Rapid Design Guide For Overhead Conveyors
Rapid Design Guide For Overhead Conveyors
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PURPOSES
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A PREFACE
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This Design Guide was prepared for the purpose of offering an explanation of the
many features of Rapid Overhead Conveyors, both Power Only and Power & Free.
Maintenance instructions are included and these recommendations should be
considered essential for the trouble free operation and long life of an overhead
conveyor system. It is suggested that this Rapid Design Guide be used in conj unction with Rapid Industries, Inc., full conveyor catalog where the detail and
construction of components of overhead conveyors are more fully shown.
For those well versed in overhead conveyor design and installation, this Design
Guide may seem to be elementary. This is exactly its purpose. The standard
designs and accepted practices of the overhead conveyor industry that have been
developed over the years are incorporated into this guide. Recent developments in
the industry including robot loading/unloading, robots performing tasks while the
overhead conveyor system is in operation, and computer control and optical scanners for routing and task execution, have been touched upon in the Rapid Design
Guide. For an investigation of these recent developments, and how they may have
application to your particular circumstances, contact Rapid Industries' Engineering
Department.
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ACKNOWLEDGEMENTS
Grateful acknowledgement is given to the following for the use of specified information in this Rapid Design Guide.
To the Conveyor Equipment Manufacturers Association CEMA Standard No. 601-1980, for certain definitions of Overhead Conveyor Terms, for portions of the Design Procedure, for Preventive Maintenance information, and for Rivetless Chain Dimensions.
To the Apprentice Training Program of the United Brotherhood of Carpenters and Joiners of America for illustrations of overhead
conveyor components on pages 26, 27, 40, 42 & 46.
To the Jervis B. Webb Company, also for portions of the Design Procedure, page 16 through 25, and also Preventive Maintenance
I nformation pages 49 through 51.
To the C.L. Frost & Son, Inc., company for information on chain pull calculations on page 33.
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Rapid Overhead Conveyors transport your product through process areas such as washing and
painting booths, furnaces and ovens, freeze rooms or booths where extreme cold or hot temperat ures prevent personnel from entering.
Where solvents, acids, or dust prevent the presence of your employees. Your parts can be degreased,
dipped, plated, coated or painted, all automatically and without the need for your people to be
present.
Rapid Overhead Conveyors carry your parts or assemblies to your employees where they can
efficiently perform their task, and then to the succeeding stages in the manufacturing process,
all automatically and at a rate that YOU determine.
A Rapid Overhead Conveyor will carry continuously its maximum load suspended from each
trolley over the entire route of the conveyor system.
Each trolley may carry either single or
multiple items depending on its shape and weight.
A Rapid Overhead Conveyor will work 24 hours a day for weeks on end. Up-time in full operation
i s better than 95% of all time available. Automatic lubrication and minimal maintenance result
i n this enviable record.
A Rapid Overhead Conveyor System, with variable speed drive, will permit you to control the rate
of travel of your parts or materials to maximize efficiency and production capabilities. Automatic
l oading/ unloading by "transfer-on-the-fly" systems or robot interface increases efficiency capabilities.
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A Rapid Overhead Conveyor system uses little or no floor space. The conservation of floor space
i s an important element in todays competitive market. Often, a Rapid Overhead Conveyor system
can be installed where a floor conveyor would be precluded due to space limitations.
A Rapid Overhead Conveyor system eliminates much manual handling, loading/unloading and
transporting of your product by your employees. With a reduction in the contacts of your product
with personnel, quality is demonstratably improved.
A Rapid Overhead Conveyor system delivers a continuous flow of material or parts to and from
each production area. Your personnel become more efficient and productive because the parts or
materials they need are there on schedule and easily accessible.
A Rapid Overhead Conveyor system eliminates most of the manual handling of parts or materials.
By doing so, considerable lost motion is also eliminated resulting in a reduction of per unit costs.
A Rapid Overhead Conveyor system permits a continuous inspection process instead of a batch
i nspection method where delays are often inherent in the handling of the item to be inspected.
A Rapid Overhead Conveyor will deliver to packaging equipment a steady flow of product or
material at a predetermined rate compatable with its capacity. Shipping likewise will receive a
steady output of product that can be more readily accomodated at a known flow rate than in the
batch delivery method.
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GLOSSARY OF
OVERHEAD CONVEYOR TERMS
ACCUMULATING
AIR-OPERATED TAKEUP
An assembly of the necessary structural and mechanical parts which provides the means to adjust the
l ength of the power chain by the use of an air cylin
der to compensate for chain stretch, shrink, or wear
and to maintain proper tension.
ANTIBACKUP
ANTIRUNAWAY
AUTOMATIC LUBRICATOR
BACKSTOP
BACKUP BAR
BACKUP ROLLERS
BALANCED DRIVES
BEAM CLAMP
BEAVER TAIL
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GLOSSARY (CONT.)
"B" or BOLT ATTACHMENT
CATERPILLAR CHAIN
CATERPILLAR DRIVE
The non-driving sprocket of a caterpillar drive. Adjustable to tension the caterpillar chain.
CENTER LINK
CHAIN PIN
CHANGE OF ELEVATION
An assembly of two single vertical curves with necessary connecting track to accomplish a change in
elevation.
CONVEYOR GUARD
COUNTERWEIGHTED TAKEUP
An assembly of the necessary structural and mechanical parts which provides the means to adjust the
l ength of the power chain by the use of counter
weights to compensate for chain stretch, shrink, or
wear and to maintain proper tension.
DRIVE:
CATERPILLAR DRIVE
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DRIVE (CONT.)
SPROCKET DRIVE
GLOSSARY (CONT.)
A conveyor chain driving unit using a sprocket to
transmit power to the chain, located at a turn of
approximately 90 degrees or more.
DRIVE FRAME
DRIVE SHAFT
DRIVE SPROCKET
DROP
DROP SECTION
DUCK BILL
FROG
GUARD:
SCREEN GUARD
A structure mounted below the conveyor path to protect personnel and equipment below.
MACHINERY GUARD
HANGER STEEL
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HEADER STEEL
GLOSSARY (CONT.)
Suitable steel framing to support the overhead conveyor track with all trolleys chain and the total load
i ncluding product and hangers.
KICKER
LINK
LOAD BAR
MULTIPLE DRIVES
Two or more motorized drives applied to a single conveyor for the purpose of reducing the chain
tension in any given section.
PENDANT or "C"ATTACHMENT
PICK-AND-PLACE
The means of loading/ unloading an overhead conveyor system using automated modules or robots.
POWER DOG
POWER ONLY
PRESSURE ROLLER
PUSHER DOG
RAPID SLIDE TM
pairs of
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RIVETLESS CHAIN
GLOSSARY (CONT.)
A completely forged, heat-treated chain of pins, side
links and center links which can be assembled or
disassembled without the use of tools.
ROBOT INTERFACE
ROLL NEST
An assembly of several segment rollers in a horizontal frame formed to an arc conforming to the
degree of turn required for the track of an overhead
conveyor.
ROLLER TURN
SANITARY PAN
A trough type guard suspended under overhead conveyor systems to prevent contamination. Used in
conjunction with a "C" hook.
SCREEN GUARD
SCREW TAKEUP
The assembly of the necessary structural and mechanical parts which provides the means to adjust the
l ength of the power chain by the use of the manual
adjustment of one or more screws to compensate for
chain stretch, shrink, or wear and to maintain proper
t ension.
SEGMENT ROLLER
SIDE LINK
That portion of the chain which longitudinally straddles the center link.
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SPRING TAKEUP
GLOSSARY (CONT.)
A spring actuated assembly of the necessary structural and mechanical parts which provides the means
to adjust the length of chain to compensate for
stretch, shrink or wear and to maintain proper tension.
SPROCKET DRIVE
STORAGE BANK
SUPERSTRUCTURE
SWITCH
TAKEUPS:
The assembly of the necessary structural and mechanical parts which provides the means to adjust
the length of chain to compensate for stretch, shrink
or wear and to maintain proper tension.
TRACK
AIR-OPERATED TAKEUP
An assembly of the necessary structural and mechanical parts which provides the means to adjust the
l ength of the power chain by the use of an air cylin
der to compensate for chain stretch, shrink, or wear
and to maintain proper tension.
COUNTERWEIGHTED TAKEUP
An assembly of the necessary structural and mechanical parts which provides the means to adjust the
l ength of the power chain by the use of counter
weights to compensate for chain stretch, shrink, or
wear and to maintain proper tension.
SCREW TAKEUP
An assembly of the necessary structural and mechanical parts which provides the means to adjust the
l ength of the power chain by the use of the manual
adjustment of one or more screws to compensate for
chain stretch, shrink, or wear and to maintain proper
tension.
90 SPRING TAKEUP
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GLOSSARY (CONT.)
I n a power and free overhead conveyor, the dimension from the top of the dual channel free track to
the bottom of the power track I-Beam.
TRACK DROP
TRACK SHROUD
TRACTION WHEEL
A smooth, straightface wheel which guides the conveyor chain around a horizontal curve.
TRANSFER-ON-THE-FLY
TROLLEY
TROLLEY ATTACHMENTS:
"B" or BOLT ATTACHMENTS
TROLLEY BRACKETS
TROLLEY CONVEYOR
TROLLEY WHEEL
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GLOSSARY (CONT.)
UHMW
UNIT BRACKET
WHEEL TURN
YOKE
The steel support brackets in power and free overhead conveyor track construction that attaches and
supports the free rail toe to toe channel track under
the overhead I-Beam power track.
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OVERHEAD CONVEYOR SYMBOLS
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TYPICAL OVERHEAD CONVEYOR LAYOUT
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ELEVATION VIEW
1 CATERPILLAR DRIVE
10
SCREEN GUARD
to
HANGER POINT
ANTI-BACKUP
10 ANTI=RUNAWAY
11 LUBRICATOR
TURN
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STEP 2
STEP 3
Design A Carrier
STEP 4
STEP 5
STEP 6
STEP 7
STEP 8
STEP 9
STEP 10
STEP 11
STEP 12
STEP 13
STEP 14
STEP 15
STEP 16
Select Drive
STEP 17
Locate Drive
STEP 18
Summarize
STEP 19
Erection
STEP 20
Safety
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LAYOUT OF AREA - DRAW PLANT LAYOUT
STEP 1
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A.
Layout on grid paper to largest practical scale ('/4" = 1'-0" or 1/8" = 1'-0") the plan of the
plant in which the overhead conveyor will be installed. Indicate "North" direction relative to
building.
B.
Draw an elevation view of the plant area where conveyor is to be erected. Establish the size and
elevation of building construction from which the conveyor is to be supported. Indicate with
section lines on plan if elevations are north, east, south or west.
C.
Locate, dimension, and label all obstructions which affect the route of the conveyor, such as
columns, walls, machinery, work areas, and aisles on the plan view and duct work, pipe lines,
on the elevation views.
DETERMINE MATERIAL FLOW
STEP 2
A.
On plant layout, locate all load and unload points and any processing stations that will be
served by the conveyor.
B.
Draw conveyor route so that it connects all areas in their proper work sequence with the most
economical path for the system. Keep parallel conveyor routes as closely spaced as possible
to reduce the amount of supporting members and guards required. Avoid using horizontal
curved sections of track in an incline or decline.
C.
Be sure the path of conveyor does not interfere with any machine operations or work areas.
D.
I ndicate location of drives, vertical curves. horizontal turns. relative to column lines. Refer to
typical layout and conveyor symbols and glossary at beginning of Design Guide.
SELECTING A CARRIER
STEP 3
A.
B.
Determine number of parts to be placed on each carrier and their relative position on carrier.
Make the carrier as compact as possible.
C.
Design of carrier should permit easy loading and unloading of parts. If "transfer-on-fly" or robot
i nterface is being considered, it is suggested contact be made with a Rapid Industries' Applications Engineer.
D.
The carrier should be designed to carry loads within the rated capacity of the trolley. Avoid
eccentric loading of carrier. Ideally, the carrier with load should always hang plumb. Trolley
capacities are listed in the Trolley and Attachment Section.
E.
Carrier bracket is to be designed to fit a chain attachment to which the load or carrier can most
readily be attached. Be sure to keep within the maximum load ratings of the trolleys.
F.
Standard trolley attachments may be selected from the data and illustrations in the Trolley and
Attachments Section. In special applications, almost any type of attachment can be furnished.
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STEP a
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A.
Select a trolley arrangement, either a single trolley or double trolley with load bar, in the Trolley
and Attachment Section that has a capacity rating exceeding the total weight of the carrier
designed in Step 3 and the carried load.
B.
The trolley load carrying capacity will determine the size of the conveyor in the average
conveyor application. However, the chain pull, as calculated in Step 7 must not exceed the
recommended working load for the selected size chain as shown in the Chain Section.
DETERMINE TRACK ELEVATIONS
STEP 5
A.
B.
At loading/unloading areas, the conveyor height should permit a person to easily load and unload
the carrier if this is to be a manual operation. If loading/ unloading is to be automatic using
either a robot interface or "transfer-on-the-fly" system, provisions should be made for the install ation of this equipment.
C.
The accepted clearance over work areas and aisles is 7'-0" from floor to lowest obstruction. The
conveyor height over aisles where industrial trucks are used must allow traffic to pass freely.
D.
E.
I ndicate the elevations at all vertical curves. See typical conveyor layout at beginning of Design
Guide.
SELECT VERTICAL CURVES
STEP 6
A.
For increased conveyor life, use the largest recommended radius possible for vertical curves in
your layout. Use minimum radius vertical curves only in conveyor areas where necessary.
B.
Using Figure 1, select a degree of incline for vertical curves that will provide a clearance between
carriers when they are moving on the incline. To assure clearance between carriers, dimension
"A"must be greater than carrier length.
C.
D.
Because of carrier sway, clearance must be provided between top of carrier and conveyor chain.
E.
F.
I ndicate on drawing the horizontal length (tangent to tangent) of each vertical curve, its radius
and degree.
G.
Locate each vertical curve relative to some adjacent component, as shown on typical conveyor
l ayout following the overhead conveyor schematic in this Design Guide.
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SELECT VERTICAL CURVES (CONT.)
FIGURE 1
STEP 7
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A.
Make a plan view layout of horizontal turn as shown in Figure 2. Clearance between adjacent
carriers while they are negotiating turns will determine the minimum horizontal turn radius.
B.
For increased conveyor life, use the largest standard radius possible for horizontal turns in
your layout. Select the horizontal turns best suited to your requirements from the Roller Turn
or Traction Wheel Section.
C.
Provide for one (1) 180 degree horizontal turn in your layout, as near as possible on the output
side of the drive unit, for use as a slack chain takeup. Refer to Takeup Section. If possible,
place this takeup at the bottom of a vertical curve.
FIGURE 2
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STEP 8
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A.
B.
C.
Be sure loaded carriers will clear all guards. Six inches clearance on each side is usually
sufficient. It is especially important to check clearances on horizontal and vertical curves.
Carrier templates can be used for this purpose.
D.
Locate each guard relative to some adjacent conveyor component or column line on your layout.
STEP 9
A.
B.
The following example illustrates the proper procedure to determine "number of carriers per
minute" based on the parts capacity of the carrier.
STEP 10
1.
2.
3.
Required number of carriers per hour equals 2400 divided by 8 or 300 carriers.
4.
A.
Refer to Step 6, letters C, D, and E and Step 7, letter A. Note the carrier spacing selected for
proper clearances.
B.
Refer to the Trolley and Attachment Section and note the recommended maximum spacing for
trolleys.
C. If your required carrier spacing is greater than the recommended trolley spacing, intermediate
trolleys are required.
D.
STEP 11
When laying out the conveyor path, a distance equal to the maximum trolley spacing selected
should be allowed between tangent lines of vertical curves and horizontal turns.
DETERMINE MAXIMUM CONVEYOR SPEED
A.
B.
Required conveyor speed in feet per minute is equal to the number of carriers per minute
multiplied by carrier spacing in feet.
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STEP 11 (CONT.)
C.
D.
E.
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I n Step 9 we determined that five (5) carriers per minute are required.
2.
3.
Five carriers per minute multiplied by carrier spacing of 2 feet, equals a conveyor speed of
10 ft./min.
2.
Using a 3 to 1 ratio variable speed drive would give you a speed range of 6.6 ft./min to
20 ft./min.
Refer to Drive Section for variable and constant speed drive information.
STEP 12
A.
B.
Obtain the sum of all arc lengths on the horizontal turns by using the horizontal turn lengths
and takeup length in the Roller Turn and Traction Wheel Turn Sections.
C.
Obtain the sum of all arc lengths and tangents including incline straight track on the vertical
curves by using the vertical curve formula in the Vertical Curve Section.
D.
The total length of the conveyor is equal to the sum of above. When ordering chain for the
conveyor, add 3% or a minimum of 10'-0" to the total length.
E.
A second method to determine conveyor length is to trace the conveyor layout with a "map
measure" as follows:
1.
Providing all dimensions on your conveyor layout are in scale, trace the path of the
conveyor with a "map measure". This will give the length of the horizontal path in inches.
2.
Multiply the traced length by the scale of the drawing. Example: Drawing scale is 1/4"=
1'-0". Multiply the traced length in inches by 4 and the result will be the conveyor length in
feet.
3.
To calculate the additional length required for changes in elevation, add all of the elevation
changes and divide the sum by 3.
4.
Add the result of the traced length and the elevation changes; then, add 3% or a minimum
of 10'-0" to the total length.
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STEP 16
SELECT DRIVE
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A.
Refer to Drive Section of Rapid Industries Conveyor Catalog for features and speed of caterpillar
and sprocket drives.
B.
Knowing your required speed and chain pull, select proper drive size from the informatior
found in Drive Section of Rapid Industries Conveyor Catalog.
LOCATE DRIVE
STEP 17
A.
B.
Locate the drive so it will apply a pulling force on the most heavily loaded portion of the system.
C.
For best results, locate the drive at some high point in the conveyor system and place the
takeup just after the drive at a lower point.
D.
Show information on selected drive and location on conveyor layout. Relate location to some
adjacent component as shown in Typical Conveyor Layout at beginning of this section.
SUMMARY
STEP 18
A.
For quick and easy reference, make a legend on your layout covering the following subjects
( Refer to Typical Conveyor Layout).
1.
2.
Length of conveyor.
3.
Trolley spacing.
4.
Carrier spacing.
5.
6.
7.
Weight of carrier.
8.
9.
Moving load.
1 0. Lift load.
11. Maximum chain pull.
12. Type, number and kind of drives selected; electrical specifications, (explosion proof c
TEFC motors).
13. Guard cross section with dimensions. (Expanded metal, wire mesh, or sheet drip par
type).
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STEP 18 (CONT.)
B.
SUMMARY (CONT.)
HOME
Make a list of all components required to complete your conveyor system. The following is a
suggested check list:
1.
2.
3.
Carriers.
4.
Roller turns.
5.
Traction wheels.
6.
Takeups.
7.
Drive.
8.
9.
STEP 19
Contact your Rapid Industries, Inc. sales engineer -- he has wide experience on conveyor
systems and components. His services are available for surveying your plant, inspecting your
l ayout, or assisting in placing your order.
ERECTION
I f you have the necessary equipment and facilities to completely install your newly designed
conveyor system, we refer you to the Installation Section of this Design Guide.
Throughout the United States and Canada, Rapid Industries has a staff of competent installation
superintendents and experienced crews. The Rapid Industries sales engineer in your area will be
happy to procure for you the services of these experts in all phases of conveyor installation.
STEP 20
SAFETY
Determine whether your overhead conveyor layout conforms to your company's safety policies and is
i n compliance with State and Federal OSHA requirements. Are all required guards in place? Does
electrical conform to code? Are there sufficient safeguards and controls with ready access to insure
the ability to maintain safe working conditions under normal and emergency conditions?
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TRACK
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Rapid Overhead Conveyors utilize, in both Power Only and Power & Free systems, a high carbon structural shape
or a roll formed heat treatable steel track. The Power Only systems use a high carbon [-Beam, S3x5.7, S4x7.7,
or S6x12.5 depending on the type of system, or a roll formed heat treatable enclosed track. Power and Free
conveyors use the same track as Power Only systems with the addition of high carbon structural channels, C3x4.1.
C4x5.6. C6x8.2, C6x12, depending on type of Power & Free system. The track of overhead conveyor systems must
sustain all of the load placed on it. As a rule, the track is the limiting factor in the amount of load an overhead
conveying system will handle, providing the header and hanger steel have been properly designed and installed.
The lower flange of the track must withstand the load and were imparted to it from the conveying trolleys without
undue peening or deformation.
Rapid Overhead Power Only conveyors are offered in enclosed track (Rapid Flex). 3", 4", & 6" track sizes while the
Rapid Flow Power & Free overhead conveyors are available in Enclosed Track over 3" channel (O Flex), 3" I Beam
over 3" channel, 4" I Beam over 4" channel, & 4" I Beam over 4" channel as well as custom sizes.
TRACK ACCESSORIES
Track accessories for the Rapid Power Only and Rapid Flow Power & Free overhead conveyors include a variety of
mechanical devices. either manually or automatically operated, that control the trolley's direction and position in the
system. These include push across transfers, track expansion joints, track splices. switches, anti-backups. anti-runaways,
stops, drop lift sections, bank and accumulating tracks, either singular or parallel, and other miscellaneous controls
and devices. Examples of some of these are shown below.
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TRACK ACCESSORIES
RAPID FLOW" POWER & FREE TROLLEY
STOP
RAPID FLOW"' Power & Free Trolley Stops may
be located at any point on the free track where
free trolleys are required to stop or accumulate.
They are available in many designs and styles.
To stop movement of a load, RAPID FLOW
Trolley Stops disengage free trolleys from the
power chain. The stop blade extends until it is
positioned in the path of the power dog on a
l eading free trolley. The power dog pivots as it
makes contact with the stop blade until it becomes
completely free of the side link pusher dog.
Subsequent trolleys disengage similarly when
each power dog contacts a beaver tail (refer to
accumulation page). To resume movement of the
trolleys, the stop blade is simply retracted.
ANTI-BACKUPS
Anti-backups are used as a precaution in the event of a possible chain
breakage due to overloads or jams. An anti-backup is a counterweighted
device that is mounted on the free track of a Rapid Flow Power & Free
system and on the power track of a Rapid Power Only system by a pivot.
I n normal operation, the trolleys push the anti-backup out of its path
and after the trolley has passed, the anti-backup returns to its position.
I n the event of chain breakage, the anti-backup will engage the trolley
bracket or the body of the trolley and prevent reverse conveyor travel.
Electrical limit switches are often incorporated into the anti-backup
device to shut down the electrically powered drive of the conveyor.
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RAPID FLOW" POWER & FREE PUSH TRANSFER
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A Transfer in a Power & Free overhead conveyor is a device used to move or transfer a power & free trolley from one
pusher dog on a power chain to the pusher dog on another power chain. The push transfer utilizes the pusher dog
of the power chain to make the transfer.
The first conveyor has a quick drop section installed in the proper position to allow the pusher dog on the first chain
to engage the transfer dog on the trailing free trolley. After the leading free trolley has been released at the transfer
point, the carrier is then pushed by the rear free trolley a sufficient distance to permit the leading free trolley to engage
the pusher dog on the second conveyor. This permits the two conveyors to operate completely independent of each
other. In most cases, no interlocking, pusher dog synchrunization, or speed relationship is required.
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Leading Trolley
The leading trolley consists of a standard body with power dog and holdback dog assemblies; each is normally
i n the driving position, as shown above.
The side link pusher dog passes over
the hold-back dog and becomes trapped on the power dog thus driving the
trolley forward To disengage the free
trolley, a stop blade is incorporated,
which is positioned in the path of the
power dog. The power dog pivots as it
engages with the stop blade causing
Intermediate Trolley
This is a standard body which is always
fitted between the leading and the traili ng trolleys and is used for supporting
long or heavy loads.
Trailing Trolley
This free trolley consists of a standard
body, auxiliary pusher and beaver tail.
The beaver tail allows accumulation
by causing the same action as the
free trolley stop blade. The auxillary
pusher allows transfers from chain to
chain without using external devices.
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Drop forged, high strength steel brackets are attached to the wheels
by riveting or swaging. All Rapid brackets are designed with a
ribbed construction for maximum strength.
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Drop forged rivetless chain for Power Only and Power and
Free conveyors, has a high strength to weight ratio, is
extremely flexible in both horizontal and vertical planes, is
easy to assemble without tools, and remains intact while in
service with minimum maintenance.
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CHAIN LOADING SPECIFICATIONS
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Allowable chain loading (pull) providing maximum chain life is dependent on the design and environment
of the application. The following are condition descriptions which are used to define allowable chain loads
( pull) in given environments.
CONDITION 1
CONDITION 2
TYPICAL - Conservative design using lower chain pull. The design and environment
criteria as described in Condition No. 1 are used resulting in longer chain life.
CONDITION 3
SEVERE - Horizontal turns and vertical curves are the minimum allowable radii.
System has many directional changes. Heavy individual loads and large elevation
changes result in severe reactional loading. Adverse environmental conditions such as
temperatures exceeding 250 F, concentrated alkalies and/cr acids present, dusty and
dirty condtions, humidity changes, etc.
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ALLOWABLE TROLLEY LOADS AND CHAIN PULL (INTERRELATED)
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The allowable trolley loads and chain pull are interrelated and limited by the track (I-Beam) load capacity.
This track load capacity is known as "Track Wear Rating" (TWR), because loading above this limit will
cause "grooving" of the beam flanges at the trolley wheel contact point. Track loading is a combination of
trolley loads (L) plus chain reaction loads (R).
At vertical curves, the chain exerts an
additional
force on the trolleys and the track flanges. This resultant (R) force acts toward the center of curvature
of the vertical curve, and is additive to the force
exerted by the trolley loads (L) (live load plus carrier)
on the trolley wheels and track flanges. When selecting multiplane trolley conveyors, consider these
factors and make selections that keep the track
flange loads within recommended limits . . . Track
Wear Rating (TWR) = Load Limit Without Damage to
the Track.
I-BEAM SIZE
3'
3"
4"
6"
TROLLEY DESIGN
Sani-Trolley` Thermo-Plastic Wheel
TWR
200 lbs.
450 lbs
800 lbs.
1,600 lbs.
the chain reaction loads (R) are a substantial portion of TWR, in multiplane systems, reducing the
allowable trolley live loads. The following chart is a "rule of thumb" guide line for the maximum "live load"
or "swing weight" of the Track Wear Rating (TWR).
L
150 lbs.
3"
4"
200 lbs.
400 lbs.
6"
1,200 lbs
1-BEAM SIZE
3"
TROLLEY DESIGN
TROLLEY SPECIFICATIONS
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TROLLEY ATTACHMENTS
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"C" Attachment
5 lbs.
"H" Attachment
"1" Attachment
Weight: 25 lbs.
Weight: .3 Ibs.
"C" Attachment
"H" Attachment
"I" Attachment
Weight: .8 lbs.
Weight:.55 lbs.
Weight: .6 lbs.
"H" Attachment
"H" Attachment
"I" Attachment
"C" Attachment
Weight: 2.7 lbs.
"H" Attachment
"I" Attachment
35
CONTENTS
LOAD BAR ASSEMBLIES
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ACCESSORIES
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VERTICAL CURVES
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I n a multiplane overhead conveyor system where it is required that the track, either Power Only or Power
and Free, change elevation, vertical curves, either single or double (Also called ''compound curves") are
used. The radius of vertical curves must be carefully selected because of the effect of the additional forces
i ncurred by the change of elevation which will be transmitted to the overhead conveyor through the power
chain and load bearing trolleys. Vertical curves are usually made as single curves and are field assembled
i nto double or compound curves, using a straight tangent section of track between the curves as is required to meet the change of elevation requirements.
Vertical curves, both incline and decline from the horizontal, are made for all track sizes in both Power
Only and Power and Free overhead conveyor systems, to the degree of arc and radius required. Standard
arcs are 30 and 45. The vertical curve radii should be as large as possible and yet consistent with the
conveyor layout requirements. Minimum vertical curve radii should be used only when absolutely required
and when consideration has been given to imposed trolley loading, chain pull, chain wear, track wear, and
possible conveyor line surge.
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DRIVES
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Rapid Overhead Conveyor Power Chain Drives are available in two general types: the caterpillar drive and
the sprocket drive. The drive is one of the most important components of an overhead conveyor system.
I n addition to powering the rivetless power chain of the system, the drive governs the speed of the power
chain and thus the rate of production. The selection of the proper type of drive, either caterpillar or sprocket,
and the proper size and gear ratio of the speed reducer, is essential in the design of the most efficient and
economical overhead conveyor system, either Rapid Power Only or Rapid Flow Power & Free for your application.
CATERPILLAR DRIVES
Stationary fixed frame Caterpillar Drives are to be located on a straight run of the track at a high point in the conveyor
system. The drive must pull, not push, the power chain. Caterpillar attachment components are mounted
on a steel frame that bolts to the main drive frame. This type of drive requires an external overload protection
device, i.e. shear pin hub. current limiting device, etc.
Floating Caterpillar Drives incorporate a system of rollers supporting the drive frame within an enclosed steel
stationary frame. Movement of the floating frame is limited by helical springs. The advantage of the
floating caterpillar drive is that, through the use of limit switches for overload protection. the replacement
of shear pins when the drive is overloaded is no longer necessary. Rapid Floating Caterpillar Drives are
available in the same capacity and ratings as Rapid Stationary Caterpillar Drives.
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SPROCKET DRIVES
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A Sprocket Drive utilizes a sprocket with an integral shear pin hub which is mounted on the speed reducer
output shaft and engages and drives the power chain of an overhead conveyor system. For use in hori zontal turns, a sprocket drive requires a 90 chain wrap as the minimum, with 180 chain wraps often
used. All components of a sprocket drive are mounted upon a welded steel frame, which, like the caterpillar drive, is installed in the high portion of the overhead conveyor system. The sprocket drive is likewise to pull, not push, the rivetless power chain.
Constant speed drives are the simplest and most economic drives where only one conveyor speed is required. Variable speed drives within the ratio of 3 to 1 are used for applications requiring a speed variation
of the overhead conveyor system.
MULTIPLE DRIVES
Wherever the length of the system, or the loading upon the system, or a combination of these two factors,
results in a chain pull greater than the capacity of the chain and drive usually furnished for that size
system, multiple drives may be required. Floating caterpillar drives should be used for multiple drive
i nstallations to eliminate successive shear pin breakage in the event one drive is overloaded. For recommendations for multilple drive variable speed systems, please contact Rapid Industries' Engineering
Department.
ELECTRICAL CONTROLS
All power and control wiring for the conveyor system is to be installed as per local, state or national
electric code. A control panel of a suitable type for the environmental conditions present is to be used to
house a fused disconnect or circuit breaker, control transformer, motor starter of proper size with required
heaters, relays if needed, and a terminal strip for connection of remote start-stop stations. A non-fused
disconnect switch may be installed adjacent to the drive motor, if desired, to isolate the drive for
maintenance.
A maintained contact start-stop push button is recommended for multiple push button stations. The
maintained push button configuration permits only the station which stops the conveyor to re-start it.
Systems requiring the actuation of multiple start buttons on start-stop stations throughout the length of
the overhead conveyor are sometimes installed to safeguard personnel who may have moved into the path
of a stopped conveyor.
I nstantaneous current trip relays may be used in lieu of shear pin hubs for both the caterpillar and
sprocket drives. Current trip relays are set for a pre-determined load and will shut down the drive when
that load condition is met.
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TAKEUPS
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Takeups are required and essential in every overhead conveyor system to control power chain tension and remove
chain slack. The takeup is incorporated into roller bank turns or traction wheel assemblies, either 90 degrees or 180
degrees, which then serve a dual function of change of direction for the power chain and a tensioning means for the
power chain. Takeups may also be included in spread track loops using two 90 degree traction wheels or roller bank
turns with a straight section of track between them up to a 20 feet maximum spread between centerlines. Takeups
are actuated by one of several means including all-thread adjustable rods, counterweights, pneumatic or hydraulic
cylinders, or are spring actuated the most common application. Takeups are made for all sizes of track in both the
Rapid Power Only and Rapid Flow Power & Free overhead conveyor systems. A takeup for a Power & Free system
i s identical to the takeup used in a Power Only system. Takeups of 8 inches, 16 inches, or 24 inches are avilable to
meet the requirements of the overhead conveyor system.
Custom designed and fabricated takeups for spread track applications in excess of 20 feet in width are
available on special order from Rapid Industries, Inc. Consult the Rapid Engineering Department for
particulars.
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CARRIERS
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Carriers, permitting either single or multiple loading of products, subassemblies or materials, are available
i n almost an infinite variety of shapes or configurations. Ease of loading/unloading carriers either
manually, "on-the-fly" or by robot is an important consideration in selecting the carrier for your particular
application. In robot loading/unloading of overhead conveyors, a PAU (program analog unit) is interfaced
with the power chain, often with a Rapid Slave Cat Interface for robot PAU, to transmit to the robot the
carrier position data and speed of the power chain. Examples of typical carriers are illustrated below. For
assistance in carrier design, contact Rapid Industries' Engineering Department.
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RAPID FLEX'"
TRACK
SECTION
Design flexibility, ease of installation, and low
maintenance are all features of the Rapid Enclosed
Track. Formed with high strength steel. each 20'-0"
section can be cut and welded without using any
special equipment to fit almost any situation.
RF-2100
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ACCESSORIES
ATTACHMENTS
RAPID FLEX"
SWIVEL ROTATOR
RAPID FLEX"
STANDARD
"H" ATTACHMENT
The swivel
rotator can be
rotated by
hand or
automatically
with rub rail
i nstalled.
75 lbs. capacity
RF-0201
RF-0204
Positive
rotation can be
provided by
adding a six
point star to the
swivel rotator.
RAPID FLEX"
RIGID "H" ATTACHMENT
75lbs capacity
R F-0202
RF-0205
RAPID FLEX"
I NDEXING
90
HOOK
RAPID FLEX"
EXTENDED "H"
Two piece
cam construction provides
positive 90
i ndexing.
RF-0206
Automatic
i ndexing can
be achieved by
adding a four
point star to
the standard
hook.
RF-0207
RAPID FLEXT"
LOAD BAR
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GUARDS
Guards fabricated of expanded metal, wire mesh, or sheet metal are often required to be suspended bel ow the overhead conveyor in areas where there is a potential safety hazard to personnel and to plant
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equipment in the event something is dislodged from the overhead conveyor carrier. These guards are
usually field fabricated on the site and erected as required. In food processing or packing plants the guard
i s often made of a white fiberglass sheet that is easily removable from the supporting overhead hanger
steel for cleaning purposes. Guards are usually always installed over aisles, work areas, and at inclined
sections of track at vertical compound curves. Some examples of guards are shown below.
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I NSTALLATIONS OF OVERHEAD CONVEYOR SYSTEMS
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The erection of a Rapid Power Only or Rapid Flow Power & Free Overhead Conveyor system requires that adequately
sized structural steel support members be used to hang the track, drive, and all accessories from overhead girders,
trusses, or joists, or if this is not permitted (due to the excess loading that would be placed upon building support members)
then the Overhead Conveyor system would be floor supported by the erection of properly sized columns and track
support steel. The design of this support steel, either overhead or floor supported, has been standardized for most
conditions by the industry over the years of erecting and successfully placing into operation overhead conveyor systems.
Some examples of this header support steel are shown below. The important factor to remember in installing an overhead
conveyor system is that the load carrying capacity of the conveyor is only as strong as the overead header steel or
floor support steel from which the conveyor, drive, and accessories are hung.
I n erecting Power Only and Power & Free systems, it is important that the track be aligned in both the
horizontal and vertical planes as nearly straight as possible between points where a change of direction is
i ntended. This reduces friction of the trolleys against the web of the I-Beam track on straight track and
thus reduces the power chain pull required of the drive and increases the life of the system.
Power & Free Track must be installed to very close tolerances to permit the proper operation of mechanical, electrical, or pneumatically operated devices such as stops, switches, transfers and loading and
unloading operations, especially those done by robots.
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1.
2.
Rapid Industries maintains a millwright service to inspect and lubricate Overhead Conveyors on a
periodic basis. A quotation to furnish this service will be made upon request.
3.
Trolley wheel bearings receive a minimum application of a rust-proof spindle oil at the factory for
protection during shipment only.
4.
Trolley wheels operating through bonderite, steam, elevated temperatures, caustic and abnormal
conditions should be baffled for protection and require special lubricated consideration. For recommendations, refer to chart on following page.
5.
Trolley wheels operating in elevated temperatures (above 250 F) should have an automatic lubricator
of positive connection type located a reasonable distance from oven exit to allow parts to cool down
to approximately 200 F. Lubricators may apply either a mist or fog of light penetrating oil so as to
l eave a minimum of residue, or a fluidized "dry" type molybdenum disulphide lubricant.
6.
7.
Sluggish or frozen wheels must be removed from conveyor and thoroughly cleaned and inspected for
l ater replacement use. The cost of a new trolley may be less than the cost of cleaning the
components.
8.
To remove welsh plugs. pierce with a sharp tool and pry loose, with thin tool. Replace with new
plug which must be pressed in place with a blunt tool.
9.
10.
Trolley brackets that may become bent in service must be replaced. An attempt to straighten
brackets is not often successful due to the metalurgy of the bracket.
11.
Chain must be lubricated at drive on slack chain side to insure lubricant reaches bearing point of pin
and link.
12.
13.
The floating type drive may be furnished with a chain pull indicator. Above normal (red zone) chain
pull indicates a possible lack of lubrication.
14.
15.
An adequate supply of spare parts should be on hand for replacement of components when needed.
This is especially true for brackets, half trolley assemblies, attachments, and inner caps.
16.
I -Beam track and the free track should be inspected at periodic intervals for wear and peening of
flanges at vertical curves, and wear on I-beam webs and channel flanges.
17.
I t is advisable to permit conveyors operating in cold rooms at low temperatures to be allowed to run
at reduced speed continuously overnight to prevent the freezing of lubricants.
18.
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PREVENTIVE MAINTENANCE
WHEN PROBLEMS OR BREAKDOWNS OCCUR, SEVERAL PROBABLE
CAUSES OF THE PROBLEMS MUST BE ANALYZED.
THE FOLLOWING LISTS ARE POSSIBLE CAUSES OF CONVEYOR
BREAKDOWNS AND SUGGESTED REMEDIES.
B.
A. PROBLEM
PROBABLE CAUSE
C. REMEDY
CHAIN
PROBLEM
PROBABLE CAUSES
Excessive chain wear or chair tension (NoteThe chain will grow and wear where chain pin
contacts link . this is normal wear and is no
fault of the system i
A. Lack of lubrication
B. Sluggish or frozen trolley wheels
C Roller turn roller frozen
D Obstruction in chain path
E Conveyor overloaded
2.
TROLLEYS
PROBABLE CAUSE
PROBLEM
t
ROLLER TURNS
PROBABLE CAUSES
PROBLEM
1
I -BEAM
PROBABLE CAUSES
PROBLEM
1
2.
of
flanges at
REMEDY
A. Lubricate chain
B See # 1 under Trolleys
C See # 1 under "Roller Turns.
D Remove obstruction and remove and replace
chain if damaged
E Conveyor should not be loaded beyond its
designed capabilities.
A. Adjust take up screws by increasing spring
compression, and d necessary remove links
of chain
REMEDY
A. Remove from conveyor and clean Remove
welsh plug to clean and press on new plug with
blunt tool
B. Replace wheels .
A. Remove obstruction and replace damaged
trolley bracket with new bracket. (Do not
attempt to straighten bent brackets )
REMEDY
A. Clean thoroughly or replace i f bearings are
damaged See lubrication chart
REMEDY
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PROBLEM
I
TAKE UP
PROBABLE CAUSES
REMEDY
PROBLEM
1
DRIVE
PROBABLE CAUSES
REMEDY
A Belt slippage
B set screws on pulley are loose and causing
pulley to rotate_ on shatt
C Conveyor chain tension
I s excessve
A lack of lubricatiom
B Oil leak
Slapping or pulsating
A Obstruction
caterpillar chain
or