Conveyor Systems

Introduction
The complete guide to conveyor systems on the internet.

You will learn:

 What is a Conveying System?

 Conveyor System Requirements
 Types of Conveyor Systems
 How Does a Conveyor System Work?
 And much more …

Chapter One – What is a Conveyor System?

A conveyor system moves packages, products, supplies, parts, and
equipment for production, shipping, or relocation. The different types of
conveying systems include pneumatic, screw, belt, and roller. The
construction of individual systems depends on the materials to be moved,
which includes their weight, dimensions, and ability to be transported.

Though conveying systems are essential to material handling and

production, they are also used for production applications, such as sintering,
part and assembly finishing, and part washing. In the majority of cases, they
are automated though unautomated designs using chutes and rollers are
common in retail, material handling, and shipping applications.
Conveyor System Design Requirements
There are many ways that a conveying system can fit into an operation to
increase efficiency and enhance speed. Prior to making the decision to install
a conveying system, there are certain, important considerations that have to

be examined. Each system is designed to meet the demands of a specific

application.

Space:
Conveying system manufacturers examine the available space to determine
system design. This step requires identifying interaction points, clearances,
obstructions, or any possible areas that could interfere with material
movement. Though automated systems are most common, how the system
is used will determine whether it is motorized or manual.

Load Capacity:
Once the system has been laid out and given a pattern, it has to be
determined what will be the amount of materials it can carry. Overloading a
system can damage it or cause it to stop in the midst of its operation. Factors
that influence the load capacity are overall length and bed width as well as
the drive system.

Speed:
The speed of a conveying system is measured in feet per minute (fpm). The
average speed of most conveying systems is 65 fpm, which is how fast a
person moves when carrying a 50 lb. package. Though that is the average,
the speed can be lowered or raised to fit the application

Powder or Liquid Material Handling:

Powdered material handling has a different set of parameters from
conveying systems that handle solid bulky items. A well designed powder
and liquid conveying system has to be sufficiently sealed to prevent powder
or liquid escaping. Movement of powdered, granular, and chip type materials
can have dust build up, which is considered in system design and may
necessitate some form of filtration. As with other conveying systems, a
careful examination of the characteristics of the material is required.

Configuration:
Conveying systems come in a wide variety of shapes, designs, sizes, and
forms. They can be vertical, angled, horizontal, curved, include pockets or
slats, and have z-frames. Since each system is designed to fit a special
application, it would be impossible to cover all of the different configurations.
What is important to understand is that there are very few restrictions on
adding a conveying system, regardless of the application.

Drive System:
The drive of an automated conveying system is the power that moves
materials. It has a counter bearing to keep items moving and allows
movement along the belt. They can be designed to move items in both
directions and be located in the middle, end, or beginning of the system.
Overhead systems, though they have similar drives, have ones that may be
chain or sprocket driven. Liquids, granular materials, and powders may have
conveying systems that use pneumatic power or screw drives.

Drive systems can have single or variable speeds depending on their design.
They usually have a system of gears run by a motor. Variable speed drives
have become popular for modern conveying since they allow for changes of
material flow.

Safety:
Conveyor systems are regulated by the Occupational Safety and Health
Administration (OSHA) and must meet government safety requirements. All
conveyor manufacturers are aware of the regulations and adhere to them.
Conveying systems are a preventative measure that protect employees from
having to lift and move bulky materials.

Note in the image below the emergency stop button, a keyed motor
activation, and symbols displaying conveyor operation.

Types of Conveyor Systems

There are a multitude of conveyor types, designs, and processes. The most
common types are belt, roller, and overhead with overhead and floor
mounted being the two broad categories. Conveying systems have as many
benefits as there are types and are a normal part of large scale operations.

Belt Conveyors–
Belt conveyors are the most common and simplest form of conveyor and can
have variable speeds. They have a moving belt that rests on a steel frame
that supports the belt and the materials being moved. Ones that have a
supporting frame underneath are referred to as sliding style. When the belt
is supported by closely placed rollers, it is called a roller belt style.

Gravity Roller Conveyors

Gravity roller conveyors have a set of equally spaced rollers connected to a
side frame. The position of the rollers provides a surface to place materials
for movement. If a gravity roller conveyor is tilted or mounted on an angle,
materials move by gravity. Though pieces of varying sizes can be loaded on a
gravity roller conveyor, workers need to be cautious of larger materials
running into smaller ones. Gravity roller conveyors are used by shipping
companies to load and unload trucks.

Chain Conveyors–
Chain conveyors can have two or several sets of chains that make contact
with the bottom of items to be moved. The materials rest on the chains as
they are moved. Chain driven conveyors are ideal for items with uneven
bottom surfaces or ones that are very heavy. Ones that have a heavy frame
can have pallets placed directly on them. Due to the types of items chain
conveyors move, they operate very slowly.

Motorized Roller Conveyors

Motorized roller conveyors use motors, placed along the conveyor frame, to
power evenly spaced rollers. The design is similar to a gravity conveyor with
the addition of motors. The number of motors is dependent on the load to
be moved and the overall design of the system. The connection between the
rollers can be a chain or belt. In some systems, there is a sensor that starts
and stops the motor to avoid pieces getting packed together.

Slat Conveyors–
Slat conveyors have the same design as chain conveyors with flat slats
connected to the chain. In some ways, they are similar to belt conveyors with
slats replacing the belt.

The slats have a very smooth surface that prevents damage or harm to items
being moved, making them ideal for assembly applications. Since the surface
is smooth and without obstructions, slat conveyors can be loaded and
unloaded using robotic automation.

Overhead Conveyor Systems

There are several different types of overhead conveyor systems, each of
which has a similar function with a different design. The main purposes of
overhead conveyors are to free up floor space and make part and
component movement easy and efficient.

Enclosed Track Conveyor - An enclosed track conveyor has an enclosure

that completely covers the trolley connectors with only a small gap for the
movement of the trolley. The enclosure protects the track from wear and
makes it easier to place bends and curves in the system.
Open Track Conveyors - Open track conveyors do not cover the track and
use I beams as the track. They are easy to install and ideal for long straight
configurations.
Chain Overhead Conveyors - Chain overhead conveyors use a continuous
powered chain that runs along a track. Fitted to the chain, at regular
intervals, are pendants from which parts or products hang. In other designs
where pendants are not used, pusher dogs may be used to move trolleys
along a second track positioned beneath the chain track. This type of system
is referred to as power and free.

Monorail Conveyors–
Monorail conveying systems have carriers to move materials and are ideal
for use over long distances. Rails are suspended from the structure of the
building and have power supplied by signal lines from conductor lines inside
the mounted rails. Monorail conveyors make use of the space above the
production area. In some designs, the carriers lower to the level of
production and then go up, out of the way.

Power and Free Conveyors–

Power and free conveying systems are designed to move parts through the
production and assembly process. Items being assembled move from
workstation to workstation. They stop at each station to be worked on and
then move on. Power and free systems are a special form of overhead
conveying system.

The unique design of power and free systems allows a product to be

buffered along the conveying path, start and stop automatically, and are very
versatile and adjustable. Unlike continuous flow chain conveying systems,
power and free systems make it possible to stop individual loads for
adjustments.

Inverted Conveyors–
Inverted conveyors are floor mounted and can be used as power and free
conveyors. They normally have a drive system that does not involve a belt or
chain.

Paternoster Conveyors–
Paternoster conveyors are a vertical conveying system that uses equal
spaced load carriers connected to a chain drive, which moves in a continuous
loop. They are also known as platform conveyors.

Chute Conveyors–
Chute conveyors have a smooth flat surface made of wood, metal, or plastic
that is set on an angle in a frame, which can be straight, spiral, or circular.
Items are slid down the surface.

Screw Conveyors–
Screw conveyors are used to move bulk substances such as granular
products, chips, and loose materials. The central part of a screw conveyor is a
rotating helicoid on a shaft inside a pipe. Screw conveyors are known as
auger, helix, and spiral conveyors. The blades of the screw flights are
designed to carry the material upwards.

Pneumatic Conveyors–
Pneumatic conveyors transport bulk materials using a pressurized gas that
pushes the material through a sealed pipeline. As the pressure builds in the
pipeline, powders or granular materials are lifted and moved through the
pipe.

Vibratory Conveyors–
A vibrating conveyor uses vibrations to move materials along a conveying
trough and is ideal for materials such as grains, various solids, vegetables
being picked in a field, and quarried rocks. The agitations and constant
motion gently moves products through the use of vibration cycles. Each form
of vibratory conveyor has a specific design to fit its function with ones for
mining being radically different from those made for harvesting and food
production.

A major benefit of vibrating conveyors is their excellent performance in the

harshest conditions and environments.

Chain on Edge Conveyors (COE)

A chain on edge conveyor is a single strand chain conveyor that runs on its
side and uses a roller chain that runs in a plate supported channel. The chain
is capable of flexing along the horizontal axis allowing it to make horizontal
turns and is capable of making vertical curves. The various types of twists
and turns a COE makes allows it to be more versatile than traditional chain
driven conveyors.

Skid Conveyor
Skid conveyors are another form of floor mounted conveyor that moves
products on fixtures that have longitudinal runners called skids with travel
being longitudinally and transversely. There are several elements to a skid
conveying system that include power rollers, pivot tables, shuttle carriages,
and two strand chain systems. Skid conveyor systems are valued for the
efficiency and quiet mode of transport. The variations in skid conveyor
systems are due to the many components and control systems that can be
included.

Friction Conveying System

A friction conveying system uses a motor to drive a friction wheel made of
non metallic material to create driving force. The system consists of a friction
drive, load bearing track, switch, stopper, trolley, elevator, and steel
structure. Friction conveying systems are a safe alternative to power and free
systems with the major benefit of operating cleaner and quieter. They have a
flexible layout, unit construction, easy speed changing, can easily be
expanded, and low overall cost.

The main purpose for friction conveying systems is to assist with operations
that have a high production rate. They can be inverted or overhead
depending on their basic design. Friction conveying systems transmit force
directly to a skid, slide, pallet, or carrier using a friction wheel.

How does a Conveyor System Work?

Conveyor systems work as an integral part of a larger process. When
explaining the function of a system, it is important to examine all aspects of
the overall production process and how the various pieces fit together. Much
of the determination of the workings of the system is set during the design
phase. Once the system is in place, its inner workings become a complex
moving process that is critical to the efficiency and success of an operation.

How a Conveyor System Works

To limit the discussion of conveying systems, the information below focuses
on belt conveying systems since they are the most common.

Belt:
Belt conveyors use a system of motorized pulleys that have a belt made of
thick durable material looped over the pulleys. When the motor is activated,
the belt is pulled between the pulleys.

Support System:
The support system allows the belt to move smoothly. It is specifically
designed to hold the moving material without sagging. In the design phase,
the weight capacity of the frame is determined and the frame is constructed
to meet the needs of the operation.

Pulleys:
Conveyor belt systems have at least two pulleys to control belt movement, a
drive pulley and tail or return pulley. In between them are idler or dummy
pulleys that are moved by the belt. The drive pulley pushes or pulls the load,
while the tail pulley returns the belt. As can be seen in the diagram, idler
pulleys serve a variety of functions in guiding the belt, which include
controlling its tension.

Belt Cleaner:
The purpose of a belt cleaner is to remove any carryback that may remain on
the belt after the load is discharged from the belt. Carryback is common in all
belt systems and is one of the major issues that causes belt malfunctions.

Drive:
The drive for the belt can be located in various positions in the conveying
system. For most belt conveyors, the drive is located at the discharge or head
of the belt. Other locations can be anywhere along the belt depending on the
design. AC motors are generally used to power the pulley that moves the
belt.

Conveyor System Applications

As automation and production have become more technologically advanced,
conveyors have rapidly developed into an essential part of material
processing and movement as well as enhancing the speed of various
production operations.

Conveyor System Applications

Sintering:
Sintering is a production process used to significantly lower the temperature
of a piece just below its melting point to shape and form the piece.
Conveyors transport the piece into the high-temperature furnaces for the
sintering process.

Packaging:
A packaging conveyor is designed to assist with product packaging, such as
placing finished products in containers, efficient labeling, or preparation of
products for shipping. The function of a packaging conveyor system is to
move products from completion and assembly for shipment. They provide a
safe method of moving materials and avoid the need for employees to carry
heavy items.

Production Line:
A production line conveyor is designed to bring work to workers, which
avoids the need to move an assembly crew. The advantages of a production
line conveyor is to easily move products through the assembly process for
each task to be efficiently performed. What begins as raw materials at the
beginning of the assembly process is a completed product at the end.

Pharmaceutical:
The pharmaceutical industry requires specially designed conveying systems
that can be installed in a sterile environment but be flexible, reliable, and
easily accessible to prevent contamination. Pharmaceutical conveyors move
products in and out of sterilization processes that use toxic chemicals. This
requires conveyors made of materials capable of withstanding such
exposure.

Metalworking:
The demands for metal production has increased the use of conveying
systems to improve productivity and efficiency. The various processes of
metalworking can be completed accurately and precisely by using a
conveying system. Cutting and molding for the production of large quantities
of products can be done quicker. Press out conveyors are used to remove
molded pieces from the pressing line or on to other operations.

Airport:
Though airports have people moving conveyors, the main conveying system
is for luggage handling, which speeds up the process of getting luggage from
the checkin counter to the airplane and off the airplane to luggage pickup.
Highly sophisticated and complex systems limit manual involvement and
move packages and bags. Airport conveying systems employ several
different varieties of conveying systems, which can be on an angle, vertical,
or horizontal.
Mining:
Conveyors are essential for mining operations to move raw materials but
must be durable enough to withstand extremely harsh conditions. Most
mining operations are in secluded areas that make it difficult for trucks to
access. Mining conveyors remove the need to create a means for trucks to
reach the operation. Though mining conveyors vary in size and length, the
majority of them are on an incline and move several tons of material. They
have to be evenly loaded to avoid spillage or empty spaces. Depending on
the design, they operate very rapidly up to 100 fpm.

Automotive:
The automotive industry uses several varieties of conveyors for material
handling. Parts and car bodies can be easily moved from one operation to
the next. They are especially helpful in moving heavy items such as doors,
bumpers, chassis, and frames.

Food Processing:
Food conveyors move foods and organic materials safely and quickly at a
lower cost than that of manual labor. The term food conveyor covers a
variety of systems that includes rollers, belts and dumpers or anything used
to move food products through the manufacturing process. As with all
conveying systems, food processing conveyors are customized to fit the
needs of the manufacturer and the application. The one factor that makes
them unique is the requirement to meet governmental regulations for
sanitation and cleanliness

Printing:
Printing conveyors, for screen printing, use a conveyor dryer process for
drying screen printed material. Though there are other methods for drying
screen prints, conveyor dryers are used for large volume production and
come in several varieties. In the drying process, hot air is forced on to the
garment at a controlled temperature with an even flow as the item passes
along the conveying system.
Benefits of a Conveying System
Conveyors have become an important part of manufacturing, mining,
production, and finishing operations. They increase efficiency and help
reduce labor costs. The use of conveyors has led to greater volume,
increased production, and prevention of injuries.

Regardless of the industry, conveyors have been proven to be a boost for

production processes.

Benefits of Conveying Systems

Time Savings:
Materials can be moved from location to location or from one level to
another rapidly and easily

Continuous Operation:
Materials are continuously loaded and unloaded for long periods of time
without interruption or stoppage.

Automated Unloading:
Conveyors can be designed to automatically unload materials without the
need for manual labor.

Control of Movement:
Conveying systems have speed controls to monitor how rapidly items move
along the system, which eliminates the concern for handling issues or
breakage

Directional:
Though older conveying systems were able to move in only one direction,
modern conveyors, with CNC controls, can move in forward or back. This
helps in adjusting manufacturing operations.

Low Maintenance:
The majority of conveyors require little maintenance, though there are some
varieties with motors and parts that need to be continually checked and
replaced. The need for maintenance depends on the conveyor's use and
environment.

Safety:
Conveyors are the safest method for moving materials through a facility or
production floor. They have built in on and off switches, emergency stop
switches, and speed adjustments. The image below is of a safety cable stop
for conveyors.

High Volume:
Conveyors are a part of an automated system capable of moving hundreds
or thousands of tons of material per hour or in a day.

Conveying System Malfunctions

There are malfunctions that can occur in a conveying system that is
continuously in use. Some of these can be avoided by regular maintenance
checks.

Conveying System Malfunctions

Mistracking
Mistracking is also known as belt drift, where the belt drifts to one side. A
misaligned belt can seriously damage the belt by uneven wear or damage
items on the belt. The image below is of a belt that has drifted to the left.

Seized Rollers
Part of the mistracking problem may be associated with a seized roller, which
can lead to sharp edges that would shut down the system. Since conveyor
systems are made from metal, a seized roller can develop sharp edges.

Slippage
Slippage on a belt conveyor can occur due to tension being too high or low,
which can lead to stretching and conveyor belt slippage.

Blockage
Conveyor systems are designed to operate continuously without interruption
or stoppage. Any form of blockage can be damaging to the system and lead
to major repairs.

Carryback
There are several varieties of carryback. The most common is when material
sticks to the belt and goes past the transfer point and falls off. Carryback can
be seen at the bottom of the image below

Spillage
When a belt conveyor is overloaded, or too packed, materials can fall off the
sides. This can occur when employees are not trained properly, or there is a
problem up the line

Unload or Chute Blockage

Unload problems occur when material does not flow properly from the
conveyor at the off load point. When this happens, the whole system can
shut down.

Pneumatic Systems
Pneumatic blower packages never fail and will run for a very long time. The
first sign of a problem is a change in system pressure, which include issues
with feeding, build up in the line, uneven feed, and a plugged pipe. For most
pneumatic conveying systems, there are five places where a problem can
occur – blower package, conveying line, bin vents, filter, or airlocks. The
image below is of product build up in the line.

Screw Conveyors
Fatigue in a screw conveyor occurs when there is build up in the pipe as the
conveyor turns. There is always a gap between the wall of the pipe and the
blades of the screw. In that gap, material collects and hardens. As the screw
turns, the material breaks up and moves on in solid form. On some
occasions, the solidified material remains and causes the screw to work
harder, which places strain on the centerline of the screw

Conveyor System Maintenance

Though it may seem that a conveying system is one machine, in actuality, it is
a system of several interacting pieces that are dependent on each other to
function properly. To successfully maintain a conveying system, and avoid
problems, it is important to examine each individual piece and how they play
a part in the total operation.

Repair or Replace
Making the decision to replace a component on a system has several cost
factors, such as the downtime for the system, finding the right component,
and hiring a specialist to do the replacement. This expense can be offset with
regular maintenance and monitoring of the system.

Motor
The key part of a conveying system is its motor. Most motors fail due to
problems with bearings and windings with bearings being the main cause.
Bearing failure can be attributed to lubrication problems. This can be
avoided by having a regular maintenance cycle for bearing upkeep. The
temperature level of the motor should never exceed its recommended
operating temperature.

Pulley Bearings
Pulley bearings are completely filled with lubricant to keep out water and
contaminants. In most cases, they never need repair if they are regularly
checked and maintained. Manufacturers recommend to schedule
maintenance in accordance with the amount of use of the system.

Cleaning
Regardless of the type of system, keeping it clean is important. Belts, rollers,
chains, motors, slats, and all visible areas should be cleaned regularly. This is
especially true with products that have received some form of treatment or
coating, which can cause components to become contaminated and be
seriously damaged.

Belt Tracking
Belt conveyors can have premature wear due to improper belt tracking,
which should be checked every time the belt is activated. Problems with belt
tracking can be caused by misuse of the conveyor, its environment, and poor
maintenance. Neglecting the belt can lead to expensive repairs.

Pneumatic Pressure
Many conveying systems have pneumatic components. As a part of
maintenance, it is important to make pressure adjustments as well as flow
control and regulator adjustments. Pipeline pressure should always be kept
at system specifications. High pressure on the pipeline can cause damage to
individual components.

Grounding
Conveying systems are susceptible to stray voltages that can short out the
system. Proper grounding can avert this problem.

Conveying System Safety Requirements

The Occupational Safety and Health Administration (OSHA) provides a set of
guidelines for the operation of conveying systems. Also, the American
National Standards Institute (ASNI), using the American Society of Mechanical
Engineers (ASME) guidelines, has safety considerations for conveyor design.

Each year the OSHA and ASME review these requirements and update them
to meet new technology and developments.

OSHA Guidelines
1926.555(a):
General requirements.

1926.555(a)(1):
A motor stoppage switch must be located at the operator position. The
system should have a warning light with sound that activates when the
system is turned on.

1926.555(a)(2):
Remote operations must have a stoppage switch at the motor.

1926.555(a)(3):
Emergency stop switches prevent reactivation of the system until the
emergency switch is reset to "ON".

1926.555(a)(4):
Protective coverings and protection on screw conveyors are required.

1926.555(a)(5):
Overhead conveyors must have protective coverings below the conveyor.
This can be overlooked if the position of the conveyor is away from
employees.

1926.555(a)(6) & 1926.555(a)(6):

Warning signs should be placed on crossovers, aisles, and passageways.

1926.555(a)(7):
Conveyors must be locked out or have warning signs during regular
maintenance.

1926.555(a)(8):
Conveyors must be constructed and maintained according to ANSI B20. 1-
1957 Safety Code for Conveyors, Cableways, and Related Equipment.
ASME Guidelines
The safety standards for conveyors is included in ASME B11.0-2020, which
covers the safe use of machinery and includes various safety devices that
should be part of the installation and construction process.

ASME B20.1-2018:
ASME B20. 1 -2018 includes the requirements for the design, construction,
maintenance, and operation of a conveying system regarding hazards. It is a
set of general safety guidelines. ASME B20. 1-2018 is for conveyors for
industrial use and not those designed to move people.

ASME B20. 1-2018 is included in the specifications in ASME B20.1, ANSI

B11.19, ANSI A1264.1, ANSI 244.1, which cover safety guidelines for
conveyors and walking surfaces.

ASME B20.1 and ANSI B11.19:

These are the part of ASME B20. 1-2018 that outlines the requirements for
construction, installation, maintenance, inspection, and operation of a
conveying system.

ASME B20.1, ANSI B11.19, ANSI B11.0:

These are further details regarding safety procedures for permanent,
temporary, and portable conveyors.

Conclusion
 Conveying systems are an essential part of automation and
production.
 Each conveying system is developed to fit a specific application.
 Though belt conveying systems are the most and easily recognizable,
other types include screw, pneumatic, chute, and roller.
 As with any form of machine, conveying systems require regular
maintenance.
 Safety is essential with conveying systems. OSHA and ASME provide
guidelines and regulations regarding the use and construction of
conveying systems.