Finding the right precision conveyor drive can help enhance efficiency and improve the production of any facility. However, there are many options, and selecting the right conveyor drive can be challenging. Below, we explore a few precision conveyor drive options so you can make the best selection for your needs.
Conveyor systems move items along a conveyor belt drive. They make it easier to transport products from one point to another, reducing the need for manual intervention by employees. One specific type of conveyor system is the indexing conveyor. These conveyors operate in fixed steps or “indexes” — the conveyor moves a bit, stops and moves again instead of continuously. Users have the ability to customize the preset indexes offered by the system.
Conveyor systems play many important roles in manufacturing, including:
There are many types of precision conveyor drives. Each option offers a unique way of moving the belt:
There are advanced ways to power and control conveyor systems. This technology offers the end user the ability to adjust the operations of the conveyor at any time based on real-time data that the system provides. It can also gather data on how the conveyor system is performing. Some technology examples include:
These motors communicate with other systems and machines by adjusting their speeds and power based on current circumstances. For example, if a smart motor detects that the conveyor is overloaded, it may slow down to prevent damage.
These systems use sensors, software and real-time data to help monitor and control the conveyor. For instance, if there is a jam and the sensor detects it, the system can stop the conveyor and then alert employees to fix the problem.
VFDs enable AC motors to run at various speeds. These drives vary the frequency and voltage applied to AC motors so they operate slower or faster, depending on need.
Some recommended conveyor drives include:
The fixed mechanical option would utilize a rotary cam indexer or a parallel cam indexer to achieve a predetermined linear stroke. The cam profile used in either type of indexer will provide a smooth acceleration and deceleration as well as a mechanical locking dwell at the end of the stroke. This option will allow you to operate the indexing conveyor with a simple VFD or contactors to control the motor.
The VFD would be held at a constant Hz and be treated like a contactor. Commissioning time when using the fixed indexer for your operation will be the quickest and most cost-effective option. The limitation is that the system has a pre-determined stroke that cannot be changed, as it is controlled by the “fixed” indexer unless you change to a more flexible option.
If a change is required to go to a more flexible solution, the entire chassis can be repurposed, and a programmable transmission device can be installed in its place with a few minor changes to adapt the new programmable mechanism.
These work well in assembly lines, giving workers enough time to attach pieces or components without feeling rushed. Fixed mechanical indexers:
The similarity to the fixed indexer is that they both use “Zero Backlash” cam technology. The difference is that the servo indexer option uses a constant lead cam, which is devoid of any modified sine profile that you will have in the fixed cam indexer. The benefit of this system is that it has the flexibility to change the stroke length by changing the VFD program that controls the motor.
With the cam system operating under pre-load conditions (cam and cam followers), the RTF programmable series can achieve single digit arc seconds of accuracy. The RTF series can be adapted to accept almost any type of servo motor brand or AC motor equipped with an absolute encoder.
All the positioning with the programmable RTF indexer is based on encoder counts, which rely on higher-end drives to control the movement. Commissioning time and cost is based on how experienced the controls engineer is who will be performing this task.
The servo indexer option allows for very precise positioning and speed control. For example, in a pharmaceutical factory, a servo indexer can accurately position bottles for labeling, ensuring each label is placed correctly every time.
Some top benefits of servo indexers include:
The similarity between the servo indexer option and the low backlash gear reducer is that both need a servo motor or AC motor with brake to control the movement profile to achieve the necessary stroke between each process. Both can be adapted to accept most servo and AC motor brands.
With bypassing the RTF series servo indexer, you will be compromising some accuracy overall. Typically, the low backlash gear reducers used on these linear indexing systems have less than 1 arc minute of backlash and still maintain a very high accuracy. These low backlash gear reducers are used quite often on LFA linear precision conveyors that require flexibility.
One major advantage over the RT servo cam indexer option is that higher indexing speeds can be achieved because you do not have to go through a second reduction of the cam/cam follower mechanism. The RTF series servo system can get much higher accuracy, but is limited by the RPM that the internal barrel cam can turn. Commissioning time is the same as what is experienced with the servo indexer option.
The low backlash gear reducer helps lower small movements when a motor starts or stops. This makes the conveyor movement smoother and more precise. It also improves the accuracy of positioning, which is critical for tasks that need precision, and can help extend the life of the conveyor system by reducing wear and tear.
A major advantage to using the direct drive option is the ability to achieve both really high accuracy and fast indexing speeds. The LFA precision indexing systems can be equipped with dual direct drive motors to optimize performance, mostly to achieve higher speeds.
This option of a direct drive system is the most expensive of the four and the most time-consuming and difficult to integrate. The direct drive system takes a very experienced controls engineer to implement and make sure it is operating correctly so as not to cause mechanical failures of the linear indexing system.
There are two main conveyor systems to consider — chain drive conveyors and belt conveyor drives.
Roller drive conveyors use metal links (chains) connecting to the sprockets (gears) to move items along the conveyor. The motor’s power is transmitted through the chain, which pulls the conveyor along its path.
Some advantages of chain drive roller conveyors include:
Some considerations of chain drive conveyors include:
Belt conveyors have a continuous loop of flexible material (the belt), which runs over pulleys. The motor drives the pulleys, which move the belt and the items on it.
Some key advantages of belt conveyor drives include:
Some key considerations of belt conveyor drives include:
Choosing a conveyor belt is an essential decision that can impact your operations. Start by considering the following factors in line with your company’s goals:
The efficiency of your index drive can significantly impact production. Efficiency affects performance in multiple ways:
Motor compatibility with your conveyor system is crucial for the following reasons:
Are you looking for answers to FAQs about conveyor systems? Explore three common FAQs below:
Indexing conveyors are conveyor systems that move items in fixed steps instead of moving continuously. Their stopping and starting at certain points allows workers to pick up or place items as needed.
Conveyor indexing moves items on a conveyor belt at set distances. This means the conveyor does not move continuously.
The main components of a conveyor system include a drive motor, the belt, chains, gears, rollers or pulleys, and a support structure. Each of these parts works together to move items smoothly along the conveyor.
When it comes to selecting a provider for precision conveyor drive solutions, Motion Index Drives has established itself as a trusted leader in the industry. Our commitment to innovation, quality and support will ensure you receive the best solutions to help enhance your manufacturing operations. We are ISO 9001:2015 certified and have decades of experience.
Whether you need fixed mechanical indexers, servo indexers, low backlash gear reducers or direct drives, our experts will guide you in choosing the right solution to help you achieve your operational goals.
Finding the right precision conveyor drive can be challenging, especially with the wide range of options available. An experienced partner can help.
Motion Index Drives offers high-quality precision conveyor drives designed to support your facility’s smooth operations. Contact us today to learn more about how we can help you find the right precision conveyor drives.
