In today's fast-paced manufacturing world, conveyor systems are the unsung heroes of efficiency and productivity. These versatile machines tirelessly move materials, components, and finished products, forming the backbone of countless industrial processes.
At Production Resources Inc., we've spent decades honing our expertise in conveyor systems.
We partner with industry-leading brands to offer cutting-edge solutions for metal stamping, forming, and manufacturing customers. Whether you want to streamline your press room operations, enhance safety, or boost your bottom line, the right conveyor system can make all the difference.
Are you curious about how these powerful tools can transform your facility? In this article, we take a deep dive into the essential conveyor system parts.
Conveyor System Types and Their Unique Features
Conveyor systems are the backbone of modern material handling, streamlining operations and boosting productivity across various industries.
The most common conveyor systems we see are:
- Industrial & Automation Belted Conveyors: These versatile mechanisms offer smooth, continuous material transport, ideal for a wide range of products and environments. Their adaptability and efficiency make them a popular choice for various industries. PRI carries top belted conveyor systems from trusted brands like Dorner, Magnetic Products Inc., and New London Engineering.
- Beltless Magnetic Conveyors: Employing magnetic force to move ferrous materials, these conveyors provide a clean, low-maintenance solution for metal-rich environments. They're particularly useful in scenarios where contamination prevention is crucial, such as in food or pharmaceutical industries. Check out our selection of Magnetic Products Inc (MPI) magnetic conveyors.
- Belted Magnetic Conveyors: Combining the benefits of traditional belted conveyors with magnetic technology, these systems offer enhanced control over ferrous materials. They're excellent for applications requiring both gentle handling and precise positioning of metal objects.
- Electric Shaker Conveyors: Utilizing vibration to move materials, these conveyors excel at handling bulk items and separating small parts. Their unique motion prevents product buildup and ensures even distribution, making them perfect for applications requiring precise material flow. PRI carries MPI’s shaker conveyor systems.
- Steel Hinge Conveyors: Known for their durability and strength, steel hinge conveyors are designed to handle heavy, abrasive, or hot materials. Their robust construction makes them ideal for harsh industrial environments, such as foundries or recycling facilities. At PRI, we carry New London Engineering hinged steel belt conveyors.
- Drum Motor Conveyors: With their compact design and internal motor, drum motor conveyors provide a space-efficient and hygienic solution for material transport. They're particularly valuable in industries with strict cleanliness requirements, such as food processing or packaging.
Basic Parts and Functions of a Conveyor
Each conveyor system part is vital in ensuring smooth, efficient, and reliable performance.
Through careful engineering, every element, from the sturdy frame forming the system's backbone to the drive units powering the movement, works in harmony.
Let’s take a look at each element alongside its purpose and function.
Frame
The frame is the structural backbone of the conveyor system. It provides support and stability for all components, determines the conveyor’s path, and ensures proper alignment of moving parts.
Frames are typically constructed from materials like:
- Steel
- Aluminum
- Stainless Steel
The appropriate material selection for your needs is based on factors such as load capacity, environmental conditions, and cost considerations.
Belt
The belt is the transport materials' primary contact point, affecting conveyor efficiency and product integrity. The belt must adequately support, provide traction for, and durably handle the specific materials being conveyed.
Conveyor belts come in various materials to suit different applications:
- Fabric Belts: Often made of polyester or nylon, they are versatile and cost-effective
- Plastic Belts: Offer excellent chemical resistance and are ideal for food processing
- Rubber Belts: Popular for their durability and flexibility, they are commonly used in mining, airports, and for transporting bulk materials
- Metal Belts: These excel in high-temperature or abrasive environments
In addition to these material-based classifications, conveyor belts can also be categorized by their design or function, such as:
- Flat belts
- Cleated belts
- Filter belts
- Wire mesh belts
- Curved belts
- Inclined belts
These distinctions allow you to customize your conveyor belts to your specific operational, manufacturing, industry, and regulatory requirements.
Drive Unit
The drive unit is the powerhouse of the conveyor belt. It converts electrical energy into mechanical motion. Drive units determine the speed and direction of the belt, directly impacting throughput and overall system performance.
Common motor types include AC induction, DC, and servo motors. Your selection depends on factors like required speed control, energy efficiency, and the specific application demands.
Pulleys
Conveyor pulleys are essential in material handling systems, primarily by driving the conveyor belt and maintaining its movement. They ensure proper tension, prevent slippage, and facilitate directional changes, all while providing structural support to distribute the weight of transported materials. Additionally, pulleys help maintain belt alignment, which is crucial for the smooth and efficient operation of the conveyor system.
There are three different types of pulleys:
- Drive Pulley: Located at the discharge end of the conveyor, the drive pulley is connected to the motor and provides the primary force to move the belt.
- Tail Pulley: Positioned at the opposite end from the drive pulley, the tail pulley helps guide the belt's return path and can be used for tracking adjustments.
- Snub and Take-Up Pulleys: These additional pulleys increase belt wrap around the drive pulley for better traction and maintain proper belt tension.
Rollers
Rollers support the weight of the belt and the transported materials, reducing friction and ensuring smooth operation.
Rollers, also known as idlers, have various configurations. These include troughing idlers for bulk materials, flat idlers for packaged goods, and return idlers for the belt’s return run.
Tensioning Device
Proper tension is crucial for efficient power transmission, accurate tracking, and prolonged belt life.
Common types of tensioning systems include gravity take-up, screw take-up, and pneumatic tensioners, each offering different levels of adjustment and automatic tension maintenance.
Gearboxes
Gearboxes modify the speed and torque output from the motor to match the conveyor's specific requirements. They act as a mechanical interface between the drive motor and the conveyor, allowing for precise control of belt speed and power distribution.
Guardrails
Guardrails are essential safety components that run along the sides of the conveyor. They serve dual purposes: preventing materials from falling off the conveyor and protecting workers from moving parts. In bulk material handling, they help contain and guide the flow of materials, especially on inclined or curved sections.
Guardrail design varies based on the conveyor type and the materials transported. The height and configuration of guardrails are crucial in ensuring effective material containment and worker safety.
The Brands We Carry
We pride ourselves on providing our customers with top-tier conveyor solutions.
Each brand in our lineup brings unique strengths and specialized technologies to the table. This allows us to offer comprehensive material handling solutions tailored to your needs.
PAX: Pax manufactures ancillary pressroom equipment, including lubrication systems, safety barriers, and conveyor types for metal stamping and scrap removal. Their equipment is used globally. They specialize in low-profile slug, part, and scrap conveyors, as well as drum motor and oscillating (EGD shaker) conveyors.
New London: New London is a conveyor manufacturer that offers a wide range of custom conveyor solutions. They specialize in tough, cost-effective designs, including steel hinge and wire mesh belt conveyors for diverse industrial applications.
Dorner: Dorner offers customizable stainless steel and aluminum conveyor automation systems. They focus on intelligent motion solutions, including low-profile belted conveying systems and LPZ adjustable angle conveyors.
MPI: MPI designs, manufactures, and services magnets, material handling, and electronic inspection systems for metal control in various industries. They specialize in beltless shaker slug conveyors, magnetic slider beds, and magnetic belted conveyors, offering complete metal contamination control and material handling solutions.
Choosing the Right Conveyor System
Selecting the optimal conveyor system for your operation requires careful consideration of several vital factors. Each aspect is crucial in determining the most efficient and cost-effective solution for your material handling needs, from the nature of your materials to your facility's layout to maintenance requirements.
We understand that navigating these choices can be complex. Our team is ready to guide you through the process, leveraging our deep knowledge of conveyor systems and the diverse range of products from trusted brands.
With our expertise and comprehensive product offerings, we're committed to delivering a conveyor system that meets your current needs and positions your operation for future success.
Ready to revolutionize your material handling process? Contact Production Resources Inc. for a quote today.
