Conveyor system design three elements: material characteristics, environmental requirements and process matching

Still have a headache for the conveyor line strike in three days? Material breakage, motor burnt out, maintenance costs more than 300,000 per year?The problem with the 90% is that it ignores these three ancestors.--Material characteristics, environmental requirements, process matching. Newcomers to design always focus on the parameters of the equipment, the results of the commissioning of the car. Today, we will use the case of blood and tears to break open the crumbs to speak through, to ensure that you less step on the pit!

First, the material characteristics: first understand what you want to serve "master"

Material is the soul of a conveyor lineIf you don't understand its temperament, even the most expensive equipment will have to kneel:

Is it flour or iron?
Bulk materials (such as grain, chemical powder) have to be conveyed by closed pipe chain, anti-drift; whole goods (such as refrigerators, car parts) are preferred to chain plate or roller line, with strong load-bearing.
Petulant or leathery?
Glass bottles, chips afraid of vibration? Air cushion conveying line + shock absorbing pallet arrangement; scrap steel slag, mineral material casually made? Manganese steel chain plate line is smash-resistant.
Is it sticky or damp?
Syrup, asphalt sticky belt? Change to stainless steel mesh belt line, comes with scraper cleaning; seafood workshop humidity 90%?304 stainless steel material rust corrosion, ordinary carbon steel can not hold out for half a year.

car crash: A milk powder factory used an ordinary belt line to transport milk powder, electrostatic adsorption led to residual mould, recall losses of more than a million. Later changedFood grade PU anti-static beltThe residue is reduced by 95% straight.

Second, the environmental requirements: do not let the conveyor line "not suitable for the soil".

The environment is an invisible killer, Ignore it? Equipment life is cut in half:

environmental pain point	prescription	How much do you save?
Foundry 800 ℃ high temperature	Heat-resistant alloy chain plate + water cooling system	Ordinary chain plate changed 2 times a month → save 120,000 per year
Seafood workshop salt spray corrosion	Full stainless steel body + ceramic bearings	Carbon steel equipment scrapped in 2 years → stainless steel used in 8 years
Lithium workshop dust explosion-proof	Explosion-proof motor + IP65 protection	0 risk of explosion, save half a million on overhaul
Hospital Silencing Requirements	Silent drum + shock-absorbing base	Noise from 85dB → 60dB, complaint clearing

lesson learnt through blood and tears: A grain silo in the northeast of winter -30 ℃, ordinary bearings freeze and shut down, change to use theLow temperature grease + heating shield, the winter failure rate dropped from 37% to 5%.

Third, process matching: don't let the conveyor line drag production backward

Process is the KPI of the conveyor lineThe articulation doesn't work? Capacity is straight backed up:

Speed jam point.
Automobile assembly line requires 0.5m/s uniform speed (to workers to leave the operation time), fast leakage process, slow stacking materials; express sorting line soared to 2.5m/s, photoelectric sensors + frequency conversion speed control is just needed.
Accuracy be damned.
Positioning error of mobile phone chip ≤ 0.5mm? Double speed chain + servo positioning system arrangement; Tyre assembly needs 90°turning? InstallationPneumatic actuator + angle sensor.
Flexible production change.
Small batch multi-batch production? Modular mesh belt line, 1 hour to reorganise the layout; Mooncake factory peak season expansion? Roller line extension of 50 metres, same day production.

Question and answer time
Q: Do you believe suppliers when they say equipment is foolproof?
A: Last year, a factory believed in the evil, buy "universal" line body transport chemical barrels, the result of the barrel body slipping sideways. The actual test found thatRubber roller friction coefficient should be＞0.6The normal roll is only 0.3! Add polyurethane cover to solve the problem.

Q: How to verify process suitability?
Three axes:

Take the real thing to the factory for a test run.(Don't just look at the PowerPoint)

Analogue peak load 120%(A furniture factory was overloaded on the day of commissioning and the drums were fully bent)

Recorded video frame-by-frame analysis of articulation(0.1 second delay = 200 fewer pieces per day)

IV. Guide to avoiding pitfalls in the three elements of linkage

The real masters play link-ups, to cite a chestnut:

A photovoltaic factory shipped silicon wafers (material characteristics: brittle, afraid of static electricity) + workshop cleanliness class 10,000 (environmental requirements) + positioning accuracy of ± 0.3mm per wafer (process).
Overturning programme: Ordinary Belt Line → Silicon Chip Fragmentation + Electrostatic Dust Extraction
The Immortal Programme::

Material Characteristics→Anti-static Fluorine Rubber Belt

Environment→Totally enclosed air shower dust removal design

Process → Addition of CCD vision positioning
in the end: Breakage rate from 8% to 0.2%, saving 6 million wafer cost per year.

A final word of caution.

Old birds who have been in engineering for 20 years understand.Parameters are dead, working conditions are alive..
Don't believe in "high-compatibility" equipment, a factory smashed 3 million on the automatic robot line, the results of the transmission of screws than artificial three times more expensive.
Understand the temperament of their own materials, workshop environment and production rhythm, than any imported equipment are reliable!.
Next time you choose a conveyor line, ask three times with a clear conscience: