MODULAR PLASTIC CONVEYOR BELTS LCUS Induction System Training Manual Richmond, VA
AGENDA 1. Background on Intralox 2. Safety 3. System Overview 4. Conveyor Designs 5. Maintenance Recommendations
MODULAR PLASTIC CONVEYOR BELTS Who is Intralox?
Invented modular plastic conveyor belts in 1971 The world s largest manufacturer (7 million square feet annually) Annual revenues in excess of $200 million 700,000 sq. ft. of space in Harahan, Louisiana, a suburb of New Orleans 50,000 sq. ft of space in Savage, Maryland for Integration, Equipment Fabrication, and R&D 7 Assembly centers around the world
Intralox Solutions Value Added Engineered Products are flexible and durable Eliminates Retensioning & Retracking Vulcanizing or Splicing Reduces Maintenance Planned & Unplanned Downtime Repairs are easy and less frequent The result: Lower Cost of Ownership
Dedicated to Our Customers People You Can Count On Customer Service 24 hours a day, 7 days a week. Team of 80 customer service representatives Emergency, on-call production teams 99.4% order accuracy rate 99.6% on-time shipping record Engineering support before, during, and after startup.
A Few of Our Customers
USPS Roles: MODULAR PLASTIC CONVEYOR BELTS 1) Component Supplier 2) Equipment Supplier 3) System Integrator
Component Supplier TDS APPS AFTL
Equipment Supplier AI AFSM 100ai and FSS Programs Scope included belt curve, intermediate conveyors, sorter, spurs, minimal pressure chutes. 361 systems which included four divert points, four spurs, four chutes Approximately $7,000,000 in revenue Partnered with GDRS on the Northrop Grumman Program
Systems Integrator - HSTS High Speed Trays Sorters include equipment, controls, installation, training, and documentation. Projects ranged from $500K to $1,800K Deployments: Curseen Morris P&DC, Washington BMC, Springfield BMC, Memphis BMC, Chicago BMC, San Francisco BMC, South Jersey P&DC, Charlotte P&DC, Washington HASP, Louisville P&DC
MODULAR PLASTIC CONVEYOR BELTS Safety
SAFETY Only trained and qualified personnel should be allowed to operate the equipment. Training must include understanding of emergency stops and safety devices. Do not operate the conveyor unless all guards, covers, and maintenance panels are in place. Make sure the conveyor and adjacent areas are clear of personnel and product before starting. Pay attention to the warnings on all labels to avoid potential injury. Keep the area free of obstructions or material that could impede a clear view and ready access to emergency control and safety devices.
SAFETY Do not allow anyone to ride on, step on, sit on or cross over a moving conveyor. Do not wear loose clothing, necktie, unsecured long hair, loose jewelry or articles that might catch in a conveyor. Keep all body parts away from moving parts of the conveyor. Do not attempt to remove any jammed product while the equipment is in operation. Jams should be cleared only by authorized, trained personnel and only after the conveyor has been de-energized and locked out according to the owner/user s written energy control program. Report all unsafe conditions.
MODULAR PLASTIC CONVEYOR BELTS System Overview
Project Goals Provide a single file flow of products in front the key station operator at a combined rate of 30 parcels per minute (60 linear feet of product). This should: 1) Improve induction rates 2) Improve ergonomics 3) Buffer induction operations from unloading
Technology Highlights 1) Intralox centering belt technology to eliminate many side by side products. 2) Intralox alignment belt technology to present products near an operator for facing / keying. 3) Intralox accumulation belt technology to buffer product before the key station to minimize waiting.
Performance Factors Commercial Equipment USPS Team Operations and Maintenance USPS Unloader & LCUS Operations Conveyable Mail Note: Engineering balance between space, cost, and performance
Overall System
System Overview
Activated Roller Belts Series 400, Series 7000 Uses rollers embedded within the belt to generate lateral product movement as the belt moves forward. Rollers extend above and below belt. May incorporate combinations different angles, roller materials, and directions of rollers across the width of the belt. Intralox owns a broad portfolio of U.S. and International patents pertaining to Angled Roller Belt
Activated Roller Belt (ARB) Basics The function of Angled Roller Belt is to move products forward (like a normal belt) and also to the side.
Vector Addition Conveyor Belt Conveyor Belt Rollers in Belt Rollers in Belt Product Path
MODULAR PLASTIC CONVEYOR BELTS Conveyor Details
Incline Conveyor (USPS)
Centering Conveyor
Centering Conveyor Roller Actuation Gravity rollers, located below the belt and within the conveyor frame, is the mechanism used to drive the rollers within the belt, which inturn moves the packages.
Series 7000 Sorter The new Rack & Roll technology is located below the belt, within the conveyor frame. These individual rollers rotate and engage the rollers in the belt. The rotation of the rollers in the belt causes the package to move.
Series 7000 Roller Actuation
Alignment Conveyors
Accumulation Conveyors
Brake / Meter Conveyors
Keep an Eye out for Problems Reporting Issues to Maintenance Early - Saves the USPS $$$! Keep the area clean Identify broken parts on the floor Foreign Matter in the Belts Missing or Damaged Rollers in the Belts Unusual Noises Unusual or unsafe conditions
Keep an Eye out for Problems Missing or Damaged Rollers in the Belts
MODULAR PLASTIC CONVEYOR BELTS Maintenance
Objectives To assist in diagnosing and solving any mechanically-related problem that might arise on conveyors using the Intralox belting system. If you require further help or information, you can call Intralox 24 hours a day at (888) 427- BELT.
SAFETY Routine inspections should be conducted to insure that all safety features and devices are in place and functioning properly. A maintenance program should be set up to make sure the conveyor is operating properly. All maintenance operations should be performed by trained and authorized personnel while the conveyors are stopped and lockedout. Be aware of hazardous conditions, such as sharp edges and protruding parts. Before starting the conveyor after maintenance is completed, walk around the equipment and make certain all safety devices and guards are in place, pick up tools, maintenance equipment and clear any foreign objects from equipment.
The Intralox System Modular Belt + Sprockets + Square & Round Shafts
Modular Construction Modular composed of discrete modules Aids in repair Allows greater flexibility in design Modules are injection molded Modules are assembled into a bricklayed pattern & connected into a belt
Square Shafts Angular corners Clearance Radius No clearance SQUARE SHAFT ROUND SHAFT Better torque transmission easier sanitation sprockets float freely
Square Shaft Design Journal key way Shaft end chamfer
Square Shaft Design Retainer rings Retainer ring grooves
Centering Conveyor Roller Actuation Gravity rollers, located below the belt and within the conveyor frame, is the mechanism used to drive the rollers within the belt, which inturn moves the packages.
Series 7000 Sorter The new Rack & Roll technology is located below the belt, within the conveyor frame. These individual rollers rotate and engage the rollers in the belt. The rotation of the rollers in the belt causes the package to move.
Series 7000 Roller Actuation
Running Inspections - Daily Keep the area clean and look for broken parts on the floor Inspect for Missing or Damaged Rollers in the Belts Look for unusual or unsafe conditions Inspect sprocket engagement on belts. Listen for Unusual Noises
Visual Inspections - Belt Note damaged modules and replace during downtime window
Visual Inspections - Debris Inspect for debris stuck in sprocket pockets or wrapped around rollers and remove during downtime window.
Visual Inspections - Rods Check that rods are not walking out of belt edge. Push back in place during a downtime window.
Visual Inspection - Sprockets Check that both drive and idle sprockets are engaged. All belts should be at same height. If one belt is higher than the others at the drive or idle end, then the belt is not properly engaged on the sprockets.
Visual Inspection Belt Return Check that the return rollers are spinning and do not have trash build-up
Visual Inspection Belt Edges Inspect the edges of the belt and repair during downtime window.
Belt Pullers Maintenance Tool (Part # S400BJT) These supplied tools allow for disassembly and reassembly of the 400 Series ARB belting. Insert the pawl into the rectangular gap on the ARB belt at a functional spacing with the pawl connection holes facing each other. Use the ratchet strap to tension belting, approximately ½, to allow for connecting pin to be removed. Remove / Install Pin as required.
Belt Pullers Maintenance Tool (Part # S7000BJT-1) These supplied tools allow for disassembly and reassembly of the 7000 Series ARB belting. Insert the pawl into the rectangular gap on the ARB belt at a functional spacing with the pawl connection holes facing each other. Use the ratchet strap to tension belting, approximately ½, to allow for connecting pin to be removed. Remove / Install Pin as required. For belts between 36 72, two pullers are recommended.
Monthly PM Belt Removal Break one belt at a time to prevent belts from disengaging drive sprockets. The belts that are still together will prevent the broken belt from sliding off the drive sprockets. The belt will slip off the idle sprockets if it is not held up. To break belt, insert screwdriver into one side of belt to open the barn door. Insert second screwdriver into other side of belt and push rod out.
Monthly PM - Sprockets Remove debris that has accumulated inside conveyor frame. Debris can become wedged in belt near the shafts and can cause the belt to become disengaged. This will damage the system and will prevent the conveyor from performing correctly.
Monthly PM - Sprockets Trash removed from USPS conveyor, AI system 14 wide.
Monthly PM Sprockets Sprockets that are not positioned correctly often damage the roller belting
Monthly PM Sprockets Ensure the belts are aligned with sprockets and the sprockets are evenly distributed across idle / drive shafts. Set screws on the set collars should be set to 45 in. lbs. of torque secured with non-hardening thread-locker (Loctite #222MS)
Monthly PM Sprockets Inspect Sprockets for tooth wear and replace as required.
Monthly PM Wear Strips Inspect wear strips to make sure they are in-place and in good condition. Wear strips should be captured at the idler end of the conveyor and held in place with a roll pin.
Monthly PM Roller Belt Run hand over roller belt while conveyor is stopped and make sure roller belts contact carryway rollers. Rollers should resist turning. If rollers spin easily, check other rollers around it. If rollers are visibly worn and spin without resistance, belt may need to be replaced. Note: There are locations in the system that are strategically missing carryway rollers. Belt rollers will freespin when over this area.
Monthly PM Belting Length Inspect sag on belt return (catenary sag) and adjust belt length by removing links. Belting should be replaced when the pitch exceeds 3% of the original length Belting stretches after the first thirty days of operation and usually requires adjustments.
Monthly PM Carryway While belts are broken, run hand over carryway rollers to ensure rollers are free to turn. If roller does not turn easily, check to see if roller sleeve has migrated and is rubbing on roller support rail. If so, use razor blade to cut sleeve ½ inch off from the end of the roller. Check that roller is now free spinning. If not, roller may need to be replaced. Sleeve can be cut multiple times. However, if more than 6 inches of sleeve is removed from roller, replace roller.
Monthly PM Carryway Check that flat spots are not developing on rollers. If roller has flat spots, check to see if that roller sleeve is not touching roller support member. If it is, then cut sleeve back ½ inch. If roller sleeve is missing more than 6 inches, replace roller. Check carryway rollers under belt Cut here If roller s sleeve is bubbled up, cut sleeve above damage. Check to see if sleeve has walked down roller again. If more than 6 inches does not have a sleeve at upstream end of roller, replace roller.
Monthly PM Re-Installation of Belts Make sure that belt is not hanging up on bolts or screws extending into return path or conveyor side frame Make sure that all sprockets are engaged. Sprockets on idle shaft may need to be rotated to be able to re-engage belt.
Troubleshooting 1. Belt not engaging with drive sprockets 2. Belt not tracking 3. Excessive Belt Wear 4. Excessive Sprocket Wear 5. Excessive Edge Wear or Damage 6. Sprocket Migrating out of Belt 7. Excessive Catenary Sag
Belt Not Engaging with Drive Sprockets Incorrect belt tension around drive: Sprockets not aligned correctly on shaft: Insufficient belt wrap around drive: Provide catenary sag on return side of belt as recommended by the Intralox Engineering Program or your local Intralox office. Check sprocket alignment by laying a straight edge parallel to the shaft at the base of any tooth on the sprocket to make sure that all sprockets are in the same position across the belt. On sprockets having a tooth count that is evenly divisible by 4, teeth are automatically properly aligned when put on the square shaft. However, if the tooth count cannot be divided evenly by 4, special care must be taken to avoid problems. Relocate the first return roller after the drive shaft to insure 180 degrees or more of belt sprocket wrap around drive sprockets.
Belt Not Tracking Shafts not plumb, level and square to each other: Sprockets not aligned correctly on shaft: Locked sprocket on drive and idle not aligned: Material build-up on bottom of belt or sprocket: Return rollers not level and square: Retainer rings improperly utilized: Inspect shafts to insure they are plumb, level and square to each other. Lock into place with shaft collars. Check and adjust conveyor frame. Check shaft alignment after any adjustment in frame. It components, not level or square. may be necessary to re-plumb, level and square the shafts. Check sprocket alignment by laying a straight edge parallel to the tooth on the sprocket to make sure that all sprockets are in the same position across the belt. On sprockets having a tooth count that is evenly divisible by 4, teeth are automatically properly aligned when put on the square shaft. However, if the tooth count cannot be divided evenly by 4, special care must be taken to avoid problems. If timing holes are provided on these sprockets, they must be placed in alignment all the way across the shaft, see Sprocket and Shaft Installation. Re-align sprockets locked in place by a retainer ring or other device insuring that the drive shaft sprocket is perfectly aligned with the idle shaft sprocket. Clean bottom of belt, removing any material build up that could interfere with sprocket tooth engagement. It may be necessary to provide in-place brushes, scrapers, scrolls or tooth engagement other devices to prevent future material build up. Inspect and correct any return roller that is not level or square with conveyor frame. to conveyor frame. Replace missing retainer rings; check retainer ring location to make sure locked sprockets or missing. on drive and idle shafts are in perfect alignment.
Excessive Belt Wear Exposure to abrasive materials: Worn wearstrip material: Eliminate or reduce the presence of abrasive material which might come in contact with the belt, sprockets or wearstrip. As an example, this material could be periodically blown off the plastic conveyor parts by the use of plant pressurized air or washed off at the end of the shift. An in-place spray wash could be employed. Inspect wearstrip material and replace if required. Binding of belt in conveyor frame: Excessive belt speed: Sharp corners on carryway or returnway: Check the conveyor frame to insure it is level and square. Correct any conditions causing belt to rub or bind. High speed belts, especially those with short shaft centers, will wear faster than belts at lower speeds. Reduce belt speed if possible. Make sure the leading edge of any carryway is beveled or radiused for smooth belt travel.
Excessive Sprocket Wear Sprockets exposed to abrasive material: Incorrect tension on belt: Eliminate or reduce the presence of abrasive material which might come in contact with the belt, sprockets or wearstrip. Should be periodically blown off the plastic conveyor parts by the use of plant pressurized air or washed off at the end of the shift. Provide proper belt tension around the drive sprockets. Provide catenary sag on return side of belt as recommended by the Intralox Engineering Program or your local Intralox office. Excessive belt speed: Drive and idle shafts not plumb: Reduce belt speed if possible. Inspect shafts to insure they are plumb, level and square to each other. Lock into place level and square to each other shaft collars. Insufficient number of sprockets: Locked sprockets on drive/idle shafts not aligned: Sprockets are not aligned correctly: Shaft deflection or twisting: It is possible that the conveyor requires a more even distribution of load among sprockets. Re-align sprockets locked in place by a retainer ring or other device insuring that the drive shaft sprocket is perfectly aligned with the idle shaft sprocket. correctly. Check sprocket alignment by laying a straight edge parallel to the shaft at the base tooth on the sprocket to make sure that all sprockets are in the same position across the belt. On sprockets having a tooth count that is evenly divisible by 4, teeth are automatically properly aligned when put on the square shaft. However, if the tooth count cannot be divided evenly by 4, special care must be taken to avoid problems. Inspect shaft for evidence of deflection or twisting. Bent or twisted shafts must be replaced. An intermediate bearing may be required for wide belts. Contact Intralox for assistance.
Excessive Edge Wear or Damage Belt contacting obstructions: Belt improperly aligned and not tracking: Check the conveyor frame to insure it is level and square. Correct any conveyor belt, returnway, frame or conditions causing belt to rub or bind adjacent equipment. Re-align sprockets locked in place by a retainer ring or other device insuring that the drive shaft sprocket is perfectly aligned with the idle shaft sprocket. Check the conveyor frame to insure it is level and square. Correct any conditions causing belt to rub or bind. Thermal expansion causing belt: Correct conveyor frame dimensions to insure there is a 0.25 in. (6.4 mm) minimum edge to rub somewhere on clearance on each side of the belt when full thermal expansion (highest temperature) is conveyor frame. Conveyor frame not square or level: Check the conveyor frame to insure it is level and square. Correct any conditions causing belt to rub or bind. Shafts not held in place correctly: Insure shafts are plumb, level and square; make any corrections and hold shaft in place with shaft collars, etc., allowing the with a set collar. shafts to migrate to one side.
Sprocket Migrating out of Belt Shafts not plumb, level and square to each other: Sprockets not aligned correctly on shaft: Locked sprocket on drive and idle not aligned: Material build-up on bottom of belt or sprocket: Shaft deflection or twisting: Retainer rings improperly utilized: Inspect shafts to insure they are plumb, level and square to each other. Lock into place with shaft collars. Check and adjust conveyor frame. Check shaft alignment after any adjustment in frame. It components, not level or square. may be necessary to replumb, level and square the shafts. Check sprocket alignment by laying a straight edge parallel to the tooth on the sprocket to make sure that all sprockets are in the same position across the belt. On sprockets having a tooth count that is evenly divisible by 4, teeth are automatically properly aligned when put on the square shaft. However, if the tooth count cannot be divided evenly by 4, special care must be taken to avoid problems. If timing holes are provided on these sprockets, they must be placed in alignment all the way across the shaft, see Sprocket and Shaft Installation. Re-align sprockets locked in place by a retainer ring or other device insuring that the drive shaft sprocket is perfectly aligned with the idle shaft sprocket. Clean bottom of belt, removing any material build up that could interfere with sprocket tooth engagement. It may be necessary to provide in-place brushes, scrapers, scrolls or tooth engagement other devices to prevent future material build up. Inspect shaft for evidence of deflection or twisting. Bent or twisted shafts must be replaced. An intermediate bearing may be required for wide belts. Contact Intralox for assistance. Replace missing retainer rings; check retainer ring location to make sure locked sprockets or missing. on drive and idle shafts are in perfect alignment.
Excessive Catenary Sag Incorrect total belt length: Excess catenary sag must be at the belt s coldest operating temperature because the belt will then be contracted to its shortest length. If excess catenary is found, shorten the belt by removing rows of modules. All Intralox belts can be shortened in one module row increments. Elongation of belt due to initial break-in: Plastic belt will elongate during initial break-in period. This is a natural process that is a start-up situation or heavy loads. Catenary sag is the function of the belt acclimating itself to the application, and is more noticeable when heavy loads are present. In this case, allow the belt to adjust to operating conditions before shortening it. CAUTION: Monitor the belt during this break-in to avoid binding or catching Elongation of belt due to wear. If the belt length is 3% longer than the initial pitch, the belt should be replaced. This can be calculated by the ratio of the existing belt pitch / initial belt pitch..