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4. Sortation
5. Recirculation
6. After-sort Lines
Slide 1
There are different modes of operation for FILLING and DRAINING depending on the conveyor type:
Filling
Draining
Singulation Mode Slug Mode
LR or MDR
LR or MDR
Slide 2
Equipment Application: Accumulation LR - Belt Driven Live Roller Fill The Conveyor Singulation Mode
Case Ft/Min. = 50% of Belt Speed CONTACT accumulation!
Speed Formula:
Transport
Accumulate
Accumulate
Slide 3
Equipment Application: Accumulation AR+ Motor Driven Roller Fill The Conveyor Singulation Mode
Non-CONTACT accumulation! Speed = minimum rate required
Faster is better for rate spikes! Speed Formula:
Slide 4
Equipment Application: Accumulation Belt Driven Live Roller Drain The Conveyor Singulation Mode
Case Ft/Min. = 50% of Belt Speed CONTACT accumulation!
Accumulate
Accumulate
Transport
Slide 5
Equipment Application: Accumulation AR+ Motor Driven Roller Drain The Conveyor Singulation Mode
Non-CONTACT accumulation! Belted zones required for better accuracy and problem products
Speed Formula:
Slide 6
Equipment Application: Accumulation Belt Driven Live Roller Drain The Conveyor Slug Mode
Release a 10 ft. or 20 ft. or 30 ft. long slug of cartons at the same time, with no gaps between cartons! A slug release signal will cause all accumulation in the slug zone to be powered at the same time. All cartons will then move forward at the same time leaving no gap between cartons. When the slug release signal is stopped, the zones will enter standard singulation release mode. PhotoEye Sensor Accumulation requires the addition of a Slug Input Module and a Slug Isolation Link to control the slug zone.
Slide 7
Equipment Application: Accumulation AR+ Motor Driven Roller Drain The Conveyor Slug Mode (Train)
Non-CONTACT accumulation! Belted zones required for better accuracy and problem products Maintains gap from zone to zone upon discharge of conveyor Caution Power supply requirements change with slug release of MDR.
Speed Formula:
Slide 8
Rule of Thumb: The slower you run conveyor the better. Keep the speeds around 160 fpm or slower (120 fpm is an optimum accumulation speed). Carton side-by-sides and jams occur more frequently as speeds go over 180 - 200 fpm.
Always consider the carton size range and weight range when selecting conveyor speeds.
180 FPM - ABEC1 IS NOW OUR STANDARD PRODUCT FOR ALL SPEEDS! 230 FPM - Machine Crowned Pulleys required Slide 9
Slide 10
Slide 11
Problem Set #1
LR Accumulation Speed Accum Slug Speed = (Ave. Case Length) x (Case Rate) Factor
Conveyor Type LR Photo Eye LR Photo Eye Mode Singulation Slug CFPM Factor .5 .95
Speed = (Ave. Case + Zone) x (Case Rate) Factor Speed = (Zone Length) x (Case Rate) Factor
Conveyor Type AR+ AR+ Mode Singulation Slug CFPM Factor .9 .95
Slide 12
Problem Set #1
#1
24 Rate Carton using LR Phote Eye Singulation Release 40CPM 24/12 x 40 CPM = 80 Case Ft./Min. Required 80 cfpm / .5 Factor = 160 Ft/Min Belt Speed 24 Rate Carton using LR Photo Eye Slug Release 40CPM 24/12 x 40 CPM = 80 Case Ft./Min. Required 80 cfpm / .95 factor = 85 Ft./Min. Belt Speed
#2
Slide 13
Problem Set #1
100 ft./Min / .95 factor = 105 Ft./Min Conveyor Speed Slug Mode Formula:
Slide 14
4. Sortation
5. Recirculation
6. After-sort Lines
Slide 15
Types
Slide 16
A word or two on Air Brakes: Always use coated rollers at merge points. Actually, I recommend you always use coated rollers on air brakes, period. Consider your product: Light totes, pushed by heavy totes, can be pushed over the air brake and into the merge point causing a jam. Small cartons (9 or shorter) can dribble past an air brake if the stop signal is not timed right. Slide 17
Slide 18
Run the sweep 10% to 15% faster than the infeed accumulation conveyor
Slide 19
Align cartons to the inside of the sweep. But the outside is ok.
Run the curve 10% to 15% faster than the infeed accumulation conveyor Slide 20
Slide 21
Equipment Application: Central Merge Air Brakes and Brake Meter Belts
A word or two about air brakes and brake meter belts
Air Brakes
At higher rates.
When to use Air Brakes (with Coated Rollers): When merging slugs of product. Why? Air brakes will not guarantee a gap between cartons, so individual carton cannot be stopped 100% of the time. Why? You start merging smaller slugs, maybe individual cartons, to get the higher rate. To merge small slugs, you need gapped cartons that only the speed change of two belts can generate. Wide range of product size and weight, and small boxes. Why? The brake belt will do a better job of holding back the impact of accumulation products and prevent cartons from being pushed over the brake and into the merge. Small boxes (<9 Lg.) can sometimes dribble past the air brake causing a jam. Brake meter belts reliably stop small boxes.
For Merge Control: 10 to 30 cpm: use air brakes 40 to 50 cpm: start thinking about brake meter belts 60 cpm or higher rates: use brake meter belts.
Slide 22
Slide 23
Slide 24
Slide 25
Re-alignment section
Re-alignment section
Slide 26
A Common Problem Cartons can accumulate back into the alignment section (a hard drive section) causing carton rotation, side-by-sides, and jams. Solution #1 Locate the accumulation line-full photo eye downstream at a distance that avoids accumulating on the skew section. For this layout, this solution wont work! The accumulation conveyor is not long enough to accept all the cartons on the sawtooth, the skew section, and the accumulator. Solution #2 Put a motor on the skew section. The sawtooth has a motor already. When the accumulation conveyor fills up, simply turn off the sawtooth and skew conveyors. All merge and alignment conveyors must be cleared or stopped to avoid carton side-by-side problems.
Slide 27
Brake belt roller sawtooth 50-90 cpm Air brake merge. 20-40 cpm
Air brakes can be used at lower rates when merging slugs of product. Brake belts can be used at higher rates when merging single cartons Higher rates are possible when the release points are close together.
Problem Set #2
B
Why that one?
50# carton could push through the air brakes on the other options.
Slide 29
Problem Set #2
B
Why that one?
50# carton could push through the air brakes on the other options.
Slide 30
How fast would belt driven live roller PE accumulation run in this example if the rate was 55 CPM?
Problem Set #2
Would you choose slug or singulation release for this merge area and why?
Slide 31
How fast would belt driven live roller PE accumulation run in this example if the rate was 55 CPM?
#1
Problem Set #2
24 Rate Carton using LR Phote Eye Singulation Release 55CPM 24/12 x 55 CPM = 110 Case Ft./Min. Required 110 cfpm / .5 Factor = 220 Ft/Min Belt Speed 24 Rate Carton using LR Photo Eye Slug Release 55CPM 24/12 x 55 CPM = 110 Case Ft./Min. Required 80 cfpm / .95 factor = 115 Ft./Min. Belt Speed
#2
Would you choose slug or singulation release for this merge area and why?
Slug, to avoid running the accumulation too fast. Opinions?
Slide 32
4. Sortation
5. Recirculation
6. After-sort Lines
Slide 33
There are different carton spacing / induction methods depending upon the carton rate.
Slide 34
3. Dynamic Induction Uses slow-down / speed-up control over induction belts to release cartons onto sorter. Creates consistent gaps between cartons. BGO, SGO
Variable accel / decel ramps and variable speed motor control. 60 to 250+ CPM 2 belt or 3 belt unit. Vector or Servo motor. Consult factory for high rate applications.
Slide 35
The typical single line induction system will use either: Speed Space Induction or Stop Start Induction
Slide 36
Slide 37
2.
5.
3.
Slide 38
1.
Accumulation Speed
((24 carton / 12) x 25 cpm) / .5 CFPM factor = 100 fpm 100 FPM x 1.1 = 110 fpm Brake Belt Speed 25 x (24/ 12) = 50 fpm Choose closest standard speed (See chart on left) 60 FPM is closest standard speed Induction Belt Speed 60 FPM belt is available only with a 2:1 ratio (see chart on left) Induction belt speed is 120 fpm In this case Sorter will run 310 fpm 120 fpm + ((310 fpm 120 fpm) / 2) = 215 fpm Next Standard Belt Speed is 220 fpm
2. 3.
Induction Speed
24 9 30
4.
Scanner Belt
Slide 39
1. Accumulation Speed
((24 carton /12) x 45 cpm) / .5 CFMP factor = 180 FPM 180 FPM x 1.1 = 200 fpm Brake Belt Speed 45 cpm x 24 carton / 12 = 90 fpm 90 fpm is a standard speed. Induction Belt Speed 90 fpm belt is available with a 2:1 ratio (See Chart on Left) Induction belt speed is 180 fpm
3. Induction Speed
4. Scanner Belt
In this case Sorter will run 350 fpm 180 fpm + ((350 fpm 180 fpm) / 2) = 265 fpm Next Standard Belt Speed is 280 fpm
Slide 40
1. Accumulation Speed
((24 carton /12) x 60 cpm) / .5 CFPM factor = 240 fpm 240 fpm x 1.1 = 270 fpm
Live Roller Accumulation 3. Induction Speed Brake Belt Speed is ineffective at this 60 cpm x 24 carton / 12 = 120 fpm speed. Use as a blow 120 fpm is a standard speed. through induction lane at Induction Belt Speed lower speeds if possible. 120 fpm belt is available with
a 1.5:1 ratio (see chart on left) Induction belt speed is 180 fpm
4. Scanner Belt
In this case Sorter will run 220 fpm 180 fpm + ((220 fpm 180 fpm ) / 2) = 200 fpm 200 fpm is a standard speed.
Slide 41
1. Accumulation Speed
((24 carton /12) x 70 cpm) / .5 CFPM factor = 280 fpm 280 fpm x 1.1 = 310 fpm Brake Belt Speed 70 cpm x 24 carton / 12 = 140 fpm Choose Closest Standard Speed (see chart on left) 150 fpm is closest standard speed Induction Belt Speed 150 fpm belt is available with a 1.5 : 1 ratio (see chart on left) Induction belt speed is 220 fpm
3. Induction Speed
Live Roller Accumulation is ineffective at this speed. Use as a blow-through induction lane at lower speeds if possible.
Slide 42
New Servo Induction Belt Design Modular Construction Use a two-belt or a three-belt unit to provide the required speed control Single Line induction Dual Line Induction Multiple Belts
Slide 43
110-120 CPM
160-180 CPM
180-250+ CPM
Minimum carton size is important - having an extremely short minimum carton will add a third belt to most induction systems!
Slide 44
Slide 45
Problem: 386 fpm exceeds allowable accumulation speed! Solution 1: Reduce the Rate Carton to 12! (If only it was that easy!) Solution 2: Change the layout to a dual line induction. This will cut the rate in half and get the accumulation speed down to allowable limits. Solution 3: Use slug mode to allow blow-through from the accumulator.
Slide 46
Note: 1. 2. 3. 4. Two Stage Belt required at 42 CPM The speeds are relatively low. The sort rate and the infeed line rates are relatively low. Is the product relatively stable?
2.
3.
4.
Induction Configuration:
100 fpm
200 fpm
200 fpm
300 fpm
320 fpm
Slide 47
Slide 48
Commonly called a wedge merge. Advantages of this induction method: High sorter rate, 250+ cpm (limited to 150 cpm for both-side sorting) Multiple infeed lines Slower induction and accumulation belt speeds which reduces the amount of carton jams and sideby-sides
Slide 49
Scan Belt
Sorter
Sorter
Accumulation lines
Slide 51
6. After-sort Lines
Slide 52