. They are available in variable lengths to accommodate different roller centers and band tensions to transmit power from a motorized roller to carrying rollers. Drive Bands or Belts (Poly-V) - Semi-Elastic bands that are flat in nature with multiple V profiles used to engage a similarly profiled hub on a roller. They are available in variable lengths to accommodate different roller centers and band tensions to transmit power from a motorized roller to carrying rollers. Roller Controllers - Electrical devices that control the power provided to the motor and may contain control logic.

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Sensors - A device (typically electronic) located to detect the presence of a load on the conveyor. These sensors are usually powered from and communicate with the roller controllers. Electrical Wiring Harnesses - Multi-conductor wire harnesses are used to supply power to the motorized rollers, roller controllers, and sensors. Harnesses are also used to send/receive information between the sensors and roller controllers. Anti-Backup Protective Device - A device to prevent reversal of a loaded inclined belt when power is shut off. Some types which may be employed are as follows:

1. Eccentric pinch roller or rollers on the return run 2. Brake motor 3. Ratchet and pawl, or overrunning clutch, on a shaft of the drive 4. Anti-roll back roller (Typical for MDR)

Anti-Overrunning Device - A brake or other device used to prevent a loaded declined belt from running when power is shut off. (Typically a brake roller for MDR) Nose-Over - Curved or segmented frame sections used to provide a transition from incline to horizontal or from horizontal to decline. Powered Feeder - Curved or segmented frame sections used to provide a transition from horizontal to incline or decline to horizontal. Transfers - Devices used to remove specific loads from the conveyor line and deliver them to another line or area with a change in load direction and orientation, without manual intervention. Diverters - Devices used to remove specific loads from the conveyor line and deliver them to another line or area with a change in load direction, without manual intervention. Merge - Devices used to consolidate specific loads from multiple conveyor lines and deliver them to a single line with a change in load direction, without manual intervention. Zone - A sub portion of a conveyor bed that typically contains a motorized roller and accompanying control.

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TYPICAL CROSS SECTION

Figure 1. Roller Set High

Figure 2. Roller Set Low

Figure 3. Example of MDR Configuration

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Figure 4. Typical Section Schematic

Figure 5. Typical Section Isometric

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SECTION 2 – APPLICATION A motor driven live roller system is best used to convey totes, cartons, pallets, poly bags, and other products that do not exceed the limitations of the motorized rollers. Unlike other systems, weight can limit system speed and performance. Heavier items, steep incline angles or a combination of the two may prove too difficult or costly when using MDR. An added value of MDR lies in its flexibility and simplicity. A wide array of bed types and the absence of large drives make it a good option in limited spaces. Control options that can range from simple transportation to accumulation to complex tracking systems make it a versatile choice for many applications. Because of its relatively simple mechanical design, motor driven live roller conveyor lends itself to easier installation and lower maintenance costs. MDR can be an economical and safe solution. Power to each zone is turned on only when necessary to move a load. Therefore, energy consumption, noise generation, and mechanical wear are reduced. The rollers themselves operate at a relatively low level of torque and voltage. Low torque powered rollers can be stopped by hand, resulting in reduced risk of personal injury. There are many factors to consider when applying a MDR system. A good understanding of the system application, rate requirements, and layout is important to making the right decisions. Options can vary widely, so refer to the specific manufacturer for a complete list of their options. Common options include: frame design, conveyor width, roller centers, zone length, motorized roller type, bed types, control options, and accessories available. MDR Conveyors are best suited for applications where multiple drives would otherwise be required. For example, a 50 ft section of conveyor needs to be broken into five 10 ft sections to add personnel gates to allow access to workstations along the conveyor. Using traditional drives, this would require a conveyor drive be added to drive each section between gates, which would be costly and require space for the drives. MDR has the advantage of using one motorized roller per zone, regardless of the total distance traveled, so unlike the traditional conveyor system, the number of “drives” needed for this example would not differ from a straight unbroken conveyor. This example “system” would therefore be less expensive in both equipment and installation labor. There are applications where MDR may not be the best or the least expensive option. Where loads are exceptionally heavy, an extra motorized roller may need to be added to each zone to insure the loads move properly. Adding extra motorized rollers would increase the cost per zone. Long runs of conveyor may also be expensive due to the high quantity of powered rollers required. Overall system or area throughput rates are also a key consideration when choosing MDR conveyor. Motorized rollers contain very small electric motors so it is critical to understand their power limitations and the control schemes used to determine the actual rate the conveyor will be able to produce. The following are some of the basic considerations governing the selection of motor driven roller conveyors and components: Conveyor Width Normally the conveyor is at least 2" to 3" wider than the widest unit handled. Loads may require a greater width for clearance around horizontal curves. With certain types of installations, the loads are allowed to overhang the conveyor. Guide rails are provided where required.

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Motor driven roller conveyor is constructed typically in two styles which require consideration for conveyor width

Low-In-Frame (LIF): LIF refers to the position of the rollers within the frame. In this case, the rollers are set low in the frame, allowing for the part of the frame that extends above the rollers to serve as an integral guard rail. However, load size is limited by the distance between the frames.

High-In-Frame (HIF): HIF designs position the rollers above the top of the frame. Where required, external guard rail can be added. In some systems this can effectively increase conveyor width instead of going to the larger LIF conveyor. In some areas, HIF rollers are used to allow loads to be pushed onto or taken off the conveyor (i.e. spurs and transfers) without lifting it over the integral guard rail.

LIF (Rollers Low In Frame) HIF (Rollers High In Frame)

Figure 6. Frame Styles

Curves: Many times curves in a system will dictate the width of the conveyors for the

entire system because the load often requires additional conveyor width to negotiate the turn. This “additional space” depends upon the width and length of the load. The diagram and formula below shows one method of calculating the conveyor widths required to convey a load around a curve.

Formula for determining Width between Frame Rails (or Guard Rails) for Curves

Between Rail Width 2

2 Load LengthInside Radius Load Width Inside Radius 2"

2

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Speed and Load Motorized roller conveyors are capable of delivering a range of speeds and load handling. However, because the motors used in the rollers are small and have relatively low torque (compared to traditional conveyor drives), speed, loads, and acceleration/deceleration rates are important factors in determining the appropriate conveyor application.

Manufacturers maintain guidelines for the maximum load that a single motorized roller can move and a recommended maximum number of carrying rollers to be driven from each motorized roller. Different voltages, including AC powered units are available, but 24 volt DC is commonly used in many unit handling applications.

Typically two schemes are used for the control of speed. One scheme allows for increases in the amperage to the roller to maintain consistent speed regardless of load (within manufacturer parameters). The other scheme sets the maximum amperage and allows the motorized roller speed to decrease as weight increases. There are pros and cons to each scheme. It is important to understand which scheme your controller uses to insure the rate requirements of the system are met.

Conveyor Bed The loads are supported by one of the following types of construction:

Roller - The load is carried on rollers mounted in the frames. As a rule, horizontal conveyors performs best with three rollers under the load at all times.

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Figure 7. Load Support

Belt on Roller / Belt on Slider - The belt and loads are carried by sliding on bare metal,

galvanized metal, or rollers. This construction is used for loads with small irregular bases where smooth travel is required and for inclines and declines requiring high friction between the load and carrying surface. Higher power requirements are typically encountered with slider bed and should be taken into account.

Straight Beds These beds are used to transport and/or accumulate loads in one direction with little or no change in elevation. Typically these beds are supplied with one motorized roller per zone. The bed can be one or more zones or a short section less than a normal zone length to make up gaps in the system. Inclined / Declined Conveyors Inclines and declines carry loads to a higher or lower elevation, respectively. Typically the zones in these beds require belting or a coating on the rollers to provide more friction with the load to ensure it does not slide due to gravity and/or inertia. These zones also may have additional motorized rollers to provide more power to overcome gravity and/or better maintain speed. These motorized rollers may also have brakes or employ anti-backup devices to ensure the load will stop and stay in place when accumulating. Slope The maximum angle of elevation is governed by the coefficient of friction between the bottom surface of the load and the bed surface, center of gravity of the load, and the torque required to move the load. The relationship of the height of the unit load to its base length is important in determining the maximum slope. A safe rule to follow is to make the slope such that a vertical (perpendicular to the horizontal) line drawn through the center of gravity of the unit load will fall within the middle one third of its base length.

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Figure 8. Slope Geometry

Note: Special consideration should be given to the angle of slope if starting and stopping will occur with unit loads on the incline or decline Nose-Overs / Power Feeders These beds are used in conjunction with inclines and declines to provide smooth transitions between horizontal and angled beds. Power feeders are used at the bottom and nose overs are used at the top. These beds will also feature the belting, roller coating, additional motorized rollers and/or brakes to match the performance of the inclines and declines they are associated with. Nose-overs and Power feeders are suggested for slopes over 10 degrees and are considered a "must" for slopes over 15 degrees. Curves These beds are used to change the direction of the load while maintaining orientation. Tapered rollers are used to change the direction of load travel while maintaining its orientation on the conveyor. If a load is traveling along a straight section with its long side parallel to the side frame, it will begin turning as it enters the curve so that its long side will remain parallel to the side frame of the curve and of the next straight conveyor it comes to. Since motorized rollers generally are not tapered, it is common practice to drive the tapered rollers from straight motorized rollers mounted underneath or to place tapered cones on the motorized roller. Transfers / Diverters These devices are used to remove specific loads from the MDR line and deliver them to another line or area without manual intervention. The load is typically moved at a 30°, 45°, or 90° angle (depending on the device type) from the original direction of travel. Diverters maintain load orientation, while right angle transfers move the load laterally at 90°. Belts, wheels, chains or other means can be used to move the load. Some devices work better with different types of loads.

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Merge Spurs (or Junctions) Spurs are beds that are used to feed loads onto or take them away from a straight bed at an angle (typically 30° or 45°). These beds use a series of carrying rollers in graduated lengths to create the wedge-shaped roller surface. Zones MDR relies upon the motorized roller to power smaller sections of conveyor called zones. Zones are combined to form standard bed configurations, with each zone typically controlled individually. With the aid of a roller controller, sensors and control logic, each zone can accumulate throughout the system including inclines, declines, and curves. Most MDR systems are designed to convey one load per zone and accumulation is non-contact. The motorized roller must be able to transmit power to the carrying rollers in the zone. Typically drive bands are used to transmit this power in the form of round or poly-V for carton or tote handling, and chain for pallet loads.

Zone Length: Zone Length requirements are based on the length of the load. One of MDR’s strengths is the ability to accumulate loads without any contact between them; this is commonly referred to as “non-contact accumulation”. Generally the Zone Length should be longer than the longest load to be handled in the system by an amount that varies based on speed and weight of the load. One exception is when the shortest load is considerably less than the Zone Length, in these instances control logic is available to allow for loads longer than the zone to be moved through the system. Often referred to as “flexible” or “variable” zone length systems, these control schemes vary

Figure 9. Zone Length

Control Options There are multiple levels of control that can be used for MDR systems ranging from “dumb” to “smart” depending on the requirements. Moving loads from one location to another and having them accumulate at the end of the run is a very simple control scheme, achieved by applying a motorized roller and a roller controller with built-in accumulation logic. For systems that need to control load flow through a merge area to avoid collisions, then an external control (typically from a PLC) might be used. In some cases, customers may need to know exactly where a particular load is at all times. For these systems, there are high level network systems that monitor the status of each sensor and roller controller, as well as the location of individual loads throughout the system. There are also

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hybrid systems that use various levels of control in different areas depending on the specific requirement. MDR provides the flexibility for all of these situations with the same basic conveyor by varying the controllers and wiring harnesses. Therefore the control scheme used is critical to the proper operation of MDR Supports Floor supports should be provided with vertical adjustment for leveling the conveyor. Adjustable hangers, such as rods with threaded ends, are generally used with conveyors at elevations over the distance specified in ASME B20.1 (Guarded by Location). Support spacing is dependent on the loading, and in some cases, on the building construction. Supports must be spaced to limit frame deflection as detailed in ANSI/CEMA Standard No. 401, Roller Conveyors--Non Powered. Belting Selection A wide variety of belting types and material is available for MDR conveyor application. Some of the considerations given to belt selection are cost, strength, surface friction, abrasion, resistance, flexibility, dimensional stability, resistance to humidity conditions, oils, greases, acids, noise generated by the belt, and chemicals. The conveyor manufacturer or belting manufacturer should be consulted to select the proper type of belt to suit the application.

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SECTION 3 – TECHNICAL DATA Roller Selection The proper selection of a motorized roller is based upon two main criteria, the required torque for the application parameters and the required speed for throughput Torque Requirement For a horizontal conveyor:

TT = Total torque required to move load TL = Minimum toque required to move the load (in-lb) FT = Tangencial force (lbs) WL = Weight of Load (lbs) fR = Coefficient of rolling friction R = Radius of roller (in) N = Number of driven rollers EL = Loss per driven roller in percent (this will vary on power transmission style)

Table 1. Rolling Friction Coefficient

The Total Torque required is the Minimum Torque plus the system losses.

T L L LT T T N E

The Minimum torque required is the product of the tangential force and the roller radius.

L TT F R

Where the tangential force is the product of load weight and coefficient of rolling friction.

t L rF W f

Tube Material Metal Plastic Wood UrethaneNatural Rubber

Corrugated Cardboard

Steel 0.01 - 0.03 0.02 - 0.04 0.02 - 0.05 0.02 - 0.05 0.03 - 0.05 0.07 - 0.11Urethane Lagging 0.02 - 0.05 0.02 - 0.05 0.02 - 0.05 0.02 - 0.05 0.03 - 0.05 0.07 - 0.11Natural Rubber Lagging 0.03 - 0.05 0.03 - 0.05 0.03 - 0.05 0.03 - 0.05 0.03 - 0.05 0.07 - 0.11

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Example: An MDR conveyor is carrying a corrugated cardboard load with weight of 40 pounds on steel 1.9 inch diameter rollers with a single motorized roller and 6 driven rollers.

Tangential force: 40 lbs 0.11 4.4tF lbs

Minimum torque: 4.4 lbs 1.9 in /2 4.18LT in-lbs

Total torque: 4.18 in-lbs 4.18 in-lbs 6 2% 4.68TT in-lbs

Note: Additional factors may apply that could affect the required torque to move a product load:

Load contact of guiding devices Change in elevation Loads per zone

Speed Requirements For a straight conveyor:

S = Speed (fpm) LP = Length of product (ft) ZL = Length of zone (ft) ppm = Product rater per minute

The speed required is:

P LS L Z ppm

Example: An MDR conveyor is comprised of 30 inch zones carrying a product of 12 inches and must deliver 30 cartons per minute

2.5 ft 1 ft 30 ppm 105S fpm

Note: Additional factors may apply that could affect the required speed to move a product load:

Non straight applications (Diverts, Transfers, etc.) Carton size mixture

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Unit Handling Conveyors

OVERHEAD TROLLEY CHAIN CONVEYORS

CEMA STANDARDNO. 601-2018

CEMA Std. 601-2018 - Draft 1

ISBN 1-891171-50-XConveyor EquipmentManufacturers Association

®

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DISCLAIMER

The information provided herein is advisory only.

These recommendations provided by CEMA are general in nature and are not intended as a substitute for professional advice. Users should seek the advice, supervision and/or consultation of qualified engineers, safety consultants, and other qualified professionals.

Any use of this publication, or any information contained herein, or any other CEMA publication is made with the agreement and understanding that the user and the user’s company assume full responsibility for the designs, safety, specifications, suitability and adequacy of any conveyor system, system component, mechanical or electricaldevice designed or manufactured using this information.

The user and the user’s company understand and agree that CEMA, its member companies, its officers, agents and employees are not and shall not be liable in any manner under any theory of liability to anyone for reliance on or useof these recommendations. The user and the user’s companies agree to release, hold harmless and indemnify and defend CEMA, its member companies, successors, assigns, officers, agents and employees from any and all claims of liability, costs, fees (including attorney’s fees), or damages arising in any way out of the use of this information.

CEMA and its member companies, successors, assigns, officers, agents and employees make no representations or warranties whatsoever, either expressed or implied, about the information contained herein, including, but not limited to, representations or warranties that the information and recommendations contained herein conform to any federal, state or local laws, regulations, guidelines or ordinances.

Conveyor Equipment Manufacturers Association5672 Strand Ct., Suite 2

Naples, Florida 34110-3314www.cemanet.org

Copyright © 2018 All rights reserved.

ISBN - 1-891171-50-X

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TABLE OF CONTENTS

Section PageI INTRODUCTIONII DEFINITIONS FOR TROLLEY CHAIN CONVEYORSIII CONVEYOR COMPONENTS

Rivetless Chain Dimensions - Drop Forged Trolley Dimensions Vertical Bolts Horizontal Bolts For X-228 Chain Trolley Attachments Dimensions - Bolts Vertical Roller Turn Dimensions Traction Wheel Turn Dimensions

IV DESIGN PROCEDURE AND ENGINEERING DATA Overhead Trolley Conveyor Symbols - Plan View?? Typical Trolley Conveyor Installation Design Steps Conveyor Drives Types of Drives

Standard Drive Speed RangesDesign Data.. This is not in the content in the original document

Guards - Typical SectionsV VERTICAL CURVE DATA

Track -- Vertical Curve Radii for Overhead Conveyors as Related to Trolley Spacing Radii..THIS IS NOT IN THE CONTENT IN THE ORIGINAL DOCUMENT Compound Vertical Curve

VI TROUBLESHOOTING, LUBRICATION GUIDE AND INSPECTION CHECKLISTTroubleshooting Guide

Lubrication Guide for Overhead Monorail Conveyors Suggested Inspection Checklist for Trolley Conveyor Systems

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SECTION I - INTRODUCTION

The overhead trolley chain conveyor is an extremely flexible material handling means. It is used in practically every industry worldwide. It can be installed to follow almost any path, changing direction vertically or horizontally. Using multiple drives, a single path can be miles (kilometers) in length.

Beyond material transportation in ambient indoor or outdoor environments, typical industrial applications of trolley chain conveyors for product processing include:

• Washing/cleaning/finishing• Phosphatizing or similar treatments• Solvent degreasing• Paint stripping• Baking/drying up to 525°F (270°C)• Prime and finish painting• Freezing• Cooling• Food Handling

In certain environments, humans cannot survive or human health is endangered, yet conveying means are essential. Under many conditions, other types of conveyors are not practical or would not have an acceptable life expectancy. The overhead trolley chain conveyor combines its directional flexibility (horizontal and vertical curve movement) with its tolerance to adverse environments to broaden its applications to user requirements.

Each product carrier is especially designed to suit secure handling while providing ease in loading and unloading,whether this is done manually, semi-automatically, or automatically. Further design considerations are required where the product is processed and not merely transported.

With adequate part (or carrier) clearance within recommended allowable loading, any type of product may be transported. Carriers may be in the form of hooks, slings, boxes, racks, trays, baskets, or one of other numerous configurations to suit the application requirement.

The preferred conveyor system uses standard components wherever possible in the principal interest ofeconomics (minimum cost). Countless specially designed components are available and are used where required. In this event, it is recommended that the manufacturer be consulted.

This standard provides basic engineering guidelines to enable the proper selection of standard components and develop these into a functional conveyor layout. Content is confined to single drive systems of average loading, path configuration, and length.

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SECTION II - DEFINITIONS FOR TROLLEY CHAIN CONVEYORS

Adjustable Speed Drive - A type of drive designed with a speed changing device by which the speed of the conveyor can be changed.

Air-operated Take-up - A take-up mechanism where adjustments are made automatically by an air cylinder.

Antibackup - DEFINITION DOES NOT APPEAR IN THE ORIGINAL VERSION

Antirunaway - A safety device to stop a declining conveyor and thus prevent running away in event of an electrical or mechanical failure.

Automatic lubricator - A device used to lubricate the chain, trolley wheels, or other conveyor components automatically as they pass.

Automatic Take-up - A take-up mechanism where adjustments are made automatically.

Backstop - A mechanical device to prevent reversal of a loaded conveyor under action of gravity when forward travel is interrupted.

Backup Bar - A metal bar used to back up the caterpillar chain of a drive to hold the drive chain dogs in proper contact with the conveyor chain.

Backup Rollers - Series of rollers so mounted as to back up the conveyor chain to hold it in proper relation to the caterpillar chain dogs.

Balanced Drives - Drives so designed that two or more such drives on a single conveyor may be synchronized to pull predetermined shares of the load.

Beam Clamp - A device for gripping the flange of supporting beams or trusses for the purpose of suspending from same a structure such as a conveyor frame or track.

Bracing - Diagonal or horizontal members used to prevent swaying in conveyor supporting structure.

Caterpillar Chain - A short endless chain on which dogs or teeth are spaced to mesh with and move, or be moved by, a conveyor chain.

Caterpillar Chain Dog - A dog or tooth attached to a caterpillar drive chain to provide the driving contact with the conveyor chain.

Caterpillar Drive - A drive equipped with a caterpillar chain to provide the propelling contact with the conveyor chain.

Caterpillar Take-up Sprocket - The non-driving sprocket of a caterpillar drive.

Center Link - The loop-shaped link of rivetless chain which provides the bearing surfaces for the pins and permits passage of the trolley load support members through the chain.

Chain Pin - The pin that is used to connect succeeding links of a chain about which the links pivot.

Change of Elevation - Vertical distance between the upper horizontal track of a vertical curve to the corresponding point on the lower horizontal track.

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Compound Vertical Curve - An assembly of two single vertical curves with necessary connecting track to accomplish a change in elevation.

Conveyor Guard - A structure mounted below the conveyor path to protect personnel below.

Counterweighted Take-up - A take-up mechanism where the adjustment is made automatically by the potential energy of weights.

Drive - definition????

Drive Frame - The structure which supports the drive shaft assembly and machine parts and which contains or supports the motive power or supports the assembly to which the motive power is connected.

Drive Shaft - Main driving shaft on which the conveyor sprocket is mounted.

Drive Sprocket - Sprocket of a caterpillar drive or of a sprocket drive.

Drop - The vertical distance from the bottom of the track to centerline of the chain.

Finger Guard - Enclosure around trolleys and chain to protect personnel from falling parts.

Guard - definition????

Hanger Steel - Angles or rods by which a conveyor is hung from supports above.

Link - A chain unit of one pitch length.

Load Bar - A device to distribute a load over two or more trolleys.

Machinery Guard - A covering or barricade for safety purposes such as gear, chain, and V-belt guards.

Multiple Drives - Two or more motorized and load-sharing drives applied to a single conveyor for the purpose of reducing the chain tension in any given section.

Rivetless Chain - A completely forged, heat-treated chain of pins, side links, and center links which can be assembled or disassembled without the use of tools.

Roller Turn - A series of vertical rollers mounted in a frame to guide a conveyor chain around a horizontal curve.

Roller Turn Roller - The vertical roller with integral bearings as used in the roller turn.

Screw Take-up - A take-up mechanism having provision for manual adjustment by one or more screws.

Side Link - That portion of the chain which longitudinally connects joint portions at each end of the center link with chain pins.

Single Vertical Curve - A section of track bent in a desired curve to change the direction of a conveyor in the vertical plane.

Spring Take-up - A take-up mechanism where adjustments are made automatically by the potential energy of springs.

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Sprocket Drive - A conveyor chain driving unit using a sprocket to transmit power to the chain, located at a turn of approximately 90 degrees or more.

Superstructure - Members to which the hanger steel is connected and which transfer the load to the building members.

Take-up - The assembly of the necessary structural and mechanical parts which provides the means to adjust the length of chain to compensate for stretch, shrink, or wear and to maintain proper tension.

Track - The I-beam section on which trolley wheels roll while being propelled.

Traction Wheel - A smooth, straight face wheel without dogs or teeth.

Traction Wheel Turn - See Wheel Turn... THERE IS NOT DEFINITION OF TRACTION WHEEL TURN IN WHEEL TURN

Trolley - An assembly of two half-trolleys (each with wheel, bearing, and bracket) and an attachment. It is used to support and move suspended loads and to carry the load connecting and conveying chain.

Trolley Attachments - definition????• Bolt Attachment - A trolley attachment having a threaded rod projection for attaching a load bar or

various objects. • Clevis Pin? Attachment - A forked or clevis type trolley attachment.. COMPARE WITH THE OLD VERSION• Idler Attachment - An attachment used to complete the assembly of a non-load carrying trolley.• Pendant Attachment - A single bar trolley attachment projecting through the chain having a single hole

for supporting loads.

Trolley Brackets - Drop forged, cast, or pressed steel members to which the trolley wheels are attached with provision for connecting to the chain.

Trolley Conveyor - A series of trolleys supported from an overhead track and connected by an endless propelling chain with load usually suspended from the trolley. Trolley conveyors may be designed for single or multiple plane operation.

Trolley Wheel - The circular member with integral bearing mounted to the trolley bracket. There are to styles:• Full Ball complement - Maximum number of balls without a retainer. • Retainer Type - Balls are separated by a retainer for low friction.

Vertical Curve - definition????

Wheel Turn - A structure having a traction wheel which guides a conveyor chain around a horizontal curve.

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SECTION III - CONVEYOR COMPONENTS

Rivetless Chain Dimensions - Drop Forged

Chain Type

A*Nominal

Pitchin (mm)

BHeight of

Center Link

in (mm)

CMax.

Width of Chain

in (mm)

DHeight of

Center Link at

Flatin (mm)

E Max.

Overall Length of Pin

in (mm)

FDiameter

of Pinin (mm)

GMin.

Length of Pin

Between Heads

in (mm)

HMin.

Lengthof Flat on

Center Link

in (mm)

IMin.

Inside Width of Center

Linkin (mm)

X-228 (X-50-6) 2 (50.8) 0.47

(11.91)0.69

(17.46)0.38

(9.53)1.13

(28.57)0.25

(6.35)0.83

(21.03)1.06

(26.99)0.31

(7.94)X-348

(X-75-13) 3 (76.2) 0.75 (19.05)

1.09 (27.78)

0.5(12.7)

1.84 (46.83)

0.5(12.7)

1.28 (32.54)

1.63 (41.28)

0.56 (14.29)

X-458 (X-100-16) 4 (101.6) 1

(25.4)1.41

(35.72)0.63

(15.88)2.25

(57.15)0.63

(15.88)1.63

(41.28)2.25

(57.15)0.69

(17.46)X-678

(X-150-22) 6 (152.4) 1.28 (32.54)

2(50.8)

0.81 (20.64)

3.13 (79.38)

0.88 (22.23)

2.25 (57.15)

3.38 (85.73)

0.97 (24.61)

* Actual pitch varies from nominal.

Average Length of Production Chain

ChainType

Average Length of Nominal 10 ft Strand

in (mm)

Assembled Weightlbs/ft (kg/m)

X-228 (X-50-6) 120.60 (3063.24) 0.75 (1.12)

X-348 (X-75-13) 120.60 (3063.24) 2.10 (3.13)

X-458 (X-100-16) 120.80 (3068.32) 3.10 (4.61)

X-678 (X-150-22) 120.90 (3070.86) 6.10 (9.08)

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Trolley Dimensions - Vertical Bolts

I-Beam Size Chain Type

Drop

H Max.Width of Trolley Bracket

JCenterline of Lubrication

Fitting to Bottom of

Beam

K Min.Minimum Distance Between

Wheel Inside Faces

L Max.Overall

Width of Trolley

Assembly

in (mm) in (mm) in (mm) in (mm) in (mm)3 in @ 5.7 lbs/ft

(76.2 mm @ 8.48 kg/m)X-348

(X-75-13) 2.5 (63.5) 1.63 (41.28) 1.44 (36.51) 0.63 (15.88) 4.25 (107.95)

4 in @ 7.7 lbs/ft(101.6 mm @ 11.45 kg/m)

X-458(X-100-16)

3.19 (80.96) 2.25 (57.15) 1.88 (47.63) 0.63 (15.88) 5.38 (136.53)4 (101.6) 2.25 (57.15) 1.88 (47.63) 0.63 (15.88) 5.5 (139.7)

6 in @ 12.5 lbs/ft(152.4 mm @ 18.60 kg/m)

X-678(X-150-22) 4 (101.6) 3.38 (85.73) 2.69 (68.26) 0.75 (19.05) 7.63 (193.68)


M Max.Clearance Width of Trolley

Bracket at Lubrication

Fitting

NCenterline of Chain to Centerline of Upper Bolt Hole

OCenterline of Chain to Centerline of Lower Bolt Hole

P Min.Interface of Dimension

from Centerline of Chain

to Trolley Bracket

Q Max.Centerline of Chain to Bottom of

Bracket


(76.2 mm @ 8.48 kg/m)X-348

(X-75-13) 3.81 (96.84) 1 (25.4) 0.88 (22.23) 1.06 (26.99) 1.31 (33.34)

4 in @ 7.7 lbs/ft(101.6 mm @ 11.45 kg/m)

X-458(X-100-16)

4.63 (117.48) 1.31 (33.34) 0.81 (20.64) 1.25 (31.75) 1.31 (33.34)4.63 (117.48) 1.31 (33.34) 0.81 (20.64) 1.25 (31.75) 1.31 (33.34)

6 in @ 12.5 lbs/ft(152.4 mm @ 18.60 kg/m)

X-678(X-150-22) 7.63 (193.68) 1.63 (41.27) 1.13 (28.58) 1.56 (39.69) 1.75 (44.45)

Note: P Min. is measured vertically at outside edge of chain

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RThickness of Attachments

SDiameter of Mounting

Bolts

T Min.Slope of Wheels

from the Vertical

in (mm) in (mm) deg.3 in @ 5.7 lbs/ft

(76.2 mm @ 8.48 kg/m)X-348

(X-75-13) 0.25 (6.35) 0.31 (7.94) 1

4 in @ 7.7 lbs/ft(101.6 mm @ 11.45 kg/m)

X-458(X-100-16)

0.38 (9.53) 0.38 (9.53) 10.38 (9.53) 0.38 (9.53) 1

6 in @ 12.5 lbs/ft(152.4 mm @ 18.60 kg/m)

X-678(X-150-22) 0.5 (12.7) 0.5 (12.7) 1

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Trolley Dimensions - Horizontal Bolts


Drop




Beam


Wheel Inside Faces

L Max.Overall

Width of Trolley

Assembly

in (mm) in (mm) in (mm) in (mm) in (mm)

4 in @ 7.7 lbs/ft(101.6 mm @ 11.45 kg/m)

X-458(X-100-16)

3.81 (96.84) 2.25 (57.15) 1.88 (47.63) 0.63 (15.88) 5.38 (136.53)4 (101.6) 2.25 (57.15) 1.88 (47.63) 0.63 (15.88) 5.5 (139.7)

6 in @ 12.5 lbs/ft(152.4 mm @ 18.60 kg/m)

X-678(X-150-22) 4 (101.6) 3.38 (85.73) 2.69 (68.26) 0.75 (19.05) 7.63 (193.68)




Fitting




to Trolley Bracket



Bolts

in (mm) in (mm) in (mm) in (mm) in (mm)

4 in @ 7.7 lbs/ft(101.6 mm @ 11.45 kg/m)

X-458(X-100-16)

4.94 (125.41) 1.88 (47.63) 1.25 (31.75) 0.63 (15.88) 0.38 (9.53)4.75 (120.65) 2 (50.8) 1.25 (31.75) 0.63 (15.88) 0.38 (9.53)

6 in @ 12.5 lbs/ft(152.4 mm @ 18.60 kg/m)

X-678(X-150-22) 7.63 (193.68) 2.5 (63.5) 1.56 (39.69) 0.88 (22.23) 0.5 (12.7)


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T Min.Slope of

Wheels from the Vertical

WDistance Between

Centerline of Bolt Holes

deg. in (mm)

4 in @ 7.7 lbs/ft(101.6 mm @ 11.45 kg/m)

X-458(X-100-16)

2 1.38 (34.93)2 1.38 (34.93)

6 in @ 12.5 lbs/ft(152.4 mm @ 18.60 kg/m)

X-678(X-150-22) 2 2 (50.8)

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Trolley Dimensions - For X-228 Chain


Drop




Beam


Wheel Inside Faces

L Max.Overall

Width of Trolley

Assembly


(0.8 mm @ 5.59 kg/m)X-228

(X-50-6) 1.88 (47.63) 1.03 (26.19 1 (25.4) 0.56 (14.29) 4.69 (119.06)




Fitting


OCenterline of Chain to Centerline of Lower Bolt Hole



to Trolley Bracket

Q Max.Centerline of Chain to Bottom of

Bracket


(0.8 mm @ 5.59 kg/m)X-228

(X-50-6) 3.5 (88.9) 0.75 (19.05) 1.91 (48.42) 0.97 (24.61) 3.41 (86.52)





Bolts

T Min.Slope of Wheels

from the Vertical

in (mm) in (mm) deg.2 in @ 3.76 lbs/ft

(0.8 mm @ 5.59 kg/m)X-228

(X-50-6) 0.25 (6.35) 0.19 (4.76) 5.5

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Trolley Attachment Dimensions


NCenterline of Chain to Centerline

of Bolt Holes

RThickness

of Attachment


Bolts

UWidth of Opening Between

Assembled Clevis Halves

VWidth of

Attachment


(101.6 mm @ 11.45 kg/m)X-458

(X-100-16) 2 (50.8) 0.63 (15.88) 0.37 (9.53) 0.69 (17.46) 2.25 (57.15)

6 in @ 12.5 lbs/ft(152.4 mm @ 18.60 kg/m)

X-678(X-150-22) 2.5 (63.5) 0.88 (22.23) 0.5 (12.7) 0.88 (22.23) 3.38 (85.73)


WDistance Between

Centerlines of Bolt Holes

XCenterline of Chain to Centerline

of Load Mounting

Hole

YCenterline

of Load Mounting

Hole to Bottom of

Attachment

ZHole

Diameter for Load

Mounting

AADiameter of Rod on Bolt Attachment


(101.6 mm @ 11.45 kg/m)X-458

(X-100-16) 1.38 (34.93) 3 (76.2) 0.75 (19.05) 0.56 (14.29) 0.63 (15.88)

6 in @ 12.5 lbs/ft(152.4 mm @ 18.60 kg/m)

X-678(X-150-22) 2 (50.8) 3.63 (92.08) 1 (25.4) 0.81 (20.64) 1 (25.4)

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ABThickness of Clevis

Half

ACOverall

Length of Rod on Bolt Attachment

ADCenterline of

Load Mounting Hole to Inside

Bend Line of Clevis

Attachment

AECenterline of Chain

to Bottom of Bolt

Attachment

ANCenterline of

Load Mounting Hole to Bottom

of Pendant Attachment


(101.6 mm @ 11.45 kg/m)X-458

(X-100-16) 0.31 (7.94) 4 (101.6) 1.81 (46.04) 4.63 (117.48) 0.81 (20.64)

6 in @ 12.5 lbs/ft(152.4 mm @ 18.60 kg/m)

X-678(X-150-22) 0.25 (6.35) 3.25 (82.55) 1.69 (42.86) 6.16 (156.37) --


APBolt

Diameter for Pendant

Load Mounting

ARThickness

of Pendant Load

Mounting Boss

in (mm) in (mm)4 in @ 7.7 lbs/ft

(101.6 mm @ 11.45 kg/m)X-458

(X-100-16) 0.81 (20.64) 0.5 (12.7)

6 in @ 12.5 lbs/ft(152.4 mm @ 18.60 kg/m)

X-678(X-150-22) -- --

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Trolley Attachment Dimensions - Vertical Bolts


NCenterline of Chain to Centerline

of Bolt Holes

RThickness

of Attachment


Bolts

UWidth of Opening Between

Assembled Clevis Halves

VWidth of

Attachment


(76.2 mm @ 8.48 kg/m)X-348

(X-75-13) 1 (25.4) 0.25 (6.35) 0.31 (7.94) 0.56 (14.29) 1.5 (38.1)

4 in @ 7.7 lbs/ft(101.6 mm @ 11.45 kg/m)

X-458(X-100-16) 1.31 (33.34) 0.38 (9.53) 0.38 (9.53) 0.69 (17.46) 2.13 (53.98)

6 in @ 12.5 lbs/ft(152.4 mm @ 18.60 kg/m)

X-678(X-150-22) 1.63 (41.28) 0.5 (12.7) 0.5 (12.7) 0.81 (20.64) 3 (76.2)


WDistance Between

Centerlines of Bolt Holes

XCenterline of Chain to Centerline

of Load Mounting

Hole

Y Centerline

of Load Mounting

Hole to Bottom of

Attachment

ZHole

Diameter for Load

Mounting

AADiameter of Rod on Bolt Attachment


(76.2 mm @ 8.48 kg/m)X-348

(X-75-13) 1.88 (47.63) 3.13 (79.38) 0.63 (15.88) 0.5 (12.7) 0.5 (12.7)

4 in @ 7.7 lbs/ft(101.6 mm @ 11.45 kg/m)

X-458(X-100-16) 2.13 (53.98) 2.88 (73.03) 0.75 (19.05) 0.5 (12.7) 0.63 (15.88)

6 in @ 12.5 lbs/ft(152.4 mm @ 18.60 kg/m)

X-678(X-150-22) 2.75 (69.85) 3.63 (92.08) 1.13 (28.58) 0.75 (19.05) 0.88 (22.23)

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ABThickness of Clevis

Half

ACOverall

Length of Rod on Bolt Attachment

ADCenterline

of Load Mounting

Hole to Inside Bend

Line of Clevis Attachment

AECenterline of Chain

to Bottom of Bolt

Attachment

in (mm) in (mm) in (mm) in (mm)3 in @ 5.7 lbs/ft

(76.2 mm @ 8.48 kg/m)X-348

(X-75-13) 0.13 (3.18) 1.81 (46.04) 1 (25.4) 4.25 (107.95)

4 in @ 7.7 lbs/ft(101.6 mm @ 11.45 kg/m)

X-458(X-100-16) 0.19 (4.76) 2.13 (53.98) 1 (25.4) 4.94 (125.41)

6 in @ 12.5 lbs/ft(152.4 mm @ 18.60 kg/m)

X-678(X-150-22) 0.25 (6.35) 3 (76.2) 1.13 (28.58) 6.13 (155.58)

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Roller Turn Dimensions


Drop Bottom of Beam to Centerline of

Chain

AL Min.Bottom of

Beam to Top of Roller Hub

Nominal Radius Degrees of Turn

in (mm) in (mm) in (mm) 30 45 60 90 180

3 in @ 5.7 lbs/ft(76.2 mm @ 8.48 kg/m)

X-348(X-75-13) 2.5 (63.5) 1.44 (36.51)

18 (457.2)

24 (609.6)

30 (762)

36 (914.4)

48 (1219.2)

4 in @ 7.7 lbs/ft(101.6 mm @ 11.45 kg/m)

X-458(X-100-16)

3.19 (80.96) 1.94 (49.21)

18 (457.2)

24 (609.6)

30 (762)

36 (914.4)

48 (1219.2)

60 (1524)

72 (1828.8)

4 (101.6) 2.75 (69.85)

18 (457.2)

24 (609.6)

30 (762)

36 (914.4)

48 (1219.2)

60 (1524)

72 (1828.8)

6 in @ 12.5 lbs/ft(152.4 mm @ 18.60 kg/m)

X-678(X-150-22) 4 (101.6) 2.44 (61.91)

24 (609.6)

30 (762)

36 (914.4)

48 (1219.2)

60 (1524)

72 (1828.8)

Standard Size

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Traction Wheel Turn Dimensions


Drop Bottom of Beam to

Centerline of Chain

AF Min.Height of Traction Wheel

Rim

AL Min.Bottom of Beam to Top of

Roller Hub

Nominal Radius Degrees of Turn

in (mm) in (mm) in (mm) in (mm) 30 45 60 90 180

3 in @ 5.7 lbs/ft(76.2 mm @ 8.48 kg/m)

X-348(X-75-13) 2.5 (63.5) 2 (50.8) 1.44 (36.51)

18 (457.2)

24 (609.6)

30 (762)

36 (914.4)

42 (1066.8)

48 (1219.2)

60 (1524)

4 in @ 7.7 lbs/ft(101.6 mm @ 11.45 kg/m)

X-458(X-100-16)

3.19 (80.96)

2.5 (63.5)

1.94 (49.21)

18 (457.2)

24 (609.6)

30 (762)

36 (914.4)

42 (1066.8)

48 (1219.2)

60 (1524)

72 (1828.8)

4 (101.6) 2.75 (69.85)

18 (457.2)

24 (609.6)

30 (762)

36 (914.4)

42 (1066.8)

48 (1219.2)

60 (1524)

72 (1828.8)

6 in @ 12.5 lbs/ft(152.4 mm @ 18.60 kg/m)

X-678(X-150-22) 4 (101.6) 3 (7.62) 2.44 (61.91)

24 (609.6)

36 (914.4)

42 (1066.8)

48 (1219.2)

60 (1524)

72 (1828.8)

Standard Size

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SECTION IV - DESIGN PROCEDURE AND ENGINEERING DATA

Overhead Trolley Conveyor Symbols - Plan View??

HORIZONTAL STRAIGHT CONVEYOR VERTICAL CURVE

DIRECTION OF TRAVEL

EL EL

ANTI-BACKUP

UP

ELEL

ANTI-RUNAWAY

DOWN

ELEL

EXPANSION JOINT

CONVEYOR GUARD

OVEN

TEMP.

OVEN, WASHER, OR SPRAY BOOTH ENCLOSURE

SPROCKET DRIVE

CATERPILLAR DRIVE

ROLLER TURN TRACTION WHEEL

ROLLER TURN TAKE-UP

SPR

EAD

ROLLER TURN TAKE-UP

SPR

EAD

DIA

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Typi

cal T

rolle

y Co

nvey

or In

stal

latio

n

See

Guar

ds a

t the

en

d of

this

secti

on

for m

ore

info

rmati

on

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Design Steps

The following steps will assist you in designing an Overhead Trolley Conveyor System:

Step A. Draw Plant Layout1. Draw Layout to largest practical scale. For example: 1/4 in =1 ft or 1/8 in = 1 ft (50:1 or 100:1)2. Make a plan view of plant area in which the conveyor is to be erected. Show dimensioned column or

bay lines. Indicate “North” direction relative to building.3. Locate and label all obstructions which affect the path of the conveyor, such as columns, walls, machinery,

work areas, and aisles on the plan view.

Step B. Design a Carrier1. Determine number of parts to be placed on each carrier and their relative position on carrier. Make the

carrier as compact as possible.2. Design carrier to permit easy loading and unloading of parts.3. Design the carrier to carry loads within the rated capacity of the trolley. Trolley capacities are listed in

this section.4. Design carrier bracket to fit a trolley attachment to which the load or carrier can most easily be attached,

keeping within the load ratings.5. Standard trolley attachments can be selected from the data and illustrations in this section.

Step C. Determine Conveyor Size1. Select a trolley arrangement, either a single trolley with attachment or double trolley with load bar, in

this section that has a capacity rating exceeding the total weight of the carrier designed in Step B and the carried load.

2. The trolley size will determine the size of the conveyor in the average conveyor application. However, the chain pull, as calculated in Step N, must not exceed the recommended capacity for the selected size chain as shown in this section.

Step D. Determine Track Elevations1. Elevations are measured from floor line to top of I-beam track.2. At loading and unloading areas, the conveyor height must permit a person to load and unload the carrier

easily.3. The conveyor height over work areas and aisles must allow traffic to pass freely under guards.4. Indicate the elevation at all vertical curves. See typical conveyor layout at beginning of this section.

Step E. Determine Material flow1. On plant layout, locate all load and unload points and, also, any processing stations that will be served

by the conveyor. Typical stations: Dip tanks, paint booths, bake ovens (indicate temperature).2. Draw conveyor route so that it connects all areas in their proper work sequence with the most practical

path for the system, using standard components where possible. Keep parallel conveyor routes as closely spaced as possible to reduce the amount of supporting members and guards required.

3. Be sure the path of conveyor does not interfere with any machine operations or work areas.4. Indicate location of drive, take-up, vertical curves, and horizontal turns relative to column lines. Refer

to typical layout and conveyor symbols and glossary at beginning of this section.

Step F. Select Vertical Curves1. For increased conveyor life, use the largest recommended radius possible for vertical curves in your

layout. Use minimum radius vertical curves only in conveyor areas where necessary. See vertical curve radii chart, section V.

2. Select a load spacing.

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3. Using Figure 9, select a degree of incline for vertical curves that will provide a clearance between carriers, or load silhouette when they are moving on the incline. To assure clearance between carriers, dimension “A” must be greater than carrier length.

4. Because of carrier sway, clearance must be provided between top of carrier and conveyor chain.5. Indicate on layout drawing the horizontal length (tangent to tangent) of each vertical curve, its radius

and degree.6. Locate each vertical curve relative to some adjacent component, as shown on typical conveyor layout

at beginning of this section.

Figure 9.

Step G. Select Horizontal Turns1. Make a plan view layout of horizontal turn, as shown in Figure 10. Clearance between adjacent carriers

or maximum load silhouette while they are negotiating turns will determine the minimum horizontal turn radius.

2. For increased conveyor life, use the largest standard radius possible for horizontal turns in your layout. Select the horizontal turns best suited to your requirements from Section III, Conveyor Components.

3. Provide for one (1) 180° horizontal turn in your layout, as near as possible on the output side of the drive unit, for use as a slack chain take-up. If possible, place this take-up at the bottom of a vertical curve.

Figure 10. Plan View Layout of Horizontal Turn

Step H. Determine Guard Requirements1. For standard guard methods, refer to the end of this section.2. Select type of conveyor guard best suited to your requirements.

CLEARANCE

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3. Be sure loaded carriers will clear all guards. 6 in clearance on each side is usually sufficient. It is especially important to check clearances on horizontal and vertical curves. Carrier templates can be used for this purpose.

4. Locate each guard relative to some adjacent conveyor component or column line as shown on typical conveyor layout at beginning of this section.

Step I. Determine Trolley Spacing1. To determine the trolley spacing, refer to Step F, Numbers 3, 4 and 5, then go to Step G, Number 1.

Note the carrier spacing selected for proper clearances. Refer to Table 4 and note the recommended spacing for trolleys. If your required carrier spacing is greater than the recommended trolley spacing, intermediate trolleys are required.

2. When laying out the conveyor path, a distance equal to the maximum trolley spacing selected should be allowed between tangent lines of vertical curves and horizontal turns.

Step J. Determine Maximum Conveyor Speed1. A speed of 50 to 70 fpm is normally considered as maximum. However, 30 fpm usually allows easy

loading and unloading and assures longer conveyor life. Lowest possible speeds are recommended to suit required production. Required conveyor speed in fpm is equal to the number of carriers per minute multiplied by carrier spacing in ft.

2. To illustrate this formula: a. Assume your production rate is 1,200 parts per hour. b. Assume each carrier holds four (4) parts. c. Required number of carriers per hour equals 1,200 - 4 or 300 carriers. d. Required number of carriers per minute is 300 - 60 or 5 carriers. e. Assume a carrier spacing of 24 in or 2 ft. f. Five (5) carriers per minute multiplied by carrier spacing of 2 ft equals a conveyor speed of 10 fpm.

3. To allow for variation in production requirements, it is advisable to set a maximum speed of about two times that calculated. A variable speed drive with a speed range of about 3 to 1 is the most common.

a. The maximum speed is 20 fpm or 2 x 10 fpm. b. Using a 3 to 1 ratio variable speed drive would give you a speed range of 6.6 fpm to 20 fpm.

Step K. Determine Conveyor Length1. Obtain the sum of all straight track dimensions.2. Obtain the sum of all arc lengths on the horizontal turns.3. Obtain the sum of all arc lengths on the vertical curves by using the vertical curve charts in Section V,

Vertical Curve Data.4. The total length of the conveyor is equal to the sum of 1, 2, and 3 above.

Step L. Determine Moving Load1. The moving load on a conveyor is equal to the sum of the weights of all moving parts—chain, trolleys,

carriers, and loads.2. Establish distances from loading to unloading points and determine the number of loaded and empty

carriers in the system during maximum loading of conveyor.3. The following example illustrates the procedure for determining moving load assuming the conveyor is

300 ft long, carriers are at 2 ft centers, and distance from loading to unloading points is 250 ft. 300 ft X-458 chain with trolleys at 2 ft centers at 7.1 Ibs/ft = 2,130 Ibs 125 loaded carriers at 250 Ibs each = 31,250 Ibs 25 empty carriers at 20 Ibs each = 500 Ibs The total moving load is 33,880 lbs

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Step M. Determine Lift Load1. The lift load is the amount of force required to pull the moving load upward along the vertical curves

in the entire system.2. To calculate this force, determine the net difference in elevation of all the loaded vertical curves (inclines

and declines) in the system. This net vertical rise or fall (ft) will be considered the total lifting height of the conveyor.

3. The lift load or chain pull for the elevation changes of the conveyor is equal to the total lift height (ft) multiplied by the individual load weight (lbs), then divided by the load spacing ft.

Example: Assume that the net elevation change of all loaded vertical curves results in a total rise or lifting height of 12 ft, the load on each carrier is 230 Ibs, and the carriers are on 2 ft centers.

12 ft x 230 lbs Lift Load = = 1,380 lbs 2 ft

The chain, trolleys, and carriers are excluded from the calculations because they are balanced by the portion of the system that moves down the vertical curves. Note: If the net difference of elevation in the system is negative due to greater elevation change as a result of loaded declines, the lift load resultant will be negative The following example illustrates the procedure for determining moving load assuming the conveyor is 300 ft long, carriers are at 2 ft centers, and distance from loading to unloading points is 250 ft.

Step N. Determine Chain Pull1. Chain pull is the effort necessary to maintain the normal operating speed of a conveyor under a rated

capacity load. To arrive at this final driving effort, it is necessary to add the lift load and the friction factors, expressed as a small percentage of the moving load, which act as resistance to the progress of the conveyor. The moving load and the lift load were calculated in Steps L and M.

2. Frictional resistance is found in the bearings of the trolley wheels, roller or traction wheel turns, vertical curves, and the drive unit itself. This friction figure is represented as a small percentage and is listed in the chart below for each conveyor size. It should be noted that these percentages are for average conveyors which travel under normal conditions.

3. Select from Table 1 the friction factor indicated for your conveyor size. Notes:

- A large number of vertical and horizontal curves will create slightly higher friction.- The conveyor manufacturer should be consulted for specific information on friction factors.

Table 1. Friction Factors

Operating ConditionsBall Bearing Trolleys

2 in 3 in 4 in 6 in32°F to 325°F (0°C to 163°C) - Average Good Conditions 2 1/2 2 1 3/4 1 1/2325°F to 375°F (163°C to 191°C) - Auto Oil Lubricant 3 1/2 3 2 1/2 2For adverse environmental conditions and temperature over 375°F (191°C), consult manufacturer -- -- -- --

4. To determine chain pull due to friction, multiply total moving load by selected friction factor. Using figures from previous examples, the following illustrates proper procedure:

Total moving load (from Step L) = 33,880 lbs Multiply by friction factor (Table 1) = 0.025...factors above are better in fraction or decimal???? Friction chain pull = 847 Ibs

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5. Add lift load to friction chain pull to obtain total chain pull: Friction chain pull = 847 Ibs Lift load (from Step M) = 1,380 lbs Total chain pull = 2,227 Ibs

6. Refer to Table 3 and determine if chain size selected has sufficient capacity for required chain pull.7. Consult conveyor manufacturer to obtain a drive of sufficient size for the calculated chain pull.

Note: Above method of calculating chain pull is a fair approximation to determine drive size or number of drives required. When adverse environmental conditions exist (such as high temperature, caustic solutions, excessive dust, corrosive solutions) or the conveyor is abnormally long or complex (1,000 ft; 20 changes of direction), a progressive chain pull computation is necessary where the friction losses are progressively calculated and accumulated through the path along the conveyor.

Metric Conversion: IS IT A NOTE OR ADVISEMENT?? IT SHOULD BE AT THE BEGINNING OF THE DOCUMENT?? Calculations may be performed in the English system, as shown, or in metric.

Step O. Locate Drive1. Locate the drive so it will apply a pulling force on the most heavily loaded portion of the system.2. For best results, locate the drive at some high point in the conveyor system and place the take-up just

after the drive at a lower point.3. Locate drive on conveyor layout. Relate location to some adjacent component, as shown in Typical

Conveyor Layout at beginning of this section. Step P. Summarize

1. For quick and easy reference, make a legend on your layout covering the following subjects (Refer to Typical Conveyor Layout):

a. Speed of conveyor. Mark direction of travel. b. Length of conveyor c. Trolley spacing d. Carrier spacing e. Weight of empty carrier f. Maximum weight of loaded carrier g. Total moving load h. Maximum lift load i. Maximum chain pull j. Type of drive (caterpillar or sprocket); electrical specs k. Cross section of guard with dimensions

Step Q. Safety Codes (Reference current ANSI B20.1)1. In areas where the parted chain, cable, or other linkage would permit a runaway condition on an inclined

or declined section and where personnel are present, anti runaway or anti-backup devices shall be provided. A good rule of thumb is one device for every 5 ft of vertical change in distance. The conveyor path may be arranged so that travel of the uncontrolled conveyor will be arrested before it enters an area where personnel are present.

2. In areas where personnel perform work on the load and guards would impair their function, the loads must be cradled, hooked, bolted, or securely attached by some means to the carrier.

3. Nip points occur at traction wheels, sprockets, caterpillar drives, and roller turns and shall be guarded unless guarded by location.

4. Guards shall be provided to restrict personnel from entering hazardous loading, unloading, and transfer areas. When guarding is not feasible, clear and legible warning shall be provided.

5. Where conveyors are located above personnel and the possibility exists that the transported product may fall off for any cause, conveyor guard shall be provided

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Conveyor Drives

The most important component of the conveyor system is the drive. The drive gives the conveyor motion and controls conveyor speed.Types of Drives

Two Standard types of drives (caterpillar and sprocket) are available for overhead trolley conveyor systems. A caterpillar drive uses a chain made of precision steel rollers with driving dogs that mesh with the links of the conveyor chain to deliver driving force. A sprocket drive makes use of a sprocket whose teeth mesh with the links of the conveyor chain to deliver driving force.

Standard Drive Speed Ranges

All drives are furnished with either constant or variable speeds. Variable speed drives allow flexible production schedules. Variable speed drives are commonly 3:1. Greater speed variations are available.

Figure 11. Plan View of Drive Frames Indicating Hand of Drive

To determine the hand of the drive, look in the direction of the chain travel (the chain is moving away from you). If the drive is to be placed on the right side of chain, it is a right hand drive. If it is on the left side of chain, it is a left hand drive.

Note: Overload protection shall be provided on all drives.

CHAIN TRAVEL FOR RIGHT HAND DRIVE

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Table 2. Combined Chain and Trolley Weights per Foot of Conveyor for Uniform Trolley Spacing


Trolley Spacing in (mm)

Combined Chain and Trolley Weightslbs/ft (kg/m)

3" @ 5.7 lbs/ft(76.2 mm @ 8.48 kg/m)

X-348 (X-75-13)

6 (152.4) 8.3 (152.4)12 (304.8) 5.3 (7.87)18 (457.2) 4.3 (6.40)24 (609.6) 3.8 (5.64)30 (762) 3.5 (5.22)

4" @ 7.7 lbs/ft(101.6 mm @ 11.45 kg/m)

X-458(X-100-16)

8 (203.2) 15.1 (22.47)16 (406.4) 9.1 (13.55)24 (609.6) 7.1 (10.56)32 (812.8) 6.1 (9.09)

6" @ 12.5 lbs/ft(152.4 mm @ 18.60 kg/m)

X-678(X-150-22)

12 (304.8) 25.7 (38.25)24 (609.6) 16.2 (24.11)36 (914.4) 12.5 (18.60)

Table 3. Recommended Maximum Allowable Chain Pull on Drop Forged Rivetless Chain (Heat Treated)

Chain Type Maximum Chain Pull lbs (kg)

X-348(X-75-13) 1500 (680)

X-458(X-100-16) 3000 (1360)

X-678(X-150-22) 5500 (2500)

Table 4. Minimum Recommended Radius and Diameter Turns for Various Trolley Spacings

Chain Type

Trolley Spacing in (mm)

Traction Wheel Diameterin (mm)

Roller Turn Radius

in (mm)

X-348(X-75-13)

Up to 18 (457.2) 24 (609.6)18 (457.2)24 (609.6) 30 (762)

30 (762) 36 (914.4)X-458

(X-100-16)Up to 24 (609.6) 30 (762)

24 (609.6)32 (812.8) 36 (914.4)

X-678(X-150-22)

12 (304) 36 (914.4)36 (914.4)24 (609.6) 42 (1066.8)

36 (914.4) 48 (1219.2)

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Table 5. Approximate Allowable Suspended Load on Single Trolley

I-Beam Size Maximum Load Capacity lbs (kg)

3" @ 5.7 lbs/ft(76.2 mm @ 8.48 kg/m) 200 (90)

4" @ 7.7 lbs/ft(101.6 mm @ 11.45 kg/m) 400 (180)

6" @ 12.5 lbs/ft(152.4 mm @ 18.60 kg/m) 1200 (540)

Load Capacity = Two times single trolley

Figure 12. Dual Trolley With Load Bar

Guards

Conveyor guards are recommended where loaded conveyors pass over aisles, work stations, machinery, or where work carriers are not permanently fastened to conveyor, to prevent injury or damage from falling parts. Dimensions of guards are determined by the size of loaded carriers. 6 in minimum clearance on each side is required. Vertical height should permit loaded carriers to clear a fallen part lying on the bottom of the guard. Check all pertinent safety codes for specific requirements.

A wide variety of materials is available for guard construction, including woven wire mesh, expanded metal, and sheet steel. Size and weight of the part being handled determine the correct choice. Support steel and headers are usually structural angles.

Typical Sections

• Sheet Metal Type: Sheet metal guards are often used after dip tanks or washes, where dripping may be problem, and on conveyors carrying small or fine materials that would pass through expanded metal or wire mesh.

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• Expanded Metal or Wire Mesh Type: Conveyor guards are fabricated from heavy gauge expanded metal or wire mesh and welded to angle iron frames.

• Multiple Run: If several runs of loaded conveyors can be routed close together, a single wide guard will serve more than one conveyor.

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SECTION V - VERTICAL CURVE DATA

Table 6. Track ???-- Vertical Curve Radii for Overhead Conveyors as Related to Trolley Spacing. Minimum and Recommended Radius of Vertical Curve

Chain Type Trolley Spacingin (mm)

Radius of vertical Curvein (mm)

Minimum Recommended

X-228(X-50-6)

8 (203.2) 24 (609.6) 48 (1219.2)12 (304.8) 36 (914.4) 48 (1219.2)16 (406.4) 48 (1219.2) 48 (1219.2)20 (508) 72 (1828.8) 72 (1828.8)

24 (609.6) 96 (2438.4) 96 (2438.4)

X-348 (X-75-13)

12 (304.8) 48 (1219.2) 60 (1524)18 (457.2) 60 (1524) 78 (1981.2)

24 (609.6) 78 (1981.2) 96 (2438.4)30 (762) 92 (2336.8) 120 (3048)

36 (914.4) 108 (2743.2) 144 (3657.6)

X-458X-100-16

8 (203.2) 36 (914.4) 72 (1828.8)16 (406.4) 66 (1676.4) 96 (2438.4)24 (609.6) 84 (2133.6) 120 (3048)32 (812.8) 108 (2743.2) 144 (3657.6)

X-678X-150-22

12 (304.8) 72 (1828.8) 144 (3657.6)24 (609.6) 132 (3352.8) 180 (4572)36 (914.4) 192 (4876.8) 240 (6096)

Note: Minimum radii to be used only when absolutely required and only after considering chain pull, imposed load on trolley, beam wear, and possibility of surge.

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Compound Vertical Curve

For vertical drop greater than shown subtract drop "D" of appropriate degree and radius in Table 7 from actual drop "D' and use the remainder to compute "S" and "L" dimensions as shown below:

For 15° Curves: S = Remainder X 3.864 L = Remainder X 3.732 + "L" from Table 7

For 20° Curves: S = Remainder X 2.924 L = Remainder X 2.7475 + "L" from Table 7

For 30° Curves: S = Remainder X 2 L = Remainder X 1.732 + "L" from Table 7

For 45° Curves: S = Remainder X 1.414 L = Remainder + "L" from Table 7

Example: 96 in radius, 30° curve, 60 in drop, vertical curve

Total Drop = 60 inChart Drop = 25.75 inRemainder = 34.25 in

S = 34.25 in X 2 = 68.5 in L = 34.25 X 1.732 + 96 =155.321 in

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To calculate the arc length of any curve, horizontal or vertical, for use in determining the total chain length the following formula can be used:

Example: Find the arc length of an 10 in radius, 45° horizontal turn.

3.1416 x Arc Radius x Arc Degree180Arc Length =

3.1416 x 18 in x 45°180Arc Length = = 14.137

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Table 7. Compound Vertical Curve Table

Radiusin (mm)

Dropin (mm)

Lin (mm)

Ain (mm)

AngleDeg.

48 (1219.2)

3.25 (82.55) 24.88 (631.82) 12.56 (319.09) 155.81 (147.64) 32.81 (833.44) 16.75 (425.45) 20

12.88 (327.03) 48 (1219.2) 25.13 (638.18) 3028.13 (714.38) 67.88 (1724.03) 37.69 (957.26) 45

60 (1524)

4.06 (103.19) 31.06 (788.99) 15.69 (398.46) 157.25 (184.15) 41.06 (1042.99) 20.94 (531.81) 20

16.06 (407.99) 60 (1524) 31.44 (798.51) 3035.13 (892.18) 84.88 (2155.83) 47.13 (1196.98) 45

72 (1828.8)

4.94 (125.41) 37.25 (946.15) 18.88 (479.42) 15

8.69 (220.66) 49.25 (1250.95) 25.13 (638.18) 20

19.31 (490.54) 72 (1828.8) 37.69 (957.26) 3042.19 (1071.56) 101.81 (2586.04) 56.56 (1436.69) 45

78 (1981.2)

5.31 (134.94) 40.38 (1025.53) 20.44 (519.11) 159.44 (239.71) 53.38 (1355.73) 27.25 (692.15) 20

20.88 (530.22) 78 (1981.2) 40.81 (1036.64) 3045.69 (1160.46) 110.31(2801.94) 61.25 (1555.75) 45

96 (2438.4)

6.5 (165.09) 49.69 (1262.06) 25.13 (638.18) 1511.63 (295.28) 65.69 (1668.46) 33.5 (850.9) 2025.75 (654.05) 96 (2438.4) 50.25 (1276.35) 30

56.25 (1428.75) 135.75 (3448.05) 75.38 (1914.52) 45

120 (3048)

8.19 (207.96) 62.13 (1577.98) 31.44 (798.51) 1514.5 (368.29) 82.06 (2084.39) 41.88 (1063.63) 20

32.13 (815.98) 120 (3048) 62.81 (1595.44) 3070.31 (1785.94) 169.69 (4310.06) 94.25 (2393.95) 45

144(3657.6)

9.81 (249.24) 74.56 (1893.89) 37.69 (957.26) 1517.38 (441.33) 98.5 (2501.9) 50.25 (1276.35) 2038.56 (979.49) 144 (3657.6) 75.38 (1914.52) 30

84.38 (2143.13) 203.63 (5172.08) 113.13 (2873.38) 45

180(4572)

12.25 (311.15) 93.19 (2366.96) 47.13 (1196.98) 1521.69 (550.86) 123.13 (3127.38) 62.81 (1595.44) 20

48.25 (1225.55) 180 (4572) 94.25 (2393.95) 30105.44 (2678.11) 254.56 (6465.89) 141.38 (3590.93) 45

240(6096)

16.38 (415.93) 124.25 (3155.95) 62.81 (1595.44) 1528.94 (735.01) 164.19 (4170.36) 83.75 (2127.25) 20

64.31 (1633.54) 240 (6096) 125.63 (3190.88) 30140.56 (3570.29) 339.44 (8621.71) 188.5 (4787.9) 45

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SECTION VI - TROUBLESHOOTING, LUBRICATION GUIDE AND INSPECTION CHECKLIST

Table 8. Troubleshooting Guide

Problem Possible Causes Remedy

Chain

1. Excessive chain wear.(Note: The chain will elongate due to wear; this is normal wear and is no fault of the system)

Lack of lubrication Lubricate chainSluggish or frozen trolley wheels See #1 under "trolleys"

Roller turn roller frozen See #1 under "Roller Turns"

Obstruction in chain path Remove obstruction and remove and replace chain if damaged

Conveyor Overloaded Conveyor should not be loaded beyond its designated capacities

2. Excessive slack chain

Chain growth through normal wear

Adjust take-up and, if necessary, remove links in chain

Maintenance schedule not adhered to Reinstitute maintenance

3. Surging chain Same as #1 above. Also see "Drive" Same as #1 above. Also see "Drive"

Trolleys

1. Sluggish or frozen trolley wheels

Residue accumulated from over lubrication

Remove from conveyor and clean. Remove welsh plug to clean and press on new plug with blunt tool.

Bearing corroded or worn out Replace wheels

Lack of lubrication Lubricate chainIncorrect lubrication Verify lubricant: replace if necessaryMaintenance schedule not adhered to Reinstitute maintenance

2. Bent trolley brackets Damaged in jam or by obstruction

Remove obstruction and replace damaged trolley bracket with new bracket. (Do not attempt to straighten bent brackets)

Roller Turns 1. Sluggish or frozen roller turn rollers

Dirt or grease residueClean thoroughly or replace if bearings are damaged. See Lubrication Guide

Lack of lubrication Lubricate chainIncorrect lubrication Verify lubricant: replace if necessaryMaintenance schedule not adhered to Reinstitute maintenance

I-Beam

1. Excessive wear or peening of flanges at vertical curves Excessive chain tension See #1 under "Chain"

2. Excessive wear on I-Beam web

Bent trolley brackets See #2 under "Trolleys"Eccentric loading Load carriers symmetrical

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Table 8. Troubleshooting Guide (cont.)

Trouble Possible Causes Remedy

Take-up 1. Floating frame movement sluggish or frozen

Spring compression, air pressure or counterweight load too great

Reduce the spring, air or counterweight loading

Dry or damaged expansion joints

Lubricate if dry and replace with new expansion joints if damaged.

Guide wheels worn or frozen Clean thoroughly or replace if worn

Drive

1. Decrease in conveyor speed

Belt slippage Adjust belt by loosening bolts on motor and pull back until belt is snug

Set screws on pulley are loose and causing pulley to rotate on shaft

Align pulley and tighten set screws

2. Drive stops Conveyor chain pull is excessive See #1 under "Chain"

3. Excessive noise in reducer

Lack of lubricationFill reducer with oil to oil level plate; or if needed change oil. Grease all fittings

Oil leakTighten all grease fittings and pipe plugs, clear breather tube opening and add lubricant

Worn or broken gear or bearing

Disassemble reducer and replace damaged part

4. Motor running above normal temperature

Conveyor chain pull excessive See #1 under "Chain"

Electrical Inspect electrical wiring and controlsBearing failure Inspect and replace motor

5. Slapping or pulsating caterpillar chain

Chain too looseAdjust drive take-up until chain is snug. (Do not remove any links of caterpillar chain or dogs)

Conveyor chain or caterpillar chain worn beyond use

Replace

6. Floating frames sluggish or frozen

Obstruction Remove obstruction and repair or replace any damaged equipment

Guide wheels worn or frozen with dirt or grease residue

Clean thoroughly or replace if worn

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Table 9. Lubrication Guide for Overhead Monorail Conveyors

Component Part Inspection Interval (See Note #1)

Lubricants at Temperature to 250°F (121°C)

(See Note #2)

Trolley WheelsOpen Race 30 days Oil = ISO 15-150Closed 30 days Grease = NLGI #2

Chain Pins -- 30 days Oil = ISO 15-150

Caterpillar DriveRoller Chain 30 days Oil = ISO 15-150Dogs 30 days Grease = NLGI #2

Back-up Rollers -- 30 days Grease = NLGI #2Back-up Bar -- 30 days Grease = NLGI #2

Traction WheelsAnti-friction 30 days Grease = NLGI #2Carbon 30 days NoneGraphite 30 days None

Roller TurnsAnti-friction 30 days Grease = NLGI #2Carbon 30 days NoneGraphite 30 days None

Floating Frame Wheels -- 30 days Grease = NLGI #2Take-up Frame Wheels -- 30 days Grease = NLGI #2

Track -- 30 days (Inspect for wear) None

Drive

Reducer Bearings 30 days See Manufacturer's Nameplate for lubrication requirements on reducer

and motor

Gear Box 30 daysIdler Sprocket 30 daysMotor 30 days

Note #1: The inspection interval and lubrication frequency should be adjusted according to the application; i.e.: elevated temperatures and/or process conditions.Note #2: Consult conveyor manufacturer or lubrication specialists for lubricant recommendations specific to each application especially for those above 250°F (121°C).

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Suggested Inspection Checklist for Trolley Conveyor Systems

Check for:1. Chain: Lubrication, excessive wear, slack chain2. Trolleys: Lubrication, sluggish or frozen wheels, bent bracket, loose bracket bolts3. I-Beam: Wear and peening on flanges at vertical curves; wear on web at load or unload points, horizontal

and vertical curves; obstacles on track interfering with trolley path4. Roller Turns: Lubrication, roller bearing wear, roller face wear, loose roller bolts, loose brackets bolts.5. Traction Wheels: Lubrication, bearings, rim wear, loose hub bolts, alignment6. Take-up: Lubrication, roller bearing wear, roller face wear, loose roller bolts, loose bracket bolts,travel

remaining, spring (screw) adjustment; expansion joint conditions (lubrication, wear, free movement); ease of floating frame travel

7. Drive: Lubrication (cat chain, machinery components, bearings, oil level in reducer), wear (cat chain, back-up bar, back-up rollers, cat unit sprockets), adjustments (cat unit take-up, cat chain should be tight; back-up bar; limit switch cut-off tripper bar), overload condition (chain pull indicator reading in overload zone, motor or reducer running at excessive temperature), belt drive condition (pulleys are aligned and set screws are tight, belts are in good condition and are not slipping), excessive oil leakage from reducer, loose mounting bolts, ease of floating frame travel.

www.cemanet.org

Using PredictiveMaintenanceSafety on ConveyorsCEMA BULK BELT SYSTEMS AND EMERGING TECHNOLOGIES COMMITTEE

Keith E. Meyers, P.E.

SKF USA, Inc.

Predictive Maintenance (PdM), also known as Condition Based Maintenance (CBM), is well known1 to reduce costs and improve machinery and plant reliability and availability by reducing the need for corrective or reactive maintenance and avoiding unplanned downtime. It is also well known2,3 that PdM improves worker safety in industry, including mining and quarrying by reducing the need for maintenance repairs. The PdM program can use a number of different detection techniques / technologies depending on the asset type and operating conditions. The most common PdM technologies used on conveyors is vibration analysis followed by lubrication analysis and thermography. Vibration analysis can be applied to the conveyor pulleys-—head, tail, bend and take-up, and the gear drives and motors.

The vibration analysis must be properly implemented to be done safely. Vibration monitoring can be done with a portable vibration data collector with either a “portable” sensor or permanent mounted sensors. Vibration monitoring can also be made on a continuous basis using permanent mounted sensors and monitored by either a vibration transmitter or on-line system. The output of the vibration transmitter can be connected to the plant automation for monitoring. Portable data collectors and on- line systems are then evaluated by a vibration analyst.

Portable sensors, usually sensors attached to a magnetic base, can only be safely used if they can be attached to the conveyor pulley bearing housing or driveline outside of any guarding. Usually the guarding prohibits temporary attachment of the portable sensor. Good safety practices and regulation (MSHA in USA) prohibit reaching around the guarding. Cases have been seen where the guarding is inappropriately modified to allows access to the pulley bearing housings. See Figure 1.

The safest technique for vibration monitoring on conveyors is to use permanent mounted sensors fastened to the conveyor pulley bearing housing, gear drive and motor, and the sensor cables routed outside the protective guarding. Permanent mounted sensor should have a low profile with sideexit cable. The cable should be integral with the sensor body and have a steel over braiding. See Figure 2. These features are needed to ensure the reliability of the sensors and cables and ensurethe sensors themselves don’t become maintenance items. The sensor cables are routed to a common enclosure with BNC type connectors that the portable vibration data collector can connect to, or to a common enclosure for wiring to the vibration transmitter or on-line system. Permanent mounted sensors, besides being used where the conveyor has guarding, can also be used where theconveyor is elevated or has risky access, thus helping avoid worker exposure to hazards. 4

The maximum distance between the sensor on the conveyor and the BNC enclosure for portable data collection is 30m (98 feet). Permanent mounted sensors and portable vibration data collectors used in underground coal mines must have local regulatory (MSHA in USA) approval.

Sound monitoring of the conveyor idler rollers using a portable data collector can also be applied as an objective means to detect failing idlers. This can help detect a failing idler earlier than might be detected by the human ear, thus avoiding the risk of a seized idler that might damage the belt, requiring potentially hazardous repairs or fire.

1 Making maintenance smarter Predictive maintenance and the digital supply network. Chris Coleman, Satish Damodaran, Mahesh Chandramouli, Ed Deuel, May 09, 2017, Deloitte University Press.2 Predictive Maintenance: Marrying Safety With Productivity. https://www.mbtmag.com/article/2016/12/ predictive-maintenance-marrying-safety-productivity3 How predictive maintenance can improve worker safety in dangerous industries. http://www.genesissolutions.com/how-predictive-maintenance-can-improve-worker-safety-in-dangerous-industries4 For More Operation, Maintenance, and Safety information see the 7th ed. Belt Conveyors for Bulk Materials

Figure 2. Vibration / temperature sensor designed specifically for mining, mineral processing and cement

Figure 1. Inappropriate modification of guarding