modular plastic conveyor belts lcus induction · pdf fileconveyor belt rollers in belt product...

MODULAR PLASTIC CONVEYOR BELTS

The Right Belts • The Best Service

LCUS Induction System Training Manual

Richmond, VA


AGENDA

1. Background on Intralox

2. Safety

3. System Overview

4. Conveyor Designs

5. Maintenance Recommendations



Who is Intralox?


Invented modular plastic conveyor belts in 1971

The world’s largest manufacturer

(7 million square feet annually)

Annual revenues in excess of $200 million

700,000 sq. ft. of space in Harahan, Louisiana, a

suburb of New Orleans

50,000 sq. ft of space in Savage, Maryland for

Integration, Equipment Fabrication, and R&D

7 Assembly centers around the world


Engineered Products are flexible and durable

Eliminates

Retensioning & Retracking

Vulcanizing or Splicing

Reduces

Maintenance

Planned & Unplanned Downtime

Repairs are easy and less frequent

The result: Lower Cost of Ownership

Intralox Solutions Value Added


Dedicated to Our Customers People You Can Count On

Customer Service

24 hours a day, 7 days a week.

Team of 80 customer service

representatives

Emergency, on-call

production teams

99.4% order accuracy rate

99.6% on-time shipping record

Engineering support before,

during, and after startup.


A Few of Our Customers

http://www.pg.com/en_US/index.jhtml

http://www.conagrafoods.com/

http://www.federated-fds.com/home.asp

http://www.gp.com/

http://www.homedepot.com/

http://www.baxter.com/

http://www.colpalcommercial.com/index.cfm

http://www.technicolor.com/Cultures/En-Us/Home

http://www.sony.net/

http://images.google.com/imgres?imgurl=http://www.unicefusa.org/atf/cf/%257BB35DBA70-2A32-4E25-999B-FA3A590864DB%257D/logo_bd.gif&imgrefurl=http://www.unicefusa.org/site/apps/nl/content2.asp%3Fc%3DduLRI8O0H%26b%3D1199529%26ct%3D2284359&h=57&w=150&sz=3&hl=en&start=4&um=1&tbnid=nliQveD63nwzYM:&tbnh=36&tbnw=96&prev=/images%3Fq%3Dbecton%2Bdickinson%2Blogo%26svnum%3D10%26um%3D1%26hl%3Den

http://www.fedex.com/us/ground/main/



USPS Roles: 1) Component Supplier 2) Equipment Supplier 3) System Integrator


Component Supplier

AFTL

APPS TDS


Equipment Supplier – AI AFSM 100ai and FSS Programs

Scope included belt curve, intermediate

conveyors, sorter, spurs, minimal pressure

chutes.

361 systems which included four divert

points, four spurs, four chutes

Approximately $7,000,000 in revenue

Partnered with GDRS on the Northrop

Grumman Program


Systems Integrator - HSTS High Speed Trays Sorters include equipment,

controls, installation, training, and documentation.

Projects ranged from $500K to $1,800K

Deployments:

Curseen Morris P&DC, Washington BMC,

Springfield BMC, Memphis BMC, Chicago BMC,

San Francisco BMC, South Jersey P&DC,

Charlotte P&DC, Washington HASP, Louisville

P&DC



Safety

SAFETY

Only trained and qualified personnel should be allowed to operate the

equipment. Training must include understanding of emergency

stops and safety devices.

Do not operate the conveyor unless all guards, covers, and

maintenance panels are in place.

Make sure the conveyor and adjacent areas are clear of personnel

and product before starting.

Pay attention to the warnings on all labels to avoid potential injury.

Keep the area free of obstructions or material that could impede a

clear view and ready access to emergency control and safety devices.


SAFETY

Do not allow anyone to ride on, step on, sit on or cross over a moving

conveyor.

Do not wear loose clothing, necktie, unsecured long hair, loose jewelry

or articles that might catch in a conveyor.

Keep all body parts away from moving parts of the conveyor.

Do not attempt to remove any jammed product while the equipment is

in operation. Jams should be cleared only by authorized, trained

personnel and only after the conveyor has been de-energized and

locked out according to the owner/user’s written energy control

program.

Report all unsafe conditions.




System Overview

Project Goals

Provide a single file flow of products in front the key

station operator at a combined rate of 30 parcels per

minute (60 linear feet of product).

This should:

1) Improve induction rates

2) Improve ergonomics

3) Buffer induction operations from unloading


Technology Highlights

1) Intralox centering belt technology to eliminate

many side by side products.

2) Intralox alignment belt technology to present

products near an operator for facing / keying.

3) Intralox accumulation belt technology to buffer

product before the key station to minimize waiting.


Performance Factors

Commercial Equipment

USPS Team – Operations and Maintenance

USPS Unloader & LCUS Operations

Conveyable Mail

Note: Engineering balance between space, cost, and

performance


Overall System


System Overview



Activated Roller Belts™ Series 400, Series 7000

Uses rollers embedded within the belt to generate lateral product movement as the belt moves forward.

Rollers extend above and below belt.

May incorporate combinations different angles, roller materials, and directions of rollers across the width of the belt.

Intralox owns a broad portfolio of U.S. and International patents pertaining to Angled Roller™ Belt


Activated Roller Belt (ARB) Basics

The function of Angled Roller Belt is to move

products forward (like a normal belt) and also

to the side.


Vector Addition

Conveyor Belt

Rollers in Belt

Product Path

Rollers in Belt

Conveyor Belt



Conveyor Details

Incline Conveyor (USPS)


Centering Conveyor



Centering Conveyor Roller Actuation

Gravity rollers, located

below the belt and

within the conveyor

frame, is the mechanism

used to drive the rollers

within the belt, which in-

turn moves the

packages.

Series 7000 Sorter


The new Rack & Roll

technology is located

below the belt, within the

conveyor frame. These

individual rollers rotate

and engage the rollers in

the belt. The rotation of

the rollers in the belt

causes the package to

move.


Series 7000 Roller Actuation

Alignment Conveyors


Accumulation Conveyors


Brake / Meter Conveyors


Keep an Eye out for Problems


Reporting Issues to Maintenance Early - Saves the USPS $$$ !

Keep the area clean

Identify broken parts on the floor

Foreign Matter in the Belts

Missing or Damaged Rollers in the Belts

Unusual Noises

Unusual or unsafe conditions

Keep an Eye out for Problems


Missing or Damaged Rollers in

the Belts



Maintenance

Objectives

To assist in diagnosing and solving any

mechanically-related problem that might arise

on conveyors using the Intralox belting system.

If you require further help or information, you

can call Intralox 24 hours a day at (888) 427-

BELT.

SAFETY


Routine inspections should be conducted to insure that all safety

features and devices are in place and functioning properly.

A maintenance program should be set up to make sure the conveyor

is operating properly.

All maintenance operations should be performed by trained and

authorized personnel while the conveyors are stopped and locked-

out.

Be aware of hazardous conditions, such as sharp edges and

protruding parts.

Before starting the conveyor after maintenance is completed, walk

around the equipment and make certain all safety devices and

guards are in place, pick up tools, maintenance equipment and clear

any foreign objects from equipment.

The Intralox System


Modular Belt + Sprockets + Square & Round Shafts

Modular Construction “Modular” – composed of discrete modules

Aids in repair

Allows greater flexibility in design

Modules are “injection” molded

Modules are assembled into a “bricklayed” pattern & connected into a belt

Square Shafts

SQUARE SHAFT

Better “torque” transmission

easier sanitation

sprockets float freely

ROUND SHAFT

Clearance

Radius

No clearance

Angular corners

key

way

Square Shaft Design

Shaft end chamfer

Journal

Retainer ring grooves

Retainer

rings

Square Shaft Design


Centering Conveyor Roller Actuation

Gravity rollers, located

below the belt and

within the conveyor

frame, is the mechanism

used to drive the rollers

within the belt, which in-

turn moves the

packages.

Series 7000 Sorter


The new Rack & Roll

technology is located

below the belt, within the

conveyor frame. These

individual rollers rotate

and engage the rollers in

the belt. The rotation of

the rollers in the belt

causes the package to

move.


Series 7000 Roller Actuation

Running Inspections - Daily


Keep the area clean and look for

broken parts on the floor

Inspect for Missing or Damaged

Rollers in the Belts

Look for unusual or unsafe

conditions

Inspect sprocket engagement on

belts.

Listen for Unusual Noises

Visual Inspections - Belt Note damaged modules and replace during downtime window


Visual Inspections - Debris Inspect for debris stuck in sprocket pockets or wrapped around

rollers and remove during downtime window.


Visual Inspections - Rods

Check that rods are not walking out of belt edge. Push back in

place during a downtime window.


Visual Inspection - Sprockets

Check that both drive and idle sprockets are engaged.

All belts should be at same height. If one belt is higher than the others

at the drive or idle end, then the belt is not properly engaged on the

sprockets.


Visual Inspection – Belt Return

Check that the return rollers are spinning and do not have trash

build-up


Visual Inspection – Belt Edges Inspect the edges of the belt and repair during downtime

window.


Belt Pullers – Maintenance Tool


(Part # S400BJT) These supplied tools

allow for disassembly and reassembly of

the 400 Series ARB belting.

Insert the pawl into the rectangular gap

on the ARB belt at a functional spacing

with the pawl connection holes facing

each other.

Use the ratchet strap to tension belting,

approximately ½”, to allow for connecting

pin to be removed.

Remove / Install Pin as required.

Belt Pullers – Maintenance Tool


(Part # S7000BJT-1) These supplied tools

allow for disassembly and reassembly of

the 7000 Series ARB belting.

Insert the pawl into the rectangular gap

on the ARB belt at a functional spacing

with the pawl connection holes facing

each other.

Use the ratchet strap to tension belting,

approximately ½”, to allow for connecting

pin to be removed.

Remove / Install Pin as required.

For belts between 36” – 72”, two pullers

are recommended.

Monthly PM – Belt Removal Break one belt at a time to prevent belts from disengaging

drive sprockets.

The belts that are still together will prevent the broken belt from

sliding off the drive sprockets. The belt will slip off the idle

sprockets if it is not held up.

To break belt, insert screwdriver into one side of belt to open

the “barn door.” Insert second screwdriver into other side

of belt and push rod out.


Monthly PM - Sprockets

Remove debris that has accumulated inside conveyor frame.

Debris can become wedged in belt near the shafts and can cause the

belt to become disengaged. This will damage the system and will

prevent the conveyor from performing correctly.


Monthly PM - Sprockets Trash removed from USPS conveyor, AI system 14” wide.


Monthly PM – Sprockets

Sprockets that are not positioned correctly often damage the

roller belting



Ensure the belts are aligned with sprockets and the sprockets

are evenly distributed across idle / drive shafts.

Set screws on the set collars should be set to 45 in. lbs. of

torque secured with non-hardening thread-locker (Loctite

#222MS)



Inspect Sprockets for tooth wear and replace as required.


Monthly PM – Wear Strips

Inspect wear strips to make sure

they are in-place and in good

condition.

Wear strips should be captured at

the idler end of the conveyor and

held in place with a roll pin.


Monthly PM – Roller Belt

Run hand over roller belt while conveyor

is stopped and make sure roller belts

contact carryway rollers. Rollers

should resist turning.

If rollers spin easily, check other rollers

around it. If rollers are visibly worn

and spin without resistance, belt may

need to be replaced.

Note: There are locations in the system

that are strategically missing

carryway rollers. Belt rollers will free-

spin when over this area.


Monthly PM – Belting Length

Inspect sag on belt return

(catenary sag) and

adjust belt length by

removing links.

Belting should be

replaced when the pitch

exceeds 3% of the

original length


Belting stretches after the first thirty days of

operation and usually requires adjustments.

Monthly PM – Carryway

While belts are broken, run hand

over carryway rollers to ensure

rollers are free to turn.

If roller does not turn easily, check to

see if roller sleeve has migrated

and is rubbing on roller support

rail. If so, use razor blade to cut

sleeve ½ inch off from the end of

the roller. Check that roller is now

free spinning. If not, roller may

need to be replaced. Sleeve can

be cut multiple times. However, if

more than 6 inches of sleeve is

removed from roller, replace

roller.


Monthly PM – Carryway Check that flat spots are not developing on

rollers.

If roller has flat spots, check to see if that roller

sleeve is not touching roller support member. If

it is, then cut sleeve back ½ inch. If roller sleeve

is missing more than 6 inches, replace roller.

Check carryway rollers under belt

If roller’s sleeve is bubbled up, cut sleeve above

damage. Check to see if sleeve has walked

down roller again. If more than 6 inches does

not have a sleeve at upstream end of roller,

replace roller.


Cut here

Monthly PM – Re-Installation of Belts

Make sure that belt is not hanging up on bolts or screws

extending into return path or conveyor side frame

Make sure that all sprockets are engaged.

Sprockets on idle shaft may need to be rotated to be able to

re-engage belt.


Troubleshooting

1. Belt not engaging with drive sprockets

2. Belt not tracking

3. Excessive Belt Wear

4. Excessive Sprocket Wear

5. Excessive Edge Wear or Damage

6. Sprocket Migrating out of Belt

7. Excessive Catenary Sag

Belt Not Engaging with Drive Sprockets

Incorrect belt tension around drive: Provide catenary sag on return side of belt as recommended

by the Intralox Engineering Program or your local Intralox

office.

Sprockets not aligned correctly on shaft: Check sprocket alignment by laying a straight edge parallel

to the shaft at the base of any tooth on the sprocket to make

sure that all sprockets are in the same position across the

belt. On sprockets having a tooth count that is evenly

divisible by 4, teeth are automatically properly aligned when

put on the square shaft. However, if the tooth count cannot

be divided evenly by 4, special care must be taken to avoid

problems.

Insufficient belt wrap around drive: Relocate the first return roller after the drive shaft to insure

180 degrees or more of belt sprocket wrap around drive

sprockets.

Belt Not Tracking Shafts not plumb, level and

square to each other:

Inspect shafts to insure they are plumb, level and square to each other. Lock

into place with shaft collars. Check and adjust conveyor frame. Check shaft

alignment after any adjustment in frame. It components, not level or square.

may be necessary to re-plumb, level and square the shafts.

Sprockets not aligned correctly

on shaft:

Check sprocket alignment by laying a straight edge parallel to the tooth on the

sprocket to make sure that all sprockets are in the same position across the belt.

On sprockets having a tooth count that is evenly divisible by 4, teeth are

automatically properly aligned when put on the square shaft. However, if the

tooth count cannot be divided evenly by 4, special care must be taken to avoid

problems. If timing holes are provided on these sprockets, they must be placed

in alignment all the way across the shaft, see Sprocket and Shaft Installation.

Locked sprocket on drive and

idle not aligned:

Re-align sprockets “locked” in place by a retainer ring or other device insuring

that the drive shaft sprocket is perfectly aligned with the idle shaft sprocket.

Material build-up on bottom of

belt or sprocket:

Clean bottom of belt, removing any material build up that could interfere with

sprocket tooth engagement. It may be necessary to provide in-place brushes,

scrapers, scrolls or tooth engagement other devices to prevent future material

build up.

Return rollers not level and

square:

Inspect and correct any return roller that is not level or square with conveyor

frame. to conveyor frame.

Retainer rings improperly

utilized:

Replace missing retainer rings; check retainer ring location to make sure locked

sprockets or missing. on drive and idle shafts are in perfect alignment.

Excessive Belt Wear Exposure to abrasive materials: Eliminate or reduce the presence of abrasive material which

might come in contact with the belt, sprockets or wearstrip.

As an example, this material could be periodically blown off

the plastic conveyor parts by the use of plant pressurized air

or washed off at the end of the shift. An in-place spray wash

could be employed.

Worn wearstrip material: Inspect wearstrip material and replace if required.

Binding of belt in conveyor frame: Check the conveyor frame to insure it is level and square.

Correct any conditions causing belt to rub or bind.

Excessive belt speed: High speed belts, especially those with short shaft centers,

will wear faster than belts at lower speeds. Reduce belt

speed if possible.

Sharp corners on carryway or returnway: Make sure the leading edge of any carryway is beveled or

radiused for smooth belt travel.

Excessive Sprocket Wear Sprockets exposed to abrasive

material:

Eliminate or reduce the presence of abrasive material which might come in contact with the belt,

sprockets or wearstrip. Should be periodically blown off the plastic conveyor parts by the use of plant

pressurized air or washed off at the end of the shift.

Incorrect tension on belt: Provide proper belt tension around the drive sprockets. Provide catenary sag on return side of belt as

recommended by the Intralox Engineering Program or your local Intralox office.

Excessive belt speed: Reduce belt speed if possible.

Drive and idle shafts not plumb: Inspect shafts to insure they are plumb, level and square to each other. Lock into place level and

square to each other shaft collars.

Insufficient number of

sprockets:

It is possible that the conveyor requires a more even distribution of load among sprockets.

Locked sprockets on drive/idle

shafts not aligned:

Re-align sprockets “locked” in place by a retainer ring or other device insuring that the drive shaft

sprocket is perfectly aligned with the idle shaft sprocket. correctly.

Sprockets are not aligned

correctly:

Check sprocket alignment by laying a straight edge parallel to the shaft at the base tooth on the sprocket

to make sure that all sprockets are in the same position across the belt. On sprockets having a tooth

count that is evenly divisible by 4, teeth are automatically properly aligned when put on the square shaft.

However, if the tooth count cannot be divided evenly by 4, special care must be taken to avoid

problems.

Shaft deflection or twisting: Inspect shaft for evidence of deflection or twisting. Bent or twisted shafts must be replaced. An

intermediate bearing may be required for wide belts. Contact Intralox for assistance.

Excessive Edge Wear or Damage

Belt contacting obstructions: Check the conveyor frame to insure it is level and square. Correct any

conveyor belt, returnway, frame or conditions causing belt to rub or

bind adjacent equipment.

Belt improperly aligned and not

tracking:

Re-align sprockets “locked” in place by a retainer ring or other device

insuring that the drive shaft sprocket is perfectly aligned with the idle

shaft sprocket. Check the conveyor frame to insure it is level and

square. Correct any conditions causing belt to rub or bind.

Thermal expansion causing belt: Correct conveyor frame dimensions to insure there is a 0.25 in. (6.4

mm) minimum edge to “rub” somewhere on clearance on each side of

the belt when full thermal expansion (highest temperature) is conveyor

frame.

Conveyor frame not square or level: Check the conveyor frame to insure it is level and square. Correct any

conditions causing belt to rub or bind.

Shafts not held in place correctly: Insure shafts are plumb, level and square; make any corrections and

hold shaft in place with shaft collars, etc., allowing the with a set collar.

shafts to migrate to one side.

Sprocket Migrating out of Belt Shafts not plumb, level and

square to each other:

Inspect shafts to insure they are plumb, level and square to each other. Lock into

place with shaft collars. Check and adjust conveyor frame. Check shaft alignment after

any adjustment in frame. It components, not level or square. may be necessary to re-

plumb, level and square the shafts.

Sprockets not aligned

correctly on shaft:

Check sprocket alignment by laying a straight edge parallel to the tooth on the sprocket

to make sure that all sprockets are in the same position across the belt. On sprockets

having a tooth count that is evenly divisible by 4, teeth are automatically properly

aligned when put on the square shaft. However, if the tooth count cannot be divided

evenly by 4, special care must be taken to avoid problems. If timing holes are provided

on these sprockets, they must be placed in alignment all the way across the shaft, see

Sprocket and Shaft Installation.

Locked sprocket on drive and

idle not aligned:

Re-align sprockets “locked” in place by a retainer ring or other device insuring that the

drive shaft sprocket is perfectly aligned with the idle shaft sprocket.

Material build-up on bottom

of belt or sprocket:

Clean bottom of belt, removing any material build up that could interfere with sprocket

tooth engagement. It may be necessary to provide in-place brushes, scrapers, scrolls

or tooth engagement other devices to prevent future material build up.

Shaft deflection or twisting: Inspect shaft for evidence of deflection or twisting. Bent or twisted shafts must be

replaced. An intermediate bearing may be required for wide belts. Contact Intralox for

assistance.

Retainer rings improperly

utilized:

Replace missing retainer rings; check retainer ring location to make sure locked

sprockets or missing. on drive and idle shafts are in perfect alignment.

Excessive Catenary Sag

.

Incorrect total belt length: Excess catenary sag must be at the belt’s coldest operating temperature

because the belt will then be contracted to its shortest length. If excess

catenary is found, shorten the belt by removing rows of modules. All Intralox

belts can be shortened in one module row increments.

Elongation of belt due to initial break-in: Plastic belt will elongate during initial “break-in” period. This is a natural

process that is a start-up situation or heavy loads. Catenary sag is the

function of the belt acclimating itself to the application, and is more noticeable

when heavy loads are present. In this case, allow the belt to adjust to

operating conditions before shortening it.

CAUTION: Monitor the belt during this “break-in” to avoid binding or

catching

Elongation of belt due to wear. If the belt length is 3% longer than the initial pitch, the belt should be

replaced. This can be calculated by the ratio of the existing belt pitch / initial

belt pitch.

modular plastic conveyor belts lcus induction · pdf fileconveyor belt rollers in belt product...

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