This article contains everything you will need to know about vertical conveyors and their use.
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A vertical conveyor system is a designed mechanical solution for transporting items, including goods, products, supplies, and components, between different elevations. It optimizes time and reduces manual labor by efficiently moving materials to accessible locations, whether from a lower to a higher level or vice versa.
Commonly known as vertical reciprocating conveyors (VRCs), these systems are specially designed and tailored to accommodate various size, space, and lifting specifications for different applications. Since their emergence in the mid-20th century, vertical conveyors have become essential components in material handling and supply chain operations.
Vertical Reciprocating Conveyors (VRCs) fall under a category of material handling equipment regulated by the American Society of Mechanical Engineers (ASME) under code B20.1 safety standards. They are designed for the vertical transportation of materials between different floors or levels. VRCs provide a safer, more convenient, and efficient alternative to elevators or manual transport, especially for moving goods from basements, mezzanines, or multi-story buildings. Their use often proves to be more economical compared to other lifting solutions.
Vertical conveyors, or VRCs, encompass a diverse array of specialized and inventive solutions for material handling. These systems offer a range of capabilities through their various designs, which can be tailored to meet specific requirements for different applications, such as transporting cement bags or preparing packages for shipment.
While some vertical conveyors, such as those used on construction sites for transporting materials between levels or for unloading trucks, may appear straightforward, most vertical conveyors are custom-engineered to suit specific applications. This is evident in their diverse uses, from airport systems for handling luggage to conveyors designed for the food processing industry.
Spiral vertical conveyors are continuous motion systems that efficiently transfer materials between different levels. They are known by various names, such as spiral elevators, spiral curves, helixes, and spiral conveyors. This term broadly encompasses two main types of vertical conveyors: bulk conveyors and those using belts or slats.
A bulk vertical conveyor is designed to transport loose, bulk materials like grains or powdered chemicals. Typically, this type of conveyor features a screw mechanism housed within a tube or pipe. As the screw turns, it elevates the material from a large container. Bulk vertical conveyors are versatile, allowing for the movement of granular or powdered substances not only vertically but also horizontally or at an angle.
Much like a bulk vertical screw conveyor, but with a more complex and intricate design, spiral vertical conveyors move a wide assortment of materials, products, containers, and parts. Their use is due to their small footprint and efficiency. Spiral vertical conveyors have a gentle slope such that products will not gain enough traction to move independently and stay on the conveying system.
Unlike conveyor belts, which require significant length to achieve a gradual incline, spiral vertical conveyors are compact by wrapping around a central column. This design allows for a more efficient use of space while providing the necessary slope for smooth and safe transport of goods between different levels. The gradual incline ensures a gentle and effective transition, whether moving items from lower to higher levels or vice versa.
One distinctive type of vertical spiral conveyor is the multiple entry spiral conveyor, which enables loads to enter or exit at various elevations. This design is particularly beneficial for multi-level warehouses and order picking, facilitating the easy transfer of items from upper storage areas to loading docks. In production and manufacturing settings, these conveyors can swiftly and efficiently deliver materials to production lines, enhancing overall workflow.
Vertical reciprocating conveyors (VRCs) function as vertical lifts designed to transport goods and materials rather than people. Unlike elevators, which are subject to stringent safety regulations and inspections, VRCs have different legal classifications and are not required to adhere to the same safety standards. It is crucial to note that VRCs should never be used to lift people. The reduced regulatory oversight for VRCs typically means fewer frequent inspections for material handling operations.
Vertical reciprocating conveyors (VRCs) come in two main types, based on their powering mechanisms: hydraulic and mechanical. Hydraulic VRCs utilize hydraulic cylinders to drive the lift, whereas mechanical VRCs are powered by an electric hoist, allowing them to handle heavier loads. Mechanical VRCs are more versatile and generally have a longer service life, although they tend to be more expensive compared to hydraulic models.
Regardless of their power source, vertical reciprocating conveyors (VRCs) serve the same purpose: to elevate goods from a lower level to a higher one. In standard manufacturing operations, VRCs are often used alongside work platforms to facilitate the easy transport of parts during assembly. Typically, the process involves opening the gate to load items onto the VRC's platform, securing the gate, and then activating the VRC to lift the load upward.
For safety, vertical reciprocating conveyors (VRCs) are enclosed in a protective cage to prevent materials from falling and ensure safe handling. Unlike forklifts, which require precise placement for lifting loads, VRCs provide a safer operation and better worker protection. They can be engineered to reach various heights and are commonly used at construction sites for high-rise buildings.
Vertical reciprocating conveyors are a permanent addition to a site and are not mobile, much like spiral vertical conveyors. When considering placing a VRC, it is important to carefully select its location with the understanding that it is a heavy piece of equipment much like a normal elevator.
Often referred to as box lifters or vertical lift units, continuous vertical conveyors efficiently transport containers, boxes, trays, packages, sacks, bags, and other items between different levels. These conveyors are designed to handle any item with a stable surface, ensuring quick, safe, and effective vertical movement. Continuous vertical conveyors come in various types, including S or Z, C, E, F, and L configurations, each characterized by its specific method of material entry and exit within the system.
Continuous vertical conveyors offer exceptional versatility, capable of transporting loads up to 2 tons (1.81 metric tons) to heights of 120 feet (36.57 meters) while occupying a compact space. Their platforms are available in various designs to accommodate different materials. These conveyors are constructed from materials such as aluminum, carbon steel, and stainless steel, and may include features like plastic sheets or safety glass for enhanced functionality and safety.
Vertical belt conveyors are used for moving bulk materials such as vegetables, fruit, corn, grains, nuts, minerals from mining, and pet food. They are designed for steep vertical inclines and include conventional belt surfaces that have been positioned vertically. In order to hold materials, they have perforations and keyholes with custom belts and nesting attachments for carrying products and goods.
Designing vertical belt conveyors involves meticulous attention to belt tracking, indexing, and the interaction between the belt and its pulleys to prevent slippage. Typically, vertical belt conveyors feature pockets designed to securely hold products and goods. In mining applications, rubber or metal pockets are utilized to transport minerals from underground to the surface efficiently.
Circulating vertical conveyors facilitate continuous loading and unloading of materials at various levels. While their design resembles that of continuous vertical conveyors, they differ in their material handling approach. There are two main types of circulating vertical conveyors: identical load conveyors, which handle uniform loads, and different load conveyors, which manage varying types of materials.
Identical load circulating vertical conveyors handle uniform loads, where all items are in boxes or cartons of identical size and dimensions. In contrast, different load circulating conveyors accommodate various types of loads, such as cartons, trays, boxes, bags, or parcels. The choice of conveyor type is influenced by the size of the loading and unloading stations. Regardless of the type, both systems use conveyor belts to either transfer items onto the circulating conveyor or remove them from it.
The platforms of circulating vertical conveyors are supported by block chains that complete the conveyor's circuit. These chains help keep the platforms level and ensure smooth operation, preventing products from falling out of the containers.
Bucket vertical conveyors are a form of vertical belt conveyor that has buckets to carry goods, products, and bulk materials vertically. They consist of a series of buckets that are attached to a belt or chain with pulleys or sprockets at the top and bottom of the conveyor to provide power and movement for the buckets. At the bottom of a shaft or enclosure, the buckets are filled by the movement of the pulleys or sprockets. Once filled, they are pulled upward. When the buckets arrive at the top of the conveyor, they dump their load and move downward to get another load.
Bucket vertical conveyors are designed for straightforward, efficient transport of bulk materials or minerals, particularly in mining operations. They provide a compact, labor-saving solution for moving materials. The main types of bucket conveyors are positive discharge, continuous, and centrifugal, each varying in its method of loading and unloading materials.
Z-type vertical belt conveyors are designed for the inclined or vertical transport of goods in production, assembly, packaging, and logistics. Featuring a distinctive Z-shaped configuration, these conveyors consist of an upper horizontal section, an inclined segment, and a lower horizontal section, enabling efficient movement between different levels.
Z-type conveyors are categorized under bucket conveyors when there is no inclined section; instead, a long vertical leg encircles the buckets. These bucket-style Z-type conveyors are commonly used in food processing and ingredient handling, as they simplify material movement and reduce labor requirements.
The inclined Z-type vertical belt conveyors are versatile and used in various applications, including unloading trucks, transporting assemblies in manufacturing processes, and storing goods in warehouses.
Accumulation vertical conveyors are designed to hold, collect, and store products to keep upstream equipment running smoothly. They serve as a buffer for products at various stages of production, especially during picking operations. Unlike continuous vertical conveyors, accumulation conveyors feature a stop zone where goods are temporarily held and collected.
Accumulating vertical conveyors are used for various purposes, such as cooling and drying zones, monitoring different stages, and enhancing overall efficiency. A key issue with these conveyors is back pressure, which occurs when products stop and accumulate. To address this, there are two main types of systems: minimum back pressure systems and zero back pressure systems.
Minimum back pressure accumulating vertical conveyors allow items to contact each other with very low pressure, typically around 2% of the total load. These conveyors are ideal for palletizing items of uniform weight, shape, and size, but are not suitable for handling fragile or breakable items.
In zero back pressure accumulating vertical conveyors, items are kept in separate zones without making contact with each other, with each zone monitored by sensors. Vertical conveyors are well-suited for this type of system, as they naturally feature distinct platforms or separated zones to facilitate individual item handling.
Vertical accumulation conveyors feature flights designed to manage accumulation times based on the product's height, along with a stop device to align rows of products. The controls on these conveyors halt motion if there's a malfunction in the downstream system. Accumulation proceeds until rows are fully packed, and the system may reverse to return items to the loading conveyor if needed.
The dual lane spiral conveyor operates similarly to the single lane version but features two lanes within a single column. This design effectively doubles the capacity compared to a single lane vertical conveyor, allowing for more efficient movement of goods both upward and downward. The dual lane configuration offers improved efficiency, time savings, space utilization, and cost reduction.
A dual lane vertical spiral conveyor features two belts operating on bearings, which minimizes noise and reduces friction. This design allows for the swift movement of items such as bags, bundles, totes, trays, cans, cartons, and containers between levels. The lanes can operate at the same speed, different speeds, or in opposite directions to enhance efficiency. Additionally, the lanes can vary in width and height to accommodate the dimensions of different products.
Oval conveyors are predominantly installed horizontally to maintain a continuous motion for transporting products, assemblies, or materials. However, for specific applications, they can be installed vertically in a spiral configuration. This vertical design offers similar functionality to horizontal oval conveyors but operates across different levels. Oval spiral vertical conveyors are particularly useful in material handling when space constraints prevent the use of traditional column-type vertical conveyors.
Screw or helix vertical conveyors operate similarly to post hole diggers, featuring a spiral mechanism that moves bulk materials such as seeds, grains, cement, gravel, and wood chips. These conveyors are typically housed in a tube or shaft to prevent material from escaping and to manage dust control.
To be classified as a vertical screw conveyor, a screw conveyor must operate at an incline greater than 45°. As the incline becomes steeper, more energy is required to move materials, necessitating precise construction to ensure efficiency. Screw conveyors are favored for their compact design and versatility, allowing them to be installed in a variety of locations.
Most screw conveyors have a capacity of up to 6,000 cubic feet per hour and can lift materials to heights of 30 to 40 feet. They are primarily used for transporting semi-fluid materials. Specially designed screw conveyors may feature inlets on either side or align with Z or C configurations for added versatility.
The vertical conveyors discussed are just a subset of the many types offered by manufacturers. Customization of vertical conveyors is often necessary to accommodate special conditions, varied product sizes, shapes, packaging, and specific requirements. This adaptability is evident in the growing online product market, where tailored solutions address diverse warehousing and production needs.
Vertical conveyors serve a broad range of applications, primarily focused on altering the level of goods for easier access. They offer a labor-saving and safe solution for transporting materials between levels, protecting both the products and the workforce. This demand has spurred the development of specialized and unique vertical conveyors, designed by innovative engineers to meet diverse and specific needs.
The tilting deck vertical transfer unit functions similarly to a standard vertical conveyor by moving products vertically, but features a 30° tilt to facilitate easier access to the items being transported. This design is tailored for automated processes involving robotic transfer, allowing robots to access products or parts more effectively. The precise angle of the tilt minimizes the need for robot repositioning, streamlining the transfer process.
The multiple position Vertical Transfer Unit (VTU) allows for the vertical transfer of products and materials from multiple input conveyors to various discharge conveyors. This system uses several conveying mechanisms positioned at different levels within a frame to move goods up and down relative to the input conveyors. With virtually limitless configuration options for the conveying decks, this setup facilitates efficient loading, sorting, and rapid movement of goods.
Among the various items requiring transportation, appliances, car exteriors, windmill components, furniture, large metal parts, and construction materials are particularly challenging to convey, especially vertically. Vertical conveying of wide products often becomes essential when factory floors and production facilities lack the space to accommodate such large loads.
In many scenarios, vertical conveying systems must not only lift wide products but also rotate and reposition them for specific operations or processes. Wide product vertical conveyors are designed to manage items up to 12 feet long and weighing 150 lbs., requiring precise handling to prevent damage. As with wide heavy product handling, it is crucial to control materials to avoid contact that could cause harm. Similar to accumulating vertical conveyors, wide format conveyors feature zero contact zones that are carefully monitored to protect products, which is especially critical for handling large aerospace parts and components.
The primary purpose of utilizing multiple vertical conveying systems is to offer flexibility for material input and discharge across various locations. Different types of vertical conveyors enable the design and configuration of multiple systems tailored to a diverse range of applications and requirements.
While the term "conveyor" often evokes images of horizontal belt systems, conveyor designs extend far beyond this basic concept. They include a variety of systems capable of handling everything from delicate computer components to vertical conveyors that support multiple production lines across different levels. As demonstrated by conveyor manufacturers, vertical conveyors offer extensive flexibility and capability with few limitations.
Multi-function conveyors offer numerous advantages that enhance efficiency and save time. Key benefits include:
Vertical lift conveyors function similarly to forklifts or Automated Guided Vehicles (AGVs) by elevating flat-bottomed loads between levels. However, they differ in their lifting capacity, as they can raise items up to 48 meters (157 feet), and multiple lifts can be connected to achieve even greater heights.
While a vertical lift conveyor might be mistaken for a Vertical Reciprocating Conveyor (VRC), it differs in construction, lacking an enclosure and resembling more closely to an elevator. Like many conveyors, vertical lift conveyors come in various designs to suit specific application needs. Typically, they resemble a forklift without the forks, featuring a flat platform instead.
Vertical lifts can function as continuous systems, allowing for constant loading and unloading based on application requirements. Smaller vertical lifts may be designed to be mobile, enabling them to be relocated as needed for efficient and rapid product lifting.
Vertical conveyors are valued for their capability to efficiently lift materials between different levels and floors in buildings and industrial settings. They facilitate the rapid and smooth transfer of heavy equipment and materials from one level to another. Additionally, vertical conveyors and lifts provide a safer alternative to forklifts and Automated Guided Vehicles (AGVs).
In auto dealerships, vertical lifts are essential for moving showroom vehicles between floors when ramps are not available. They enable cars to be transported to mezzanines, showrooms, and storage areas across multiple levels. Given the space constraints typically found in auto dealerships, large elevators or other lifting devices may not be feasible. Vertical conveyors provide a reliable and robust solution for positioning and storing vehicles.
The food industry relies heavily on vertical conveyors due to the diverse nature of food products and production processes. Essential qualities for food industry equipment include ease of cleaning and sanitary conditions. Vertical conveyors can handle various environmental conditions, such as extreme heat, subzero temperatures, and wash-down requirements, ensuring exceptional performance across different scenarios.
While retail operations do not face the same restrictions as food processing, they still benefit significantly from vertical conveyors. In multi-story retail environments, vertical conveyors provide a convenient and efficient method for transporting delivered goods from the loading dock to the sales floors. This is achieved using various vertical conveyor systems equipped with chain drives and belts.
In aircraft assembly, the significant height of the assembly makes it challenging to handle delicate components that could be damaged by mishandling. Vertical conveyors provide a safe and efficient solution for transporting complex and sensitive components onto the aircraft, minimizing the risk of damage. To protect these components, vertical conveyors are designed with enclosed carriage structures that prevent vibrations, jolts, and impacts. This design helps reduce unnecessary movement of components within the factory and between assembly stages.
Hospitals utilize various methods, such as totes, carts, and trays, to deliver meals, medications, linens, and equipment. To ensure prompt, efficient, and safe service to patients, vertical conveyors are employed to transport materials between floors. A critical advantage of vertical conveyors in hospitals is their quiet operation, which helps minimize disturbances to patients.
For centuries, farmers have managed the loading of barns with feed, hay, grains, seeds, and fertilizers using baskets, ropes, or nets pulled between levels by horses or tractors. Over time, vertical conveyors became a staple in agricultural operations, significantly simplifying the process of loading baled hay and straw compared to traditional pulleys. Today, few farmers recall the days when pulleys were the norm.
Similar to farming, early mining operations depended heavily on manual labor and animal power to extract minerals, leading to unsafe and injury-prone conditions. The introduction of vertical conveyors greatly enhanced the safety and efficiency of mining, transitioning much of the process to electric-powered equipment. Mining vertical conveyors efficiently transport minerals from deep within the pits to the surface for truck loading, significantly reducing manual handling and increasing overall safety.
The primary advantage of a conveying system is its capacity to enhance efficiency and boost production while reducing overall time and labor costs. Given the wide range of vertical conveyor types available, selecting the ideal system to perfectly match the specific needs of an operation or application can be challenging.
The initial consideration when choosing a vertical conveyor is the requirement to transport goods between different levels. While forklifts and Automated Guided Vehicles (AGVs) can perform this task, they may not always provide the necessary safety, especially when handling goods at significant heights or with stability concerns. The robust and durable design of vertical conveyors makes them a logical choice, prompting the need to select the most suitable type for the specific application.
Choosing the right conveyor type begins with considering the nature of the items being transported. For large and heavy materials, a robust vertical conveyor is essential to handle the weight and size. Conversely, for delicate items, a more gentle conveyor is needed to prevent damage. Additionally, the method of loading products onto the conveyor affects the choice; whether the items are loaded from another system, manually, or directly from a container can determine the most suitable conveyor type.
The type of vertical conveyor you choose is significantly affected by the weight of the items being moved, as the conveyor must support the load effectively. Chain-driven vertical conveyors might struggle with heavy automobile components or filled containers, whereas some platform vertical conveyors are designed with the strength and durability needed to handle substantial loads.
The size and weight of materials automatically disqualify some vertical conveyors for certain applications. For instance, large items such as car exteriors or equipment frames cannot be transported using smaller Z-type vertical conveyors. Due to their substantial size, only the most robust and heavy-duty vertical conveyors can handle these large components. Most vertical conveyors are intended for handling totes, tubs, and containers, not for oversized parts and goods.
Vertical conveyors are essential for their ability to quickly deliver goods for loading or assembly. Accumulating vertical conveyors, in particular, ensure that parts are readily available and manage the delivery process efficiently. Businesses often choose vertical conveying systems for their speed and effectiveness, which boost productivity, reduce labor costs, and enhance workplace safety compared to traditional methods.
The selection process for vertical conveyors essentially boils down to whether they use containers or operate without them. Conveyors are categorized based on whether they transport items in containers or move goods independently. In warehousing, vertical conveyors often handle totes or tubs to shift products between levels. Evaluating current handling methods can help determine if the conveyor should be designed for containers. Typically, products that are bagged, boxed, or wrapped with flat surfaces do not need totes or containers.
A vertical conveyor is essentially a horizontal conveyor rotated to operate vertically, allowing it to transport goods and products between different levels. This innovative design enhances efficiency and productivity, making vertical conveyors a highly effective solution for moving products and materials.
Depending on the design, a vertical conveyor can utilize both sides to facilitate the movement of materials in opposite directions. This dual-side functionality enhances throughput while maintaining efficient use of floor space, ensuring it does not disrupt other operations.
The operating costs of vertical and horizontal conveyors are generally comparable. However, vertical conveyors can often be more cost-effective due to their ability to handle goods on both sides, maximizing their efficiency and utility.
A key advantage of vertical conveyors is their flexibility. Their compact design allows them to be repositioned easily to accommodate various applications without occupying much floor space. Vertical conveyors can handle multiple types of products without structural modifications, making them ideal for environments like pharmaceuticals and food industries.
Vertical conveyors are typically easier to clean compared to horizontal conveyors. Metal vertical conveyors, in particular, prevent the growth of bacteria and contaminants due to their non-porous surface. Additionally, the lack of lubricants in these conveyors reduces the risk of contamination.
Customization is crucial for vertical conveyors, as they often need to be tailored to specific facility requirements. While some models can be installed with ease, most require careful configuration and engineering to adapt to diverse environments and usage needs. High-efficiency vertical conveyors are typically designed to fit the unique conditions of their intended locations.
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