Precision Conveyor Drive Options

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.

Introduction to Conveyor Index Drives

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:

Speed: Conveyors can move items quickly, benefiting factories with many products.
Organization: These systems move items in a straight line, making it easier for the workspace to stay organized.
Safety: Workers can skip potentially unsafe manual tasks, as conveyors can complete that work for them.
Return on investment: Conveyers generally offer a quick return on investment due to increased efficiencies.

There are many types of precision conveyor drives. Each option offers a unique way of moving the belt:

End drives: The motor and drive components are located at the end of the conveyor. These are often used in package handling, assembly lines and material handling systems.
Center drives: The motor and drive system is located in the middle of the conveyor and allows for balanced power distribution.
Internal drives: The motor and drive components are located inside the conveyor’s frame or structure. This helps provide a compact and efficient way to power the conveyor belt drive.

Advanced Drive Technologies

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:

1. Smart Motors

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.

2. Automated Control Systems

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.

3. Variable Frequency Drives (VFDs)

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.

Precision Conveyor Drive Types

Some recommended conveyor drives include:

1. Fixed Mechanical Indexer

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:

Move items in fixed distances, which means they can stop where necessary
Have a simple design that is easy to maintain
Work well with repetitive tasks

2. Servo Indexer

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:

High accuracy, which is important for tasks that need exact placement
The ability to change speeds and positions based on the production line needs

3. Low Backlash Gear Reducer

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.

4. Direct Drive

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.

Comparing Conveyor Drive Systems

There are two main conveyor systems to consider — chain drive conveyors and belt conveyor drives.

Chain Drive Roller Conveyors

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:

High load capacity: They are designed to handle heavy loads.
Durability: Chain conveyors are durable and can withstand harsh conditions, including exposure to high temperatures.
Easy to repair: If a link in the chain needs repairing, you can replace it without needing to repair the whole system.

Some considerations of chain drive conveyors include:

Maintenance intensive: These chains may need regular lubrication and alignment checks to ensure smooth operation.
Noise: Chain drive conveyors may be noisy during operation, which may not be ideal for environments where noise reduction is important.

Belt Conveyor Drive

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:

Gentle handling: The soft surface of PVC belts or rubber makes them ideal for transporting delicate materials without causing damage.
Low maintenance: Belt conveyors need less maintenance because of the few moving parts.

Some key considerations of belt conveyor drives include:

Replacement costs: If a belt gets damaged, it will need to be replaced entirely.
Limited load capacity: Belt conveyors may not be suitable for heavy materials, as the belts can wear out more quickly.

Key Factors to Consider When Selecting a Conveyor Index Drive

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:

Load capacity: Ensure the drive can handle the weight of your products without breaking.
Space: Some drives are large and require more space. Consider your factory or warehouse and how much space you currently have.
Cost: Some drives have a simpler motor and are more cost-effective. Consider your budget to see which drive will be more suitable.
Speed: As different drives operate at different speeds, understanding your unique needs is important. Ultimately, you will want a conveyor speed that gives you the best opportunity to meet your takt times.

Index Drive Efficiency

The efficiency of your index drive can significantly impact production. Efficiency affects performance in multiple ways:

Energy savings: When you have an efficient drive, it will use less electricity or fuel to work. This can help lower energy consumption.
Less wear and tear: The more efficient the drive is, the less strain it can put on the conveyor system. This can help lead to increased machine uptime and longer equipment lifespan.
Reduced lead time: When the index drive is efficient, it can move items quickly along the conveyor belt, leading to improved throughput.

Motor Compatibility and Integration

Motor compatibility with your conveyor system is crucial for the following reasons:

Performance: The more compatible the motor and conveyor system are, the more efficiently they can move items along the belt.
Longevity: With better compatibility, the motor and conveyor systems may last longer, as they work together seamlessly without causing extra wear and tear.
Safety: A compatible motor can help ensure the conveyor belt drive rollers operate safely without the risk of overheating or breaking down.

Frequently Asked Questions

Are you looking for answers to FAQs about conveyor systems? Explore three common FAQs below:

1. What Are Indexing Conveyors?

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.

2. What Is Conveyor Indexing?

Conveyor indexing moves items on a conveyor belt at set distances. This means the conveyor does not move continuously.

3. What Are the Main Components of a Conveyor System?

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.

Why Trust Motion Index Drives for Your Precision Conveyor Drive Needs?

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.

Find the Right Precision Conveyor Drive From Motion Index Drives

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.