Over / Under Conveyor
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- Dana Griffith
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1 Compact, reliable and economic solutions for Transferring Accumulating Positioning Infeed and exit conveyors
2 The compact and modular conveying system for transferring and accumulating parts with or without pallets between Manual workstations Automatic stations (e. g. robot, gantry, pick & place) and Machine tools or assembly machines. Product Features Working as an accumulating or index conveyor Part / pallet transport horizontal. Vertical transport index conveyor only. Transport on roller chains (steel hardened) Heavy duty and very reliable by using standard ALTRATEC AL - profiles Roll top type guarding system at the chain / pallet return saves space and costs Loading and unloading is manual or automatic Multiple machines can be serviced with one manual operator Pallets with load as well as empty pallets can be accumulated Length & width of pallets can be individually sized and optimized for the part size, due to the modular design High part weight capacity Oils or coolants have no detrimental influence Automatic chain lubrication (Option) Long life Technical Data Conveyor speed Length Payload capacity Pallet size (length x width) Part weigth including pallet weight Pallet positioning accuracy Sensors 6 m/min = Standard (1, 3, 9, 12 m/min Option) max. 30 m (subject to part weight / number of pallets) max kg Higher loads upon request 100 mm x 300 mm up to mm x mm (subject to part weight and pallet dimensions) Larger length & width upon request max. 60 kg per profile segment, transport on top max. 30 kg per profile segment, hanging transport on bottom (equal load distribution) ± 0,15 1,0 mm sensor (index conveyor) Sensor M12, (M18 Option) Optical sensor M12, (M18 Option) 2
3 Transport Systems - Examples Accumulating conveyor / Pallet transfer horizontal Infeed of castings into machine Accumulating conveyor / Part transfer without pallet horizontal / Infeed of blanks into machine Accumulating conveyor / Pallet transfer horizontal Infeed of car body parts into welding cell conveyor / Pallet transfer horizontal Infeed of car body parts into welding cell conveyor / Pallet transfer vertical Infeed of car body parts into welding cell 3
4 The Components Pallet profile segment Pallet sensor target Roller chain with divided rollers Running shoe (Only accumulating conveyor) bracket (Only accumulating conveyor) Pallet guide AL / hard anodized Pallet impact strip (Option) Sheet metal cover (Option) Chain support / steel Transfer profile 50 mm x 200 mm Position bushing (Option) Backlash Prisms for pallet centering Sensor flap Chain tensioning unit Drive unit with mechanical chain tensioning unit / Pre-stop with backlash and AL-sheet metal cover / Pre-stop in the conveyor installed parallel Flip door with part contour and sensor to check part positioning Pre-stop Hold down Pallet Part present light sensor Pallet present Part present reflector Automatic workstation Basic equipment with pallet positioning Accessories / Options Automatic workstation Pallet positioning double station Pallet present Sensors Part present Optical sensors to check load / unload Lubrication system Line Drain connection Lubrication cartridge with holder FRL Pressure switch Air distribution Drip pan integrated in divided supports Automatic chain lubrication Basic pneumatic equipment Electrical and pneumatic installation with / without controls 4
5 Flexible Pallet System For Part Transfer Base Configuration Base component of the universal pallet system for accumulating and index conveyor is the AL - profile segment 25 mm x 100 mm with running shoes for the accumulating conveyor with clamping units for the index conveyor The Advantages Pallet size is defined by the part dimensions and transfer requirements T-slots in the profile segments and the matching fasteners allow easy and precise mounting of the parts nest Position bushings give a high pallet positioning accuracy (Option) Pallet - Base Component Accumulating conveyor conveyor Running shoes Clamping units 5
6 Accumulating Conveyor Simple Transfer Solution The roller chain principle allows the power and free transfer of parts and pallets. For this, the conveyor is using two continuous and synchronuous running chains with rollers. On the roller chains, the parts or pallets can be stopped, metered, accumulated and located at any position. On the top and in the return, the pallets segments always form a level surface. At the end of the conveyor, the pallets are checked for part present. Only empty pallets will be released to enter the return, because the pallets are transferred in the return section hanging with the parts nest upside down. The segments of the pallets are connected with belts which allow the segments to closely follow the radius of the return sprocket. At the workstations, manual or automatic, the pallets are stopped, if necessary with a prestop and a positioning unit. Safety The pallet returns for manual workstations are secured with guarding and a flip door against manual intervention. For automatic workstations the area is secured by the guarding of the automatic loading system or machine tool. Flexible Pallet System Pallets are put together with segments of ALprofile 25 mm x 100 mm with T-slots for mounting of parts nest. The pallet length can be increased in steps of 100 mm by adding additional segments. The modular conveyor allows for almost unlimited pallet widths. Wide Range Of Different Applications Parts can be transferred hanging on the bottom side of the conveyor (in the return section). Empty pallets are then returned on the top side of the conveyor (Application example 2). The conveyor can also be used for the transfer of parts without pallets with parts riding directly on the chains. Positioning bushing Flexible connection Pallet profile segment bracket for stop Pallet with 4 x profile segment Pallet profile segment Roller chain principle Transfer section Pallet is riding on the chain (on top) Roller chain principle Return section Pallet is hanging from the chain (on bottom) Roll top desk type system down Roll top desk type system up 6
7 Accumulating Conveyor Automatic Station Unloading of parts automatically Controlled Transfer & Accumulating Transfer, accumulating and metering of loaded pallets Independent Manual Station Loading of parts manually Independent Pre-stop Part, to limit back pressure Roll top type guarding with flip door Chains run continuously Positioning module Support Parts nest Transfer & accumulation of empty pallets in return section Chain pitch ¾ Pallet with 3 x profile segment Pallet can freely move on the chains Drip pan (Option) Accumulating Conveyor Application Example 1: - Part / pallet transfer horizontal ( ) - Part transfer on top, v = constant - 1 x Automatic station / 1 x Manual station Flip door Sensor Sensor Service door H = 25 L = 100 B = Roll top type guarding with flip door and sensor Roll top type guarding with service door and sensor Pallet basic segment AL-profile with T-slots 25 mm x 100 mm Pallet with 4 x profile segments and quick exchange parts nest 7
8 Accumulating Conveyor Automatic Station Unloading of parts automatically on bottom side Controlled Transfer & Accumulating Transfer, accumulating and metering of loaded pallets on bottom side Independent Automatic Station Loading of parts automatically on bottom side Controlled Chain pitch ¾ Pallet with 5 x profile segment Pallet can freely move on the chains Parts nest Transfer, accumu- empty pallets lating Chains run continuously Pre-stop, to limit back pressure Part A Support & Transfer, accumu- empty pallets lating Chains run continuously Pre-stop, to limit back pressure Part B Support & Accumulating Conveyor Application Example 2: - 2 x Part / pallet transfer horizontal ( ) - Part transfer on bottom, v = constant - 2 x Automatic station 8
9 Conveyor Simple Transfer Solution The parts and pallets are transported by dual strand chains. The pallets (AL-profile segment 25 mm x 100 mm) are bolted to the chain. The spacing between the pallets is possible in steps of the chain pitch. At the manual and automatic workstations the index of the chains is controlled by a limit switch or index sensor to stop the chains. At the end of the conveyor, the pallets are checked for part present. Only empty pallets are allowed to proceed for return. conveyors with hanging parts nest allow for the return of parts nest with parts (Application example 3). Safety conveyors have the same guarding against manual interference as the accumulating conveyor. In addition, the return section on both sides of the conveyor has covers. Automatic Station Unloading of parts automatically Transfer Transfer of loaded pallets Manual Station Loading of parts manually Part Roll top type guarding with flip door Chains indexes sensor Parts nest Transfer of empty pallets in return section Chain pitch ¾ Pallet with 2 x profile segment Pallet bolted to chains Drip pan (Option) Support Conveyor Application Example 1: - Part / pallet transfer horizontal ( ) - Part transfer on top, v = constant - 1 x Automatic station / 1 x Manual station 9
10 Conveyor Wide Range Of Different Applications For a number of part configurations the parts nests can be bolted directly to the chain. This transfer principle can be used especially for round and long parts. For transfer of parts with different lengths, the conveyors are optionally available with one or two chain strands adjustable. This allows for spacing adjustment in accordance with part lengths. Using an index conveyor with hanging parts nest, multiple part types can be transferred mixed and sorted by part type. The index conveyor serves as a transfer between two operations. The return section of the conveyor serves as an additional buffer (Application example 3). Vertical transfer of parts is therefore also possible (Application example 4). Automatic Station Transfer Manual Station Unloading of parts automatically Transfer of loaded parts nest Loading of parts manually sensor Part Roll top type guarding with flip door Chains indexes Transfer of empty parts nest in return section Parts nest return Chain pitch ¾ Parts nest Parts nest bolted to chain Drip pan (Option) Support Parts nest return Conveyor Application Example 2: - Part / parts nest transfer horizontal ( ) - Part transfer on top, v = constant - 1 x Automatic station / 1 x Manual station 10
11 Conveyor Automatic Station Unloading of parts automatically Transfer & Return Transfer of loaded pallets Automatic Station Loading of parts automatically sensor Part A Part B Parts nest Chains indexes chain pitch ¾ Pallet with 1 x profile segment Pallet hanging from pendulum bearings with a brake bolted to chains Drip pan (Option) Support Conveyor Application Example 3: - Part / pallett transfer horizontal ( ) - Part transfer on top & on bottom, v = constant - 2 x Automatic station - Loading mixed (part A and B) - Unloading sorted (part A or B) - Hanging parts nests Spacing Drip pan conveyor Parts nests bolted to chain Parts nests return Parts nests bolted to chain Adjustable spacing and drip pan (Option) Movable side covers 11
12 Conveyor Automatic Station Unloading of parts automatically Transfer Transfer of loaded and empty pallets Manual Station Loading of parts manually sensor Transfer of empty pallets Chains indexes Transfer of loaded pallets with flip door Frame Conveyor Application Example 4: - Part / pallet transfer vertical ( ) - v = constant - 1 x Automatic station / 1 x Manual station 12
13 Checklist - System Inquiry Company... Date Name... Department... Phone... Street... Fax... City, State This checklist should simplify the planning of your system and be the base for your detailed system inquiry. 1 Scope of Quotation System assembled complete incl. sensor brackets (without pneumatic / electric / controls) System assembled complete including pneumatic and electric (no controls) System complete including controls 2 System Data Accumulating Conveyor Conveyor Hanging Parts Nests 90 Rotated Part Transfer horizontal vertical on top on bottom With pallet Without pallet Directly on parts nest bolted to chain Length / Width of transfer section (per layout) Overal length with protection device / devices Conveyor height (top of pallet) Cycle time (time per pallet) Transfer speed (1), (3), 6, (9), (12) Number of manual stations / automatic stations mm mm mm seconds m/min #.../ /... Designed for anti-static? No Yes Special conditions (Chips, dust, water, grease, oil, heat, cold, electro magnetic fields etc.) to consider? If yes, which ones:... Drip pan required? No Yes 13
14 Checklist - System Inquiry 3 Pallet, Part Nest and Part Pallet-Length (in transfer direction) / Pallet-Width Number of pallets = Length of Conveyor / Pallet-Length Part-Weight Weight of parts nest Pallet-Height (incl. parts nest) mm # kg kg mm.../ Part overhangs pallet / parts nest? No Yes,... mm Is part hanging lower than pallet? No Yes,... mm Is part stable on pallet? No Yes Is part centered on pallet? No Yes Necessary positioning accuracy of pallet / parts nest? ± 0,15 mm ± 0,5 mm ± 1,0 mm 4 Electric / Pneumatic Main power supply Control voltage Air supply... V... V... PSI (bar)... Hz Any special specifications for electric / pneumatic to consider? If yes, please attach. 5 Electric and Pneumatical Installation Motors without connector Motors with connector Actuators tubed to valve pack with interface Multipol ASI Profibus Sensors wired to I/O - Module with interface Cable ASI Profibus 6 Controls Siemens S7 (Europe & North America) Allen Bradley Compact Logix (North America) Other... HMI Siemens... HMI Allen Bradley... 7 Documentation 2 copies in English Other language, please specify:... 14
15 Product Range Of Transfer Systems with / without pallets Modules Belt Conveyor Chain Conveyor Roller Conveyor Over / Under Conveyor Transfer Table Corner Module Single Belt Conveyor Dual Belt Conveyor Roller Chain Conveyor Roller Conveyor Horizontal Accumul. Conveyor Roller Chain Corner Module Flat Belt Conveyor Roller Chain Conveyor Friction Roller Conveyor Horizontal Conveyor Rotate Unit Plate Chain Conveyor 90 Rotated Conveyor Lift Transfer Unit 3D- Plate Chain Conveyor Adjustable Width Conveyor Lift Vertical Conveyor 15
16 Technical changes and errors excepted. Reproduction (even extracts) only by permission from ALTRATEC. Over / Under Conveyor Modular & Cost Efficient Based on the ALTRAPROFILbuilding-block-system. For intelligent, modular and price efficient solutions. The installations and systems shown in this brochure have been designed exclusively with the ALTRAPROFIL-building-blocksystem. Even so, geared for the specific requirements of the machine building industry, the system-blocks can also be used for many other applications, e.g. machine supports, guardings and protective devices. A L T R A P R O F I L - building-block-system. Cost effective All components available from stock Universal application These advantages have been confirmed by many users of our systems and of our building block components. Besides our excellent product range, we also offer concept solutions based upon your requirements and ideas. Please don t hesitate to contact us. Schwieberdingen plant Neukirchen plant ALTRATEC Montagesysteme GmbH Herrenwiesenweg 22. D Schwieberdingen Phone: +49 (0)7150 / Fax: +49 (0)7150 / sw@altratec.de Südstraße 9. D Neukirchen Phone: +49 (0)371 / Fax: +49 (0)371 / nk@altratec.de 16
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