ENGINEERING MANUAL 167

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1 ENGINEERING MNUL 167

2 COMPNY PROFILE Engineering Plastics IRP Engineering Plastics CC was founded in 1987 and has been the industry leader in Engineering Plastics ever since. n opportunity was recognised for the real need in local manufacturing of plastic conveyor components used by the food, beverage and packaging industries, which had previously been sourced from Europe and merica. IRP's Manufacturing capabilities has continually developed over the years and now consists of a full CNC manufacturing Division, Injection Moulding Division, elt, Chain and Component ssembly Division and a Stock Holding Division with more than 000 conveyor components. IRP's Injection Moulding facility consists of injection moulding machines ranging from 50ton to 360ton capacities and is complete with a fully operational tool room to handle injection moulding projects from start to the nish product. IRP's CNC Manufacturing Division is dedicated to producing custom made parts and comprises th of CNC Lathes, CNC Machining Centres and CNC Vacuum ed Routers complete with 4 xis capabilities. ll machines are linked to sophisticated utocad and CNC programming systems for superior accuracy and speedy delivery. IRP's Technical Design Centre is equipped with the Cimcore II portable measuring arm which is the latest in portable measuring technology. Cimcore II enables IRP to accurately reverse engineer any complex parts with ease which can be done onsite, reducing downtime or at our Technical Design Centre. IRP's Modular elting and Chain ssembly Division has over dedicated assembly lines locally producing standard modular belts and non-standard made to width modular belts and chains. IRP's Modular elting and Chain ssembly Division boasts a modular belting range that consists of a 1mm pitch, 15mm pitch, 5,4mm pitch, 31.75mm pitch and 50.8mm pitch belts in both straight running and side exing applications. IRP locally produce and supply the full range of plastic, stainless steel slatband chains and crate conveyor chains. IRP's range of modular belting and chains has been used and supplied extensively to all food, beverage and packaging industries over the last 5 years. IRP supply a wide range of nylon stock shapes and is capable of supplying sheets sizes 600mm x 1300mm up to 0mm thick with Nylon rods and tubes that can be produced up to 00mm in diameter. IRP's Nylon (Polyamide) range consists of Molybdenum, Oil and Wax lled grades that increases wear resistance and reduces friction. This Nylon is commonly used in parts such as change parts, bottle feed equipment for bottling and canning plants, corner tracks, wearstrips and bearing applications. MISSION STTEMENT To continually strive for customer satisfaction brought about by being a World Class Supplier of conveyor components for use in the food, beverage and packaging industries, by offering technical assistance based on experience and know-how and by developing innovative solutions that both enhance the customers' business as well as our own.

3 SERVICES / PRODUCTS / INDUSTRIES SERVICES Core Services IRP Engineering Plastics offers a wide range of services that set us apart from our competitors Superior Stock Holding, Monitoring and Stock vailability Onsite Measuring and Reverse Engineering CNC Manufacturing and Design Custom Injection Moulding Modular elting and Chain ssembly CONVEYOR COMPONENT PRODUCTS IRP Engineering Plastics produce and stock a broad selection of conveyor components that service and supply the food, beverage and packaging industry. Our range of conveyor components include : stainless steel & plastic slatband chains, guide rail systems, sprockets & idlers, modular belting, bends & straight tracks and specialized machined components including bottle feed equipment. Stainless Steel Slat band chains Plastic Slat band Chains Sprockets and Idlers Components Guide Rail Systems ends and Straight Tracks Modular elting ottle Feed Equipment Specially Machined Components ucket Elevator Components Wear Strips & Chain Guides INDUSTRIES IRP Engineering Plastics produce and stock a broad selection of conveyor components that service and supply a wide variety of industries. Our range of conveyor components include : stainless steel & plastic slatband chains, guide rail systems, sprockets & idlers, modular belting, bends & straight tracks and specialized machined components including bottle feed equipment. IRP Services the following industries: ottling and everage Filling Food Conveying Glass Manufacture and Conveying read Manufacturing and Conveying Dairy Manufacturing, Filling and Conveying Pharmaceutical Manufacturing, ottle Conveying and Filling Conveyor uilding Supply ulk Materials Handling 1

4 Engineering Plastics ENGINEERING MNUL IRP SLTND CHINS CONVEYOR DESIGN Slip Stick / Pulsating Effects Slip-stick is caused by the difference between static friction and dynamic friction. Slip-stick effects can cause a pulsating chain operation. The chance of a pulsating operation increases with long, low speed conveying. Level in/outfeed Inclining / Declining Conveyor Configuation Slatband chains can be used on in- or declined conveyors which are basically constructed in the same way as level conveyors. Main concern is to avoid that the products slide down or tip. Conveyors can be constructed with a level in/outfeed section, see diagrams on the left. Inclined/declined conveyors that are equipped with a Magnetic Flex curve, we recommend a minimum level section of 1mtr. This eliminates the chance of the chain lifting out of the curve. No in/oufeed Max. Possible ngle The maximum possible angle depends on several factors: Coefficient of friction between chain and product; acceleration/deceleration; product stability and external factors like dirt or debris. elow is a general table showing maximum angles determined by chain friction. Maximum angles inclines / declines Chain Type Lubricated Dry running Steel chains Plastic chains Rubbertop chains Variations can vary due to actual circumstances. 168 Engineering Manual

5 ENGINEERING MNUL - IRP SLTND CHINS CONVEYOR DESIGN Uni-directional End Driven Conveyors 140 Wrap round ngle Recommended wrap angle on sprockets is: 140º +/- º.When the wrap angle is too small, the sprocket will not be able to transfer the load to the chain anymore causing the chain/belt to jump on the sprockets. When the wrap angle is too big, the chain/belt can stick to the sprocket. = 1.5 X These conveyors have the drivemotor and sprocket at the end of the conveyor i-directional Conveyors with End Drive = 1.5 X These conveyors have the drivemotor and sprocket at the end of the conveyor i-directional Conveyors with Centre Drive = 1.5 X = 1.5 X These conveyors can have a small end roller to reduce the transfer area Drive Constructions Inclines C C=0.5X =1.5X 169

6 Engineering Plastics ENGINEERING MNUL IRP SLTND CHINS CONFIGURTIONS Straight Running Configuration Tail Shaft 1 mtr max. Drive Shaft The length of a conveyor is not limited. There is a certain maximum length for each application. The limits are depending on factors like chain - or belt type, lubrication, kind of product, load. The exact maximum conveyor length can be calculated with the readily available calculation programme. Generally for straight running conveyor we recommend a Max. track length of 1 mts. (see diagram) Shorter conveyors are built to obtain lower backline pressure by means of better control facilities. The chainspeeds can be controlled using frequency controlled drives. When for instance one conveyor runs full, the chainspeed of the preceding conveyor can then slowly be decreased. Pasteurisers, warmers and coolers can require longer tracklengths. Tail shaft Preferred Side Flexing Configuration When planning a side-flexing conveyor layout, the designer must consider the following factors that affect chain life: Minimise the number of corners whenever possible. When conveying from point to point, design the conveyors so that the drive is positioned further from the last corner (see diagram), resulting in lower chain tension and maximising chain life. void Tail shaft Drive shaft 170 Engineering Manual

7 ENGINEERING MNUL - IRP SLTND CHINS CONVEYOR DESIGN Catenary Sag 140 Catenary Sag It is recommended to create a catenary sag just behind the sprocket which provides a complete discharge of the chainload and ensures proper running. = 1.5 X Chain Type (mm) (mm) Vertical Sag Y(mm) Slatband Crate Chains LP-Chains N/ 1) 400 ) ) Use flat return for Crate Conveyor-series chains ) Use guide shoes/flat return for LP chains Note the chain can elongate due to strain and wear of the pins and hinge eyes. Therefore it is important to check and adjust the catenary regularly. Tensioner Construction Tensioner Construction tensioner construction is only necessary if the conveyor design does not allow for a proper catenary sag. tensioner can also be used with declined conveyors, but in all other cases it is not recommend to tension the chain/belt. The tensioner roller/sprocket can be fixed on an arm or move up and down in slots in the conveyor sideplates. This will bring constant tension, independent of length differences in the chain. Roller Diameter for Slatband Chains Chain Type Slatband Chains LP Chains Crate Conveyor Chains Idler rollers > 0mm >0mm 0mm Return Rollers 60-0mm Guideshoes are recommended 60-0mm ackflex Rollers 300mm Not recommended mm The recommended roller diameters in the table are an indication. The width of the conveyor is not taken into account. The diameter of the shaft should be large enough to avoid deflection of the roller. t the same time it is recommended not to exceed the maximum diameter, because the roller friction may be too high to be set in motion by the belt

8 Engineering Plastics ENGINEERING MNUL IRP SLTND CHINS CONVEYOR DESIGN GUIDING OF SLTND CHINS Guiding of single 3.5 chains Guiding of multiple 3.5 chains Guiding of 4.5 plastic chains Guiding of plastic chains GUIDING OF DOULE HINGE SLTND CHINS Guiding of stainless double hinge chains Guiding of plastic double hinge chains GUIDING OF HEVY DUTY SLTND CHINS Guiding of stainless Heavy Duty chains Guiding of Heavy Duty plastic chains 17 Engineering Manual

9 ENGINEERING MNUL - IRP SLTND CHINS WERSTRIP MTERILS Metal Wearstrips Metal wearstrips can be used in most situations using plastic chains and are strongly recommended in abrasive environments. Stainless steel: Recommended for abrasive conditions due to avoiding of dirt embedding in the wearstrips; Recommended for plastic chains/belts in dry environments with speeds > 60m/min; Cold rolled stainless steel with a hardness of at least 5 Rc and a surface finish of maximum 1.6 μm is recommended; est results can be achieved by using stainless steel ISI 431 ISI 304 is not recommended as wearstrip material. Plastic Wearstrips Friction is low compared to steel wearstrips. Two types of plastic are suitable to be used as a wearstrip material. UHMWPE: Most common used wearstrip material with extreme low friction; Excellent resistance against many chemicals; Virtually no moisture absorption, therefore very suitable for lubricated lines; Good dimension stability; Reduces some of the noise conveyors produce; Suitable for dry running conveyors with speeds up to 60 m/min; Extruded quality 00 grade UHMWPE is recommended. Polyamide/Nylon: Relatively high moisture absorption which makes the material expand; Polyamide is also used with additives to reduce the coefficient of friction; Suitable for dry running high speed conveyors. Recommended Wearstrip Materials Wearstrip Material UHMWPE Polyamide Stainless Steel Steel Chains Plastic Chains Dry Lubr. Dry Lubr. + 1) + ) + + +/ / Recommended +/- Satisfactory - Not recommended 1) Up to 60 m/min in non abrasive conditions ) Only in non abrasive conditions It is not recommended to use the same material for the wearstrip and chain

10 Engineering Plastics ENGINEERING MNUL IRP SLTND CHINS UHMWPE WERSTRIP INSTLLTION Chamfering of Wearstrips Wearstrips should always be chamfered at the beginning of the strip where they are fixed. Chamfering reduces the risk of chain-obstruction resulting in a smooth operation.the wearstrips should be chamfered at the sides and at the top. Splitting the Wearstrips On straight sections with a length of more than 3 metres, or for high (40-70 C) application temperatures, we recommend to divide the wearstrip into several sections, because of the thermal expansion of the strips. Gap It is recommended to cut the wearstrips at 45 angles to provide smooth chain/ belt transfers. Make sure only the infeed side of the wearstrip is fixed to the conveyor frame to avoid bulging of Gap the wearstrips. Calculation Example For UHMWPE material the expansion coefficient is 0. mm/m/ C. temperature increase of 0 C would elongate a 3 meter wearstrip with: 0 C * 3mtr * 0.=1 mm In this case, the gap between the wearstrips should be a bit larger than 1 mm. We recommend a maximum wearstrip length of 6mtr. with UHWMPE wearstrips. 174 Engineering Manual

11 ENGINEERING MNUL - IRP SLTND CHINS POSITION SPROCKET - WERSTRIPS When the chain enters the sprocket, it tends to raise and fall slightly (chordal action). For this reason the sprockets should be mounted in such a way that its highest point is no higher than the top of the wearstrips. The front edges of the wearstrips should be bevelled to allow smooth and free running of the chain. The distance from the end of the wearstrip to the sprocket shaft centerline should equal dimension L, otherwise the wearstrip will interfere with the free articulation of the chain as it enters the sprockets. L L H D Chain Type Drive Sprocket H (mm) L (mm) Idler Return H (mm) L (mm) St-Steel, Plastic Single Hinge & Plastic Double Hinge Chains Heavy Duty Plastic Single Hinge Chain Plastic T, evel & Magnetic Flex Chains Heavy Duty Plastic T, evel & Magnetic Flex Chains Chains CC600-CC600D Chains Keyway Dimensions of Sprockets b Keyway Dimensions of Sprockets d1 (mm) b (mm) t (mm) t 5mm 30mm 35mm 40mm 45mm 50mm 60mm d1 (inch) b (inch) t (inch) d1 1" 1 1/4" 1 1/" 1 3/4" " 1/4 1/4 3/8 3/8 1/ 1 1/8 1 3/8 1 9/ /16 1/

12 Engineering Plastics ENGINEERING MNUL IRP SLTND CHINS CURVE INSTLLTION For Magnetic Flex curves, the following installation recommendations should be taken into account. 3mm 3mm Installing Magnetic Flex Curves Magnetic Flex curves are mounted to the conveyor frame using inserts in the curve returnpart. The upperpart is fixed to the returnpart with screws. 3mm 3mm It is important to take care of the position of the inserts. Magnetic Flex curves should only be drilled in the underpart, taking the dimensions into account shown in the drawing. Note: lways check returnpart for protruding bolts, which could obstruct the chain. Installing Multiple Track Curves For multiple track curves (>500mm) we recommend to support the curve upperpart and the curve returnpart with cross bars. Note: make sure the curve is mounted level, and the conveyor frame is positioned level Curve supported by cross bars Chamfering the Curve Infeed ll upperpart infeed sides should be chamfered to ensure a smooth running of the chains. Make sure the chamered parts stay vertical. The chamfering of the curves has to be done only at the infeed sides. Magnetic Flex Guide Shoe Installation Return guide shoes helps the chain run into the return part. The return guide shoe has to be mounted at the infeed side of the return part of the curve. Returnpart at same Level Staggered Returnpart 540 Chainbelts Returnpart guideshoe should be mounted against infeed of underpart, with underside of the guideshoe 30 mm lower than the curve underside. Curves with a track pitch of less than 89 mm, feature a staggered returnpart. Returnpart should be mounted 0 mm off the curve infeed. The infeed shoe should be positioned 0 mm below the curve infeed, at distance of 60 mm. 176 Engineering Manual

13 ENGINEERING MNUL - IRP SLTND CHINS CSE CONVEYOR CHINS Case Conveyor chains are available in different types. Plastic Case Conveyor chains have been designed to convey heavy crates, boxes and kegs and the open design is very suitable for dirty conditions and easy cleaning. Properties Pitch [mm] Max. working load [N] Tabs Height of links [mm] CC with/without 8.6 Note: Case Conveyor-chains have a preferred running direction, which is indicated on the chains. The pins can be mounted only in one direction ( in ) and dismounted only one direction ( out ). Case Conveyor-chains should not be tensioned in the W Conveyor Design Straight Sections H Chain Type W (mm) H (mm) CC CC600D T 58 0 Please check wearstrip recommendations for best wearstrip choice C Conveyor design corners Curves for Crate Conveyor chains should be made open to allow debris to fall down. The chains can be secured by guiding strips at the inner radius of the curve. Chain Type CC600D T C 19.5 Please check wearstrip recommendations for best wearstrip choice 177

14 Engineering Plastics ENGINEERING MNUL IRP SLTND CHINS INSTLLTION OF SLTND CHINS Chains can be installed using a hammer and a punch. Pins should be positioned exactly in the middle of the hinge eyes. see diagram see diagram Pins in plastic chains should have the knurl on the same side, and this knurled side should be put in the chain last. Wrong assembly. If pins stick out the chain can jam. Check running direction, since the chain should always be driven at the fixed hinge eyes. Running direction is shown at the underside of the chain. Do not tension the chain when installing. Tensioning will result in a higher chainlaod and more wear of components. During installation the proper tension is manually achieved. CHIN INSPECTION & MINTENNCE good condition of the line can be maintained when people recognise signs of initial and react accordingly. Following aspects are of importance during regular check-up. Check the condition of the chain regularly, and replace links which are damaged. Important in this matter is to try to find the cause of the damaged links. Wear patterns or damage on a chain can often lead you to a problem area elsewhere in the conveyor. Check the amount of catenary sag and remove links or modules when the catenary chains exceeds prescriptions. Remember catenary grows during full load. Check if the returnrollers turn freely, repair or replace if not. In case of lubrication check if the lubrication system operates properly. Check carryways and wear strips for excessive wear or peculiar wear patterns. Check positions of transfer plates and check the fingerplates for broken/ worn parts and repair or replace if necessary. 178 Engineering Manual

15 ENGINEERING MNUL - IRP SLTND CHINS CONVEYOR DESIGN New Chain Chain Replacement We recommend to replace slatband chains, if the following is the case: (see diagrams) 0 pitches 76mm Time to Replace Chain is elongated more then 3%, see below. The thickness of the topplate of the slatband chain is reduced to.0 mm. The surface becomes unflat or very rough due to (uneven) wear, especially in applications where product handling is critical. Side of the hinge of sideflexing chains wears away and exposes the pin. The Chain Jumps on the Sprocket. It is also important to look at the position of the chain in the productionline. Chains that run on a pressureless inliner, have to be replaced all at once. If only one chain is replaced there will be a chance of unacceptable height differences, which could result in products topping over. 0 pitches > 784mm Magnetic Flex Replacement Replacement is recommended: If uneven wear patterns, and unacceptable wear of the track are found. The chain can easily be lifted out of the curve for inspection. The chain reaches the inside of the curve, see picture. In multiple track curves, check if the wear rate is similar in all tracks. It is also important that the wear of the curve groove still shows a straight angle of 90o with the horizontal surface. Sprocket & Idler Replacement The teeth show a hookshape, which obstructs the chain. Replace sprockets when teeth are damaged or when chain jumps on the sprocket. The idler is oscillating on the shaft, because of a worn bore. If chain is replaced due to elongation, always install new sprockets! Wearstrip Replacement When chains are replaced always replace the wearstrips. Dirt or debris is embedded in the wearstrip material in unacceptable amounts

16 Engineering Plastics ENGINEERING MNUL IRP MODULR ELTS INSTLLTION OF MODULR ELTS Slip Stick / Pulsating Effects Slip-stick is caused by the difference between static friction and dynamic friction. Slip-stick effects can cause a pulsating chain operation. We have the experience that with long, low speed conveyors, the chance of a pulsating operation increases. Level in/outfeed Inclining / Declining Conveyor Configuation Modular elts can be used on in- or declined conveyors which are basically constructed in the same way as level conveyors. Main concern is to avoid that the products slide down or tip. Conveyors can be constructed with a level in/outfeed section, see diagrams on the left. In case the inclined/declined conveyor is equipped with a Magnetic Flex curve, we recommend a minimum level section of 1mtr. This eliminates the chance the chain is lifted out of the curve. No in/oufeed Max. Possible ngle The maximum possible angle is depending on several factors: Coefficient of friction between chain and product; acceleration/deceleration; product stability and external factors like dirt or debris. elow a general table is shown with maximum angles determined by chain friction. Maximum angles inclines / declines Chain Type Lubricated Dry running Plastic Modular elts Rubbertop elts Variations can vary due to actual circumstances. 180 Engineering Manual

17 ENGINEERING MNUL - IRP MODULR ELTS CONVEYOR DESIGN End-drive conveyor End-drive Conveyor & Snub Roller = 1.5 X = 1.5 X C Uni directional Centre-drive conveyor = 1.5 X 140 i-directional conveyors with End Drive (Low load) = 1.5 X i-directional Conveyors with Centre Drive = 1.5 X = 1.5 X 140 These conveyors can have a small end roller to reduce the transfer area 181

18 Engineering Plastics ENGINEERING MNUL IRP MODULR ELTS CONVEYOR DESIGN Catenary Sag Wrap round ngle Recommended wrap angle on sprockets is: 140º +/- º. When the wrap angle is too small, the sprocket will not be able to transfer the load to the chain anymore causing the chain/belt to jump on the sprockets. When the wrap angle is too big, the chain/belt can stick to the sprocket. 140 Catenary Sag It is recommended to create a catenary sag just behind the sprocket which provides a complete discharge of the chainload. = 1.5 X Chain Type (mm) (mm) Vertical Sag Y(mm) 170 SF-series 1500-series 3175-series 540 MTW-series 3175 SF-series 5080-series ) Use flat returnpart for CC-series chains ) Use guide shoes or flat return for LP chains Modular elt catenary sag could increase due to elevated temperatures and can also elongate due to strain and wear of the pins and hinge eyes. Therefore it is important to check and adjust the catenary regularly. End Drive with Tensioner 140 Tensioner Construction tensioner construction is only necessary if the conveyor design does not allow for a proper catenary sag due to lack of space. tensioner can also be used with declined conveyors, but in all other cases other it is not recommend to tension the chain/belt. Note: The tensioner roller/sprocket can be fixed on an arm or move up and down in slots in the conveyor sideplates. 140 Centre Drive with Tensioner Engineering Manual

19 ENGINEERING MNUL - IRP MODULR ELTS ROLLER DIMETER FOR MODULR ELTS elt Type 170 SFseries series series 540- series 3175 SFseries series Idler rollers ll Dimensions in mm >19 >19 >60 >50 >60 >0 Return Rollers ackflex Rollers >40 >40 >60 RR >0 >60 >80 >0 RR > WERSTRIP SPCING ELTS Parallel Wearstrips Standard construction for slatband chains and modular (Positrack) belts. Recommended for bi-directional conveyors (wearstrips should be chamfered at both sides) and for belts with Positrack guiding. Chevron Wearstrips Suitable for modular belts but not directly suitable for belts with Positrack. n extra parallel guiding strip makes Positrack possible. est construction regarding even belt wear. Parallel Wearstrips Chevron Wearstrips Pitch Pitch 183

20 Engineering Plastics ENGINEERING MNUL IRP MODULR ELTS WERSTRIP MTERILS Metal Wearstrips Metal wearstrips can be used in most situations using plastic belts and are strongly recommended in abrasive environments. Stainless Steel: Recommended for abrasive conditions due to avoiding of dirt embedding in the wearstrips; Recommended for plastic chains/belts in dry environments with speeds >60m/min; Cold rolled stainless steel with a hardness of at least 5 Rc and a surface finish of maximum 1.6 μm is recommended; est results can be achieved by using stainless steel ISI 431. ISI 304 is not recommended as wearstrip material. Plastic Wearstrips Friction is low compared to steel wearstrips. Two types of plastic are suitable to be used as a wearstrip material. UHMWPE: Most common used wearstrip material with extreme low friction; Excellent resistance against many chemicals; Virtually no moisture absorption, therefore very suitable for lubricated lines; Good dimension stability; Reduces some of the noise conveyors produce; Suitable for dry running conveyors with speeds up to 60 m/min; Extruded quality 00 grade UHMWPE is recommended. Polyamide: Relatively high moisture absorption which makes the material expand; Polyamide is also used with additives to reduce the coefficient of friction; Suitable for dry running high speed conveyors. Recommended Wearstrip Materials Wearstrip Material Dry Plastic Modular elts Lubr. UHMWPE Polyamide Stainless steel + +/ Recommended +/- Satisfactory - Not recommended 1) Up to 60 m/min in non abrasive conditions ) Only in non abrasive conditions 184 Engineering Manual

21 ENGINEERING MNUL - IRP MODULR ELTS UHMWPE WERSTRIP INSTLLTION Chamfering of Wearstrips Wearstrips should always be chamfered at the beginning of the strip where they are fixed. Chamfering reduces the risk of chain-obstruction resulting in a smooth operation.the wearstrips should be chamfered at the sides and at the top. Splitting the Wearstrips On straight sections with a length of more than 3 metres, or for high (40-70 C) application temperatures, we recommend to divide the wearstrip into several sections, because of the thermal expansion of the strips. Gap It is recommended to cut the wearstrips at 45 angles to provides smooth chain/ belt transfers. Make sure only the infeed side of the wearstrip is fixed to the conveyor frame to avoid bulging of the wearstrips. Calculation Example For MCC 00 UHMWPE material the expansion coefficient is 0. mm/m/ C. temperature increase of 0 C would elongate a 3 meter wearstrip with: 0 C * 3mtr * 0.=1 mm In this case, the gap between the wearstrips should be a bit larger than 1 mm. We recommend a maximum wearstrip length of 6mtr. with UHWMPE wearstrips

22 Engineering Plastics ENGINEERING MNUL IRP MODULR ELTS POSITION SPROCKET - WERSTRIPS When the chain enters the sprocket, it tends to raise and fall slightly (chordal action). For this reason the sprockets should be mounted in such a way that its highest point is no higher than the top of the wearstrips. The front edges of the wearstrips should be bevelled to allow smooth and free running of the chain. The distance from the end of the wearstrip to the sprocket shaft centerline should equal dimension L, otherwise the wearstrip will interfere with the free articulation of the chain as it enters the sprockets. L L H D elt Type Drive Sprocket H (mm) L (mm) Idler Roller H (mm) L (mm) 170-series 1500-series 3175-series 540 MTW-series 3175 SF-series 5080-series 540 T- FTM-chainbelt Keyway Dimensions of Sprockets b Keyway Dimensions of Sprockets d1 (mm) b (mm) t (mm) t 5mm 30mm 35mm 40mm 45mm 50mm 60mm d1 (inch) b (inch) t (inch) d1 1" 1 1/4" 1 1/" 1 3/4" " 1/4 1/4 3/8 3/8 1/ 1 1/8 1 3/8 1 9/ /16 1/4 186 Engineering Manual

23 ENGINEERING MNUL - IRP MODULR ELTS ROUND SHFTS Solid and Split versions readily available Split versions are easier to install Shafts are ready to accommodate bearings SQURE SHFTS Solid and Split versions readily available More rigid than round shafts of the same size (less torsion & deflection). No keyway preparation is required Split versions are easier to install Larger drive surface results in a better load transfer Shafts In all situations stainless steel is recommended for shaft material. Metaloxydes that come from rusty shaft are extremely abrasive and would therefore reduce the wearlife of the conveyor components. It is also important to use shafts with a sufficient hardness and a smooth surface. The shaft diameter depends on the conveyor load and its width. Note: Maximum deflection of the shaft must not exceed mm. Depending on the load and shaftlength, it can be necessary to use a larger diameter shaft or an extra bearing in the middle of the shaft to reduce the shaft deflection. Shaft Tolerances It is important that the tolerance of the shaft meets the specifications of the sprocket, so the sprocket can slide over the shaft at all times. In combination with all IRP sprockets the following shaft specifications are required, depending on the shaft diameter. Dimension (mm) < Ø 90 > Ø x x 90 x Shaft Tolerance (mm) Round Shaft max h 9 (ISO) max h 11 (ISO) Square Shafts + 0 / / / Idler Shaft Surface Finish (μm) elts with Posi-Guide Lugs If belts with Posi-Guide lugs are used, all sprockets should be able to move sideways on the shaft. If belts without Posi-Guide are used, the centre sprockets should be fixed

24 Engineering Plastics ENGINEERING MNUL IRP MODULR ELTS INSPECTION OF MODULR ELTS good condition of the line can be maintained when people recognise signs of initial wear/ failure are recognized and reacted to early. Following aspects are of importance during regular check-up. Check the condition of the chain/ belt regularly, and replace links/ modules which are damaged. Important in this matter is to try to find the cause of the damaged links/ modules. Wear patterns or damage on a chain or belt can often lead you to a problem area elsewhere in the conveyor. Check the amount of catenary sag and remove links or modules when the catenary of the chains exceeds prescriptions. Remember catenary could be larger under load. Check if the returnrollers turn freely, repair or replace if not; Remove dirt and debris which is stuck in the grid of the belt or inbetween the chain/ belt and the conveyor construction. In case of lubrication check if the lubrication system operates properly. Check carryways and wear strips for excessive wear or peculiar wear patterns. Check positions of transfer plates and check the fingerplates for broken/ worn parts and repair or replace if necessary. Note: It is very important to replace damaged modules in plastic belts and links in plastic chains as soon as possible since small damage could lead to bigger damage if it is not repaired. If any damage is found such as pieces of plastic broken off, or a wear pattern at the side of the belt, the cause of the problem should be located. CLENING Cleaning Instructions To be able to keep production lines running at highest efficiency, cleaning is most important. Cleaning should include the removal of grease, dirt, dust and bacteria from the chain/ belt and components. Cleaning is important because it gives the following results: Disinfecting results in a hygienic system Products will be cleaner when they are packed Reduction of friction between chains/belts and products results in less tipping products and less wear. Removal of abrasive particles for longer wear life and components. Note: It is recommended always to flush the chain/ belts with plenty of water after having the chains/ belts cleaned, to remove the cleaning agent from the conveyor. Cleaning Dry Running Conveyors With dry running conveyors there is no continuous cleaning like with lubricated conveying. ll products (beer or lemonade) spilled on the chain/ belt will result in pollution of the containers, increasing the friction, and the risk of products toppling over. Therefore dry running conveyors should be cleaned even more frequently than lubricated chain. How often depends on the circumstances, e.g. when sweet liquids are bottled and spilled, it might be necessary to clean every time the line stops for a few hours. Cleaning Plastic elts Cleaning of plastic belts is not different from cleaning plastic chains. gain, the chemical resistance of the materials against the cleaning agents must be checked beforehand. Flat Top belts have to be cleaned from the top and underside. Flush Grid and Raised Rib belts can be cleaned very effectively, due to the open area. Water can be sprayed through the belt to clean it. When wide belts are cleaned at a high temperature (e.g. in a pasteurizer), there must be enough space for expansion 188 Engineering Manual

25 ENGINEERING MNUL - IRP MODULR ELTS REPLCEMENTS elt Replacement elts have to be replaced if the thickness of the belts is reduced unacceptably. In the table below guidelines are shown regarding replacement criteria. elt Type 170 SF-series 1500-series 3175-series 540-series 3175 SF-series 5080-series Max Wear (mm) Surface ottom 1mm 1mm 1mm 1mm 1mm 1mm 1.5mm 1.5mm 1.5mm 1.5mm mm mm In practice, the product handling will dictate whether the surface wear is acceptable or not. If wear at the top or bottom surface results in product tippage, replacement is eminent. 3% elongation of the pitch, is the ultimate elongation limit of belts. Further elongation causes the belt jumping on the sprockets under load. Note: When replacing chains or belts always replace the wearstrips, the sprockets and idlers as well. Sprocket & Idler Replacement The teeth show a hookshape, which obstructs the chain. lso replace sprockets when teeth are damaged or when chain jumps on the sprocket. The idler is oscillating on the shaft, because of a worn bore. If belt is replaced due to elongation, always install new sprockets! Note: When replacing sprockets on multiple track conveyors, make sure all sprockets are mounted in the same position on the shaft. Wearstrip Replacement When chains are replaced always replace the wearstrips. Dirt or debris is embedded in the wearstrip material in unacceptable amounts

26 Engineering Plastics ENGINEERING MNUL IRP SIDEFLEXING ELTS SIDEFLEXING ELTS Tail shaft Preferred asic Design Considerations Side Flexing Configuration When planning the side-flexing conveyor layout, the designer must consider the following factors that affect chain life: Minimize the number of corners in each conveyor whenever possible void When conveying from point to point, design the conveyors so that the last curve is positioned furthest from the last drive (see drawing), resulting in lower chain tension and maximizing chain life. Tail shaft Drive shaft End-drive Conveyor 140 End Drive Construction These conveyors have the drivemotor and sprocket at the end of the conveyor. = 1.5 X Wrap round ngle Recommended wrap angle on sprockets is: 140º +/- º. When the wrap angle is too small, the sprocket will not be able to transfer the load to the chain anymore causing the chain/belt to jump on the sprockets. When the wrap angle is too big, the chain/belt can stick to the sprocket. End-drive Conveyor & Snub Roller 140 C = 1.5 X Centre-drive Conveyor = 1.5 X Engineering Manual

27 ENGINEERING MNUL - IRP SIDEFLEXING ELTS SIDEFLEXING ELTS Catenary Sag 140 Catenary Sag It is recommended to create a catenary sag which provides a complete discharge of the beltload. y = 1.5 X Type 170 SF-series 3175 SF-series (mm) (mm) Vertical Sag Y(mm) Modular elt catenary sag could increase due to elevated temperatures and can also elongate due to strain and wear of the pins and hinge eyes. Therefore it is important to check and adjust the catenary regularly. End Drive with Tensioner 140 Tensioner Construction tensioner construction is only necessary if the conveyor design does not allow for a proper catenary sag due to lack of space. tensioner can also be used with declined conveyors, but in all other cases it is not recommend to tension the chain/belt. Note: The tensioner roller/sprocket can be fixed on an arm or move up and down in slots in the conveyor sideplates. 140 Centre Drive with Tensioner

28 Engineering Plastics ENGINEERING MNUL IRP SIDEFLEXING ELTS ROLLER DIMETER FOR SIDEFLEXING ELTS elt Type elt Type 170 SFseries 3175 SFseries Idler rollers ll Dimensions in mm Idler Rollers >19 >60 Return Rollers Return Rollers ackflex Rollers ackflex Rollers >40 >60 RR >0 POSITION SPROCKET - WERSTRIPS When the belts enter the sprocket, it tends to raise and fall slightly (chordal action). For this reason the sprockets should be mounted in such a way that their highest point is no higher than the top of the wearstrips. The front edges of the wearstrips should be bevelled to allow smooth and free running of the chain. The distance from the end of the wearstrip to the sprocket shaft centerline should equal dimension L, otherwise the wearstrip will interfere with the free articulation of the chain as it enters the sprockets. L L H D elt Type Drive Sprocket H (mm) L (mm) Idler Roller H (mm) L (mm) 170 SF-series 3175 SF-series Engineering Manual

29 t ENGINEERING MNUL - IRP SIDEFLEXING ELTS SIDEFLEXING ELTS Keyway Dimensions of Sprockets Keyway Dimensions of Sprockets b d1 (mm) b (mm) t (mm) 5mm 30mm 35mm 40mm 45mm 50mm 60mm d1 (inch) b (inch) t (inch) d1 1" 1 1/4" 1 1/" 1 3/4" " 1/4 1/4 3/8 3/8 1/ 1 1/8 1 3/8 1 9/ /16 1/4 Wearstrip Materials Stainless Steel Wearstrips Can be used in most situations using plastic belts and are strongly recommended in abrasive environments. Uhmpwe Wearstrips Friction is low compared to steel wearstrips. Two types of plastic are suitable to be used as a wearstrip material. Recommended for abrasive conditions due to avoiding of dirt embedding in the wearstrips; Recommended for plastic chains/belts in dry environments with speeds > 60m/min; Cold rolled stainless steel with a hard-ness of at least 5 Rc and a surface finish of maximum 1.6 μm is recommended; est results can be achieved by using stainless steel ISI 431 (Werkstoff-Nr material; soft ISI 304 (Werkstoff- Nr ) is not recommended as wearstrip material. Most common used wearstrip material with extreme low friction; Excellent resistance against many chemicals; Virtually no moisture absorption, therefore very suitable for lubricated lines; Good dimension stability; Reduces some of the noise conveyors produce; Suitable for dry running conveyors with speeds up to 60 m/min; Extruded quality 00 grade UHMWPE is recommended. Recommended Wearstrip Materials Wearstrip Material Dry Plastic Modular elts Lubr. UHMWPE Polyamide Stainless Steel + +/ Recommended +/- Satisfactory - Not recommended elt Return For sideflexing belts we recommend to use rotating rollers for the returnpart. Reduced wear. Simple construction. Good accessibility Only point contact between chain/ belt and roller. small rollers may cause a rattling sound. Rollers should rotate freely therefore, rollers with rubber cover are recommended

30 Engineering Plastics ENGINEERING MNUL IRP SIDEFLEXING ELTS 3175 SIDE FLEX-SERIES Minimum backflex diameter: 60mm Minimum end roller diameter: 60mm Drive Lay-out Guidelines D C D Minimum straigth section drive side - 750mm with normal drive, 500mm width gravity tensioner. Minimum straight inbetween curves (S-bend) - 1.5*beltwidth Minimum straight section idler side - 500mm Minimum inside radius - * beltwidth Idler C Recommended Guiding Profile Dimensions for 3175 SF-series 14 The guiding profile should be used to guide the belt through the curve. Recommended material of the guiding strip is UHMWPE OR Polyamid/Nylon, which offers low friction and high wear resistance. 14 Straight Section 3175 SF-series elow a cross section drawing is shown with recommended straight section construction 14 Upper Part Return Part 14 Note : bove C-Section guide profile can be used for both upper part guide and return part guide Optional >45mm Engineering Manual

31 ENGINEERING MNUL - IRP SIDEFLEXING ELTS SIDEFLEXING ELTS Curve section 3175 SF-series elow a cross section drawing is shown with recommended curve construction. Inner Radius Outer Radius 14 Part NPart Hold Down Profile Note : bove C-Section guide profile can be used for both upper part guide and return part guide. 14 Optional >45mm Sprocket Positions 3175 SF-series eltwidth Drive Nr. of Sprockets Idler 170mm 55mm 340mm 45mm 5mm 595mm 680mm Note : Increase number of sprockets and place sprockets closer together on the inner side of curve Ø60 min 0.5x Roller Dimension 3175 SF-series Rollers should rotate freely at all times, therefor we strongly recommend to equip the rollers with bearings

32 Engineering Plastics ENGINEERING MNUL IRP SIDEFLEXING ELTS 170 SIDE FLEX-SERIES Minimum end roller diameter: 16mm Drive Lay-out Guidelines D C D Minimum straigth section drive side - 750mm with normal drive, 500mm width gravity tensioner. Minimum straight inbetween curves (S-bend) - 1.5*beltwidth Minimum straight section idler side - 500mm Minimum inside radius -.6 x belt width Idler C Recommended Guiding Profile Dimensions for 170 SF-series The guiding profile should be used to guide the belt through the curve. Recommended material of the guiding strip is UHMWPE OR Polyamid/Nylon, which offers low friction and high wear resistance. UHMWPE can also be used. 14 Straight Section 170 SF-series elow a cross section drawing is shown with recommended straight section construction 14 Upper Part Return Part 14 Note : bove C-Section guide profile can be used for both upper part guide and return part guide Optional >45mm Engineering Manual

33 ENGINEERING MNUL - IRP SIDEFLEXING ELTS SIDEFLEXING ELTS Curve section 170 SF-series elow a cross section drawing is shown with recommended curve construction. Inner Radius Outer Radius 14 Part NPart Hold Down Profile +1-0 Note : bove C-Section guide profile can be used for both upper part guide and return part guide. 14 Optional >45mm Sprocket Positions 170 SF-series eltwidth Drive Nr. of Sprockets Idler 0mm<150mm 150mm<50mm 50mm<33mm 368mm 368mm<60mm Note : Increase number of sprockets and place sprockets closer together on the inner side of curve Ø60 min 0.5x Roller Dimension 170 SF-series Rollers should rotate freely at all times, therefor we strongly recommend to equip the rollers with bearings

34 Engineering Plastics ENGINEERING MNUL IRP SIDEFLEXING ELTS SPROCKET POSITION ND STNDRD WIDTHS OF ELTS elt Type 170 Side Flexing Series 1500 Series 540 MTW Series 3175 Straight Running Series 3175 Side Flexing Series 5080 Series (mm) (mm) C (mm) D Standard elt Widths (mm) , 368, , 304.8, 457.-increments of 15.4mm , 304.8, 381-increments of 76.mm 85 85, 170, 55-Increments of 85mm 85 85, 170, 55-Increments of 85mm , 304.8, 381-increments of 76.mm Fix only one sprocket (centre sprocket), if the belt is running without positioners or any other lateral guide. C D 198 Engineering Manual

35 MTERILS CHEMICL RESISTNCE Data shown in the table was taken from laboratory tests performed on unstrained samples and are merely indicative. Chemical resistance under normal working conditions can depend on various factors, such as stress and temperature, concentration of the chemical agent and duration of its effects. Valid for ambient temperature (1 C) Chemical gent cetic cid cetone crylonitrile luminium Chloride luminium Sulphate myl lcohol mmonia mmonium Chloride niline arium Chloride eer enzene enzoic cid enzol oric cid rine utter utyl cetate utyl lcohol utyl Glycole Calcium Chloride Carbon Sulphide Carbon Tetrachloride Chlorine Water Chloroform Chomic cid Citric cid Cyclohexane Clycloexanol Decalin Dioxane Distilled Water Ethyl cetate Ethyl lcohol Ethyl Chloride Ethyl Ether Ferric Chloride Food Fats Food Oils Formaldehyde Formic cid Freon 1 Fresh Water Fruit Juice Gasoline Glycerine Hydrocloric cid Hydrofluoric cid Hydrogen Peroxide Isopropyl lcohol Lactic cid Linseed Oil METLS PLSTICS RUERS Extra ISI 304 ISI 316 OT.NI POM PT PP P PE EPDM NR SES VITON C% C% C% C% C% C% C% C% C% C% C% C% C% S S S S S 30 0 S S S 0 S S S S S S S S S

36 Engineering Plastics ENGINEERING MNUL IRP MTERILS CHEMICL RESISTNCE Chemical gent Magnesium Chloride Methyl cetate Methyl lcohol Methylene Chloride Milk Mineral Oil Nitric cid Nitrobenzene Oleic cid Oxalic cid Paraffin Petroleum Petroleum Ether Phenol Phosphoric cid Potassium ichromate Potassium romite Potassium Hydoxide Potassium Permaganate Sea Water Silicone Oil Silver Nitrate Sodium Carbonate Sodium Chloride Sodium Hydoxide Sodium Hypochlorite Sodium Silicate Sodium Sulphate Soft Drinks Suds Sulphuric cid Tartaric cid Tetrahydrofuran Tetralin Tincture of Iodine Toluol Transformer Oil Tricholoethylene Triethranolamin Turpentine Vaseline Vegetable Juice Vegetable Oils Vinegar Water and Soap Whisky Wine Xilol METLS PLSTICS RUERS Extra ISI 304 ISI 316 OT.NI POM PT PP P PE EPDM NR SES VITON C% C% C% C% C% C% C% C% C% C% C% C% C% S S S S S S Engineering Manual

37 CONVEYOR CONSTRUCTION CURVE SYSTEMS evel chain has to be kept in a curve to avoid the chain to jump up from the curve. There are 3 different curve systems commonly in use (See diagrams on your left) There can be different arguments when choosing a curve system: Tab Cost Clean-ability Easy Maintenance Security Possible presence of foreign particles brasive Conditions Inspector Demands Side Transfers etc. Comparison of Corner Systems Description Secure Chain Retention Support in Return Part Chain can be Lifted for Cleaning Jamming due to Foreign Particles evel Tab Magnetic Magnetic Especially with unstable products and a multiple strand situation evel and Tab have a disadvantage: the link is lifting somewhat in the curve creating a step between the individual strands. With the Magnet System the links remain flat on the curve 01

38 Engineering Plastics ENGINEERING MNUL IRP CONVEYOR CONSTRUCTION OPTIONS FOR POSITIONERS 6.5 Example 3175 FT/FG P Example 3175 FT/FG P Example 3175 FT/FG Example 3175 FT/FG D Thermal Expansion Factors (f) are: Calculation: LF (cetal) ~ 0.1mm/m/ C Expected Expansion mm = W * T * f NG (New Generation) ~ 0.13mm/m/ C W = elt Width (mm) / 00 PP (Polypropylene) ~ 0.15mm/m/ C T = Temperature Difference ( C -1 C) To be able to absorb the thermal expansion the belt needs some clearance on the side. Depending on the expected temperature difference the structure should be wide enough to make sure the belt will not get stuck at high temperatures or, in case of low temperatures, be small enough to still support the belt at low temperatures. Clearance Clearance The Total Clearance to be Considered is (indicative Values): 4mm for elt Width <500mm 6mm for elt Width 500 to 1500mm 8mm for elt Width 1500 to 3000mm mm for elt Width > 3000mm 0 Engineering Manual

39 PPLICTIONS GRIPPER CHINS Chain tracks must be adjusted parallel. The tolerance for the parallel adjustment of the tracks is <mm. Incorrect adjustment can lead to overloading and a high wear of gripper-flights as well as of the basic roller chain. Gripper ribs must be oriented backwards relative to the running direction of the chain, as shown in the picture. The control system of the conveyor must assure that no backline pressure is created in order to avoid damage at gripper chains. The clearance between the chain tracks must be adjusted. Gripping forces must be adjusted according to the product. General rule: as tight as necessary, as loose as possible. The product must be removable by hand. tensioning system is necessary. Tension should just take away the play out of the chain. Touching products must be avoided - particularly in curving sections. The gap between the product must be big enough. Lubrication helps to extend the service life of the chains as well as the chain guides. EXTR style curves with the stainless steel strip will significantly elongate the service life of the curves. oth chain strands must run at the same speed. ny speed differential causes damage at the chain and possibly also at the product. One central drive is recommended. Selection of Gripper Version pplication: Solid Containers, e.g. glass bottles, pressurized containers. TRVEL 03

40 DISTRIUTOR INFO: LOCLLY MNUFCTURED I GLOLLY CCEPTED JOHNNESURG CPE TOWN DURN PO ox 666 Honeydew, 040 PO ox 666 Honeydew, 040 PO ox 666 Honeydew, 040 Tel: Fax: jhb@irp.co.za Tel: Fax: capetown@irp.co.za Tel: Fax: durban@irp.co.za IRP Head Of ce: Unit 6 ero Park, Corner Thunderbolt Lane and melia Drive, Lanseria Corporate Estate, Pelindaba Road

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