Belt Conveyors
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A belt conveyor is a system designed to transport or move physical items like materials, goods, even people from one point to another. Unlike other conveying means that employ chains, spirals, hydraulics, etc...
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The content of this article contains everything you need to know about overhead conveyors and their use.
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An overhead conveyor is a material handling device that conveys parts, components, products, and supplies using a motor driven chain mechanism suspended off the floor. It is a space saving and efficient method for quickly transporting any shape or size of load for production, processing, storage, or placement. Overhead conveyors take advantage of unused vertical space and are a less intrusive method for product and part transport. They are capable of carrying items through procedures that are off limits or dangerous to humans, such as ovens, paint booths, sintering, and chemical processing.
The methods used to classify overhead conveyors are movement system, style of track, and installation. Movement systems are divided into manually hand pushed and motorized. The track types are in regard to the rails that carry vessels, parts, and containers, which can be simple I-beams or a form of enclosed track.
The installation of an overhead conveyor system is a specialized aspect of the systems and involves very careful precision planning. Although it may be assumed that an overhead conveyor system can be installed in any location, which is mostly true, the engineering and planning of an installation is due to every location being unique and requiring custom installing. Building structures, employee locations, offices, and other features of a building have to be considered prior to installing an overhead conveyor system. It is this aspect of the process that is the most challenging and takes time and preparation.
As with all forms of industrial equipment, overhead conveyors come in several different shapes and sizes since they are used by large and small manufacturing industries. In addition to the users of overhead conveyors, they also change in accordance with the types of items they carry, which can vary from automotive engines to small parts being heat treated, painted, or coated.
When discussing the types of overhead conveyors, it is necessary to keep in mind customized overhead conveyors that have been designed, engineered, and configured for a special type of operation or manufacturing process. This is especially true for industries that make unusual or unique parts that are produced by very few companies. There is a fine line between generic overhead conveyors and custom overhead conveyors since generic overhead conveyors may have to be manipulated to fit special conditions.
In the age of technology, it may seem inefficient to have a manually operated overhead conveyor since motorized overhead conveyors are more efficient. As with all forms of overhead conveyors, manual overhead conveyors serve a special function and are ideal for certain applications. The main use of manual overhead conveyors is in applications where a workpiece has to be moved from one process to another process. The use of manually operated overhead conveyors allows for easy movement between processes.
In addition, manual overhead conveyors can have conveyor switches and turntables, which makes it possible to change the direction of materials and run multiple conveyor tracks at one time. Turntables and switches transfer loads in different directions, the use of which makes better use of available space and helps in increasing efficiency and productivity. Although manual overhead conveyors operate by human power, they can have the same capacity as motorized overhead conveyors that can be over two tons (1814.37 kg).
Monorail overhead conveyors are used to move goods over long distances. They have rails that are suspended from the ceiling with power supplied from conductor lines mounted inside the rails. Monorail overhead conveyors are capable of changing levels, such as lowering a load to the work level and moving out of the way after being loaded or unloaded.
Items to be transported are loaded on attachments that hang from the monorail. The beam and chain of a monorail overhead conveyor supply traction for the movement of loads and load bearing capabilities to ensure smooth movement of materials. Monorail overhead conveyors can be motorized or hand pushed depending on the requirements of an application and its loads. Motorized monorail conveyors usually have stop and start buttons that make it easy and convenient to remove and load items.
The most basic forms of monorail overhead conveyor are found at dry cleaners and clothing stores that store clothing items in such a way that they will not be wrinkled or damaged. In manufacturing, monorail overhead conveyors are used for batch painting, movement of production lines, and assembly operations. They can be loaded by hand, forklift, crane, lifting gear, or robotics prior to moving workpieces for treatment or assembly.
The wide use of monorail overhead conveyors is due to their ability to offer a variety of methods for material flow and help in the reduction of production costs. The design of monorail overhead conveyors for finishing applications take several forms since some workpieces require exposure to multiple surfaces for complete finishing coverage. The flexibility of monorail overhead conveyors makes it possible to configure their tracks in such a way that workpieces can be returned multiple times for finishing.
Power and free overhead conveyors have a powered enclosed chain track that is positioned above an unpowered track with trolleys. Mechanisms referred to as “pusher dogs” that are simple devices that are inserted into the chain engage with the trolleys to move them along from location to location. The trolleys stop when the pusher dogs are disengaged. One power and free overhead conveyor system can have several conveyor lines for diverting and merging for the sorting and collecting of parts and materials.
The chain track of a power and free overhead conveyor is constantly moving in the upper track while loads are suspended from the lower free track. The free track has a cast body, load carrying wheels, and front and rear flippers that engage with the pusher dog to power the free track. Although the most common design for power and free overhead conveyors is to have the load carried beneath the track, there are designs where the load is carried above the track.
Power and free overhead conveyors are known as accumulating overhead conveyors and birail conveyors since they allow products to accumulate or gather together between workstations. This aspect of power and free overhead conveyors gives them greater flexibility for production operations, such as assembly lines.
As with all forms of overhead conveyors, overhead trolley conveyors have loads suspended beneath the track of the conveyor, which supports the load. The movement of an overhead trolley conveyor is by a chain or cable drive that can run endlessly with drive points placed along the chain or cable system.
The components of an overhead trolley conveyor include a single rail track, load bearing containers known as carriages, hangers with hooks, clamps, or stands, a tension method, trolleys on the track, and a chain or cable drive, with cables being rarely used. The trolleys in the track are secured to the chain or cable, which is kept taut using a take up system. The design of the pendants that hang from the chain and trolleys can vary in accordance with the types of loads and products being transported. In addition, a load bar, secured to two or more pendants, can be added to distribute the weight of heavy loads.
Overhead trolley conveyor systems are used in painting systems, cleaning parts, and coating, drying, and cooling processes. They are widely used in manufacturing for transporting parts, components, and assemblies between applications and processes. Overhead trolley conveyors can be used to deliver cases, cartons, and boxes.
The purpose of an enclosed track overhead conveyor is to prevent contaminants from reaching the chain drive and trolleys of the conveyor, which are placed in a boxlike tube with pendants hanging down through a slot at the bottom section of the box. The chain for an enclosed track overhead conveyor runs through the box or tube as the mechanism moves synchronously in the same direction and at the same distance apart.
A common use of enclosed track overhead conveyors is in painting applications where overspray can damage the conveyor system. Aside from painting, other applications that involve the application of lubricants or coatings necessitate the use of an enclosed track for the protection of the track and trolleys. In all cases, for an overhead conveyor to operate at the highest level, it has to be free of debris, dust, dirt, and other substances that can interfere with its function.
In many assembly and manufacturing processes, noise is a deterrent to efficiency and needs to be suppressed. Enclosed overhead conveyor tracks are ideal for such conditions. Since the track is enclosed in a covering, the noise it produces is kept to a minimum with certain variations capable of completely eliminating noise.
A common form of overhead conveyor, and one of the most used, is I-beam overhead conveyors that are open track overhead conveyors that are chain driven with pendants suspended from trolleys mounted on the I-beam. As with other overhead conveyor designs, I-beam overhead conveyors can support trolleys and their pendants and have materials hung directly from the pendants. The strength and durability of I-beam overhead conveyors make it possible for them to transport several hundred pounds of parts, equipment, trolleys, and components.
The flexibility of I-beam overhead conveyors makes it possible to twist and turn the track horizontally and vertically such that I-beam overhead conveyors can be installed in any location regardless of obstacles or obstructions. Unlike enclosed track overhead conveyors, I-beam overhead conveyors have their tracks exposed making it possible to easily inspect the track and lubricate it. In some designs, torque arm drives are included with sensors to monitor the track regarding potential overloads. As with many overhead conveyor designs, take up frames are included to ensure that the chain drive of the system is not over stretched.
The wide use of I-beam overhead conveyors is due to their high load capacity, which enables them to carry heavier loads per pendant and trolley. Trolleys come with capacities of 400 lbs. (181.437 kg) each with a 3 in (7.62 cm) track, 800 lbs. (362.374 kg) each for 4 in (10.16 cm) track, and 2400 lbs. (1088.62 kg) for 6 in (15.24 cm) track.
Accumulating electric monorail conveyor systems have individual powered carriers that run independently on the track. As with other overhead conveyor systems, electric monorail systems run on tracks that are suspended from the ceiling. Unlike synchronized systems that have all carriers moving together, electric monorail conveyor systems are asynchronous with each carrier operating on its own power.
There are multiple uses for accumulating electric monorail conveyor systems including the movement of automobile bodies during assembly. An electric monorail conveyor system makes it possible to move an automobile into a workstation to have adjustments performed and be easily moved on to another station. The system is similar to a powered and free system with the difference being the independent motor that powers each of the system's carriers.
Referred to as an EMS system, the motorized self-contained trolleys known as tractor drives move carriers along the same type of rail system that is used for other overhead conveyors. The tractors can work individually or be connected into groups of two to four for heavier loads. A tractor load bar assembly connects the tractor drive to its carrier. Power to the tractors, as with other monorail systems, is delivered by power in the system’s track.
The seven overhead conveyor systems that are described above are a sampling of the basic types of overhead conveyors. Since most conveying systems are configured and designed to match specific needs, it is not possible to include all of the types and forms of overhead conveyors. Generally, manufacturers rely on the efficiency, durability, and strength of overhead conveyors as a method to make better use of floor space, increase production, and prevent harm to workers.
Overhead conveyors are complex transport systems that are used to move materials, products, components, and parts for manufacturing and industrial applications. Each aspect of an overhead conveyor system is designed in detail to ensure exceptional performance. The general components of an overhead conveyor system include a chain or cable drive, enclosed or open track, a drive unit, take up unit, trolleys, carriers, and supports. Each of the various components are engineered to meet the specific needs of an application or operation.
Overhead conveyor chains take several forms with each form designed to transport unit loads and bulk goods. The selection of the chain for an overhead conveyor is dependent on the needs of an application and its longevity and dependability. Overhead conveyor chains include a set of journal bearings that consist of a shaft that rotates in a support shell and linked together by metal plates.
The chains for overhead conveyors come in a wide variety of shapes, sizes, forms, and configurations with each of which designed to meet the specific needs of a transport application. Since conveyor chains are a key element in an overhead conveyor system, they are monitored very carefully for wear and deterioration due to sprocket wear, chain slack, corrosion, and wear due to heavy loads.
The drive on an overhead conveyor is connected to the chain and drives the chain along the overhead conveyor’s track. The two types of drives are caterpillar and sprocket. The drive determines the speed of the chain and trolleys and the rate at which materials arrive at a location.
Caterpillar Drives – Caterpillar drives are located at a high point of an overhead conveyor system to pull the chain. The drive has overload protection, a shear pin hub, and a current limiting method. A geared motor moves the caterpillar that moves the chain. The operation of a caterpillar drive is smooth, efficient, and quiet and installed on an enclosed track design.
The caterpillar of a caterpillar drive is a chain that has drive dogs that connect to the chain of the conveyor. Drive and take up sprockets move the drive chain and dogs that move the overhead conveyors chain drive.
Tracks for overhead conveyors are divided into I-beam and enclosed tracks, which are chosen in accordance with the type of application and the use of the conveyor. I-beam tracks are most common and widely used due their ability to support heavy loads and trolley wheels. Enclosed conveyor tracks come in several different forms with some types having a tube while others are enclosed with a rectangular or square cross-sectional shape.
The tracks for overhead conveyors are made of heavy-duty steel that is capable of withstanding continual conveyor use. In addition, a key characteristic of overhead conveyors is their consistency and strength as well as their exceptional longevity. This aspect is one of the reasons for the popularity of overhead conveyors and is directly related to the high-quality materials used to produce them.
Trolleys are connected to the chain drive and ride on the track to carry heavy loads. They have an attachment point where any form of load carrier can be attached or suspended. As the drive moves the chain, the trolleys that are connected to it move along carrying the load of the overhead conveyor. The chain and drive control the movement of the trolley by stopping and starting it when required.
The designs of trolleys take the form of the track to which it is connected with the different forms including ones for tube enclosed tracks, I-beam trolleys, and other forms of enclosed tracks. To meet the requirements of a track, trolleys can have one wheel up to four or six wheels in order to handle loads and their weight. The wheels for trolleys are sealed to avoid contamination and are constructed to avoid excessive wear due to constant use. The various forms of trolleys are engineered to handle loads of a quarter ton up to two tons (0.227 MT up to 1.82 MT).
Take-ups for overhead conveyors maintain tension on the conveyor’s chain drive, ensure smooth movement and have a roller turn or traction wheel construction. They rectify chain stretching due to changes in temperature, which causes chains to expand or contract. The take-up is placed close to the drive at a low point in the system.
The location of take-ups varies between roller bank turns, traction wheel assemblies, or part of spread track loops. The actuators for take-ups include adjustable rods, counter weights, hydraulic or pneumatic cylinders, or springs and are made for all size tracks. Take-ups are a necessity for the smooth and continued operation of overhead conveyors. They prevent wear and tear on trolleys and chains as well as controlling and managing chain tension. Take-ups adjust the length of the chain such that it does not have to constantly be repaired or changed.
The pendants for an overhead conveyor are the attachments to the chain on which the loads of the conveyor are hung. They are designed to hold the weight of loads and are made of resilient materials capable of withstanding the stress of overhead conveyor operations. Pendants are attached to load pins on the chain and make it possible to suspend materials below the chain. They are used with an assortment of tracks, brackets, and chains as well as other overhead conveyor components.
The distance between pendants on an overhead conveyor chain drive varies according to the type of conveyor and the materials being transported. Certain items are hung from multiple pendants to increase the load capacity of the chain. The varieties of pendants include V shaped, loading hooks, swivel fixtures, and double loading hooks.
One of the challenges for any industrial organization is the movement of materials and the supply chain, which can drastically influence quotas and efficiency. This aspect of the manufacturing process has led to the development of automated methods for moving raw materials, parts, and supplies. In addition, unlike when assembly lines originated, the assembly of final products has been automated such that products are brought to a workstation, processed, and moved to the next workstation effortlessly and efficiently.
A major part of product movement has been the development of the overhead conveyor that makes use of vertical spaces that would otherwise go unused. These chain powered innovations make it possible to move any items, regardless of their size or weight, to multiple locations within a facility electrically and safely. It is for this reason that overhead conveyors have become an economical and productive part of the supply chain.
In the early days of automobile production, Henry Ford developed the assembly line that was able to rapidly produce multiple Model T Fords in a day. Eventually, the concept became the standard for auto production and was instituted by Ford’s competition. The initial assembly lines developed originally in a meat production plant became the standard for auto production.
In today’s automobile factories, every aspect of product and part movement is associated with some form of conveyor system with overhead conveyors being one of the most prominent conveying systems. Overhead conveying systems are used for painting and coating applications to protect workers and make the process accurate and efficient. The frames and bodies of automobiles are moved along an assembly line using power and free overhead conveyors, which allow workers to make additions without being concerned about the frames and bodies moving.
Warehousing has used forklifts for many years as a method for moving supplies, orders, and heavy equipment. Along with pallet jacks, forklifts are able to rapidly pick and place any type of item for packaging, storage, and shipping. In recent years, as warehouses have become more automated, various forms of conveyor systems have been included in warehouses to remove the need for manually collecting or distributing items. The result of the changes has led to more efficient and accurate picking.
Overhead conveyors are used for quickly and efficiently placing items in storage using a computerized numbering system that reduces errors, keeps accurate counts, and helps avoid losses during inventories. An overhead conveying system is ideal for facilities that have limited manpower or limited space.
There are certain materials that cannot be moved using other conveying methods due to their odd shape, complexity, or design. These types of items can easily be moved using an overhead conveyor, which transports items by having them hang beneath the chain and track of the conveying system. This particular aspect of overhead conveyors is ideal for items that have received treatments that could be harmful for other conveying methods, such materials that have been heat treated or baked.
The ever-growing use of robotics places a great deal of demand on component movement and positioning. Overhead conveyors can easily integrate into robotic systems and supply the necessary efficiency that such systems demand. Since robotics use programmed movements to complete applications, overhead conveyors can be programmed to fit into the motions, movements, and operations of a system without necessitating radical changes or adjustments.
The operations that are performed by an overhead conveyor in a robotic system include carton and part loading, transfer of items between conveyors, and vision-based programming as is found in AGVs and AMRs. The use of overhead conveyors in the age of robotics is limitless and ever growing as the two technologies combined and configured.
In a close examination of overhead conveyors, it is very evident that their introduction has had a substantial effect on industrial applications and operations. Every year, supply chain and assembly engineers have been developing new and more advanced uses for this unique and innovative technology. In many ways, overhead conveyor manufacturers look forward to being challenged by clients who require new ways and methods to implement overhead conveyors and product transport.
A foundational reason for the use of overhead conveyors is safety since the use of overhead conveyors protects workers from the dangers of handling heavy loads or being involved in necessary treatments. Since overhead conveyors are placed above employees and out of the way of workspaces, they help avoid any unnecessary interaction between conveyed items and workers. As the need for ergonomic designs and efficiency increases, overhead conveyors are being used for safety and the prevention of employee injuries.
One of the unusual aspects of any conveying system, and especially overhead conveyors, is that every system has to be adjusted, designed, and engineered to fit unique conditions and environments since there isn’t a generic overhead conveyor system that can fit into every set of conditions. Whether an overhead conveyor is being added to an existing system or being implemented for a new location, designers and engineers have to make precision calculations and plans to ensure the smooth unimpeded operation of the system. In essence, every overhead conveying system is configured to fit specific conditions.
As with all forms of conveying systems, overhead conveyors are labor saving devices that remove the need for the transport of essential items or materials, which are easily conveyed and moved by the overhead conveying system. Over the years, the manual transport of goods and materials has caused injuries, delayed production, and increased the need for personnel. The automation of an overhead conveying system is a labor saving and cost saving method that improves production and prevents shut downs and delays.
Every industrial location has vertical space that goes unused due to its location in a facility and the need for specialized equipment. Overhead conveyors make use of vertical space and allow for more efficient use of ground level space, which can be purposed for a wide range of functions or relieve equipment congestion.
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