Modular Conveyor System

Introducing The NEW Robotunits Modular Conveyor System

We have re-defined and perfected the concept of our range of Modular Conveyor Systems completely. Of course each modular conveyor is still fully built to customer requirements and our customers will benefit from the high level of standardisation of individual components. The resulting short delivery times are second to none.

Modular Conveyor System from Robotunits

 

 

 

 

 

 

Highest Flexibility in Width, Length and Layout

The new low friction design allows for an endless number of layout options which can be driven by a single motor and a multitude of transport solutions can be achieved.

Robotunits Modular Conveyor System

 

 

Examples of Layout Options (Top View)  

Modular Conveyor System 1

 

 

Examples of Layout Options (Side View)

Highest Safety

The newly designed side-plates encapsulate the sides of the modular conveyor system belt at the drive and idle end, eliminating pinch-points completely.

Modular Conveyor Safety

 

 

 

 

 

 

 

New Low Friction Design

The newly designed guide strips minimise friction and subsequently keep belt abrasion and overall running noise at an absolute minimum.

 

Modular Belt Conveyor Design

 

 

 

 

 

 

 

Benefits

+  Transport of high loads possible

+  Form locating drive sprokets eliminate belt slippage

+  No belt tracking necessary

+  Replacement of individual belt modules possible

+  Side shifting of products possible

+  Integrates with the entire Robotunits Modular Automation System

+  Multitude of belt and cleat options

+ Curved Modular Conveyor or Straight Conveyor options

Modular Conveyor Supplier

Robotunits has just released a newly developed range of curved modular conveyors. As with all other conveyors supplied by Robotunits every unit is built to exact customer specifications utilising a large number of our standard components. This allows us to stock most components and in turn enables us to deliver fully customised curved modular conveyors in as little as one week from time of order.

The new range of modular conveyors also feature many exciting new design elements, which enhance safety and reliability. The belt for instance is fully enclosed around all straight edges as well as around the drive and idle roller, which eliminates all pinchpoint issues.

Another unique design feature is the fact that our new range of curved modular conveyors is designed without a catenary, which eliminates another area of safety concerns commonly seen with most modular conveyors.

With all these exciting features and very competitive pricing look no further when deciding which modular conveyor supplier to choose for the job.

Facts

  • Conveyors are built here in Australia to customer specifications
  • Deliver in as little as one week from time of order
  • No Pinchpoints
  • All modular belt edges are enclosed
  • No catenary needed
No pinchpoints due to fully enclosed modular belt.

No pinchpoints due to fully enclosed modular belt.

 

 

 

 

 

 

 

The NEW Curved Modular Belt Conveyor and Vacuum Conveyor from Robotunits.

The NEW Curved Modular Belt Conveyor and Vacuum Conveyor from Robotunits.

 

 

 

 

 

 

 

 

Vacuum Conveyor

Vacuum Conveyor from Robotunits

 

 

 

 

Belt Conveyor Load Calculations

A lot of variables have to be considered when designing a belt conveyor. One area that requires a lot of calculations is the load a particular belt conveyor needs to carry.

The main areas that should be considered are

- Motor and gearbox specifications

- Conveyor design specifications

- Stand design specifications

Motor and Gearbox Specifications

When carrying out belt conveyor load calculation, the total payload on the belt conveyor as well as the area the load will take up on the conveyor need to be considered. Most belt conveyors are designed with the belt being dragged over a stainless steel deck.  This causes friction between the belt and the deck. Belt conveyors transporting goods in an accumulating fashion experience additional friction forces between the belt and the payload. All of this needs to be taken into account.  There may be other factors but most of the time these variables are sufficient to calculate Motor and Gearbox specifications.

Conveyor Design Specifications

The construction of a belt conveyor needs to be in relation to the load it needs to carry. Most importantly, the payload and size of the conveyor will determine the size of the drive and idle rollers.  This in turn will influence the size of bearings and other items like timing belts. A subframe for a conveyor carrying a high payload may also require additional strengthening to ensure its integrity.

Conveyor Stand Design

It should go without saying that the belt conveyor stand needs to be suitable so it can handle the load of the belt conveyor itself as well as the payload on the belt conveyor. All in all it has to be a sturdy frame, which ensures a solid construction and a safe working environment.

Here at Robotunits we use an in-house designed computer program, which calculates almost all of these variables. In the rare case where not all variables can be calculated we can draw on years of conveyor building experience here in Australia as well as from our head office in Austria.

If you have a conveyor project and find yourself trying to work out some of these factors then please feel free to call us with your requirements. Let us do all the calculations for you. Draw on our extensive knowledge and experience we gained over the years.

Call us on 03 9334 5182

Belt Conveyor

John Hart utilises Robotunits Modular Automation Technology

As a family-owned company, John Hart is a leading Australian supplier for reliable factory automation solutions. With the aim of becoming Australia’s most successful supplier of robotic solutions, John Hart strives to provide its customers with affordable, trustworthy and quality automation solutions.

John Hart employs Robotunits to supply Modular Automation Technology like aluminium extrusion and connection technology, conveyors, safety fencing, machine frames, and linear motion systems.

In a recent interview, Peter Burke of Robotunits and John Hart’s Automation and Robotics Operations Manager, Simon Hales revealed why John Hart prefers using Robotunits services and products over other providers in the market.

Simon Hales stated that Robotunits products are not only affordable but also fit their purpose well. He further went on to state that Robotunits products offer massive flexibility. This often comes in handy when creating automation solutions like machine frames, specialised conveyors and other special-purpose machinery.

He further stated that customers often have a change of opinion and are prone to requesting an alteration to their solution in the last minute. In this case it is essential to utilise equipment that can easily and quickly be re-configured. Robotunits products make such changes very easy, as their products are designed with the upmost flexibility in mind.

Hales further stated that Robotunits connection and extrusion technology offers better designing flexibility compared to that of the traditional steel construction. Ever since John Hart started using Robotunits products, they have never experienced any quality issues and have had an easy time working with the product range.

When considering customer care, Hales stated that Robotunits personnel, from their sales team to the engineers, are always helpful and focus on providing useful and helpful information.  They always provide working solutions to get the right results.

John Hart Aluminium Extrusion Cell

Robotic cell provided by John Hart utilising Robotunits aluminium extrusion and connection technology.

WMH uses Robotunits Extrusion and Conveyor Technology

The services of Robotunits were recently obtained by Ward Materials Handling Solutions in order to deliver a checkweigher system for Windolf Farms. Robotunits supplied the needed conveyors and extrusion system to build the checkweigher system.

There is a wide range of custom and standard weighing systems and checkweighers that Ward Materials Handling Solutions specialises in producing. These systems handle various duties such as verification of the weight and integrity of bags, sacks, trays, packages, bundles, bottles, punnets and boxes. The company has provided custom built checkweighers geared to the exact design of its clients for over ten years.

Ward MHS was hired by Windolf Farms to deliver a checkweigher system that would be very environmentally robust, yet user friendly so that it would have the ability to process bags of potatoes that ranged in weight from 2kg to 6kg. The system needed to handle an accuracy inside of 5 grams and deliver a throughput speed of 55 bags per minute.

Windolf Farms is a family owned and operated business, located in Queensland and is very hands on with the production, packing and the overall transportation of quality vegetables for markets that are local as well as being overseas. The new weighing system process will help to reduce costs of labor as well as making sure that the bags of potatoes are nor over or underweight.

Products that come out as overweight would cause a loss for the company, because that would really be in the category of product giveaway. If the product comes out as underweight it could cause a massive fine from the end customer, which is a multi national grocery chain.

Robotunits was chosen by Ward Material Handling Solutions to supply the extrusion systems and belt conveyors to construct the checkweighing system. The quick turnaround time and the flexibility of possible needed changes of positioning sensors, gave Robotunits the nod. Their flexibility in being able to accommodate last minute changes was also a major factor in their selection.

Ward Material Handling Solutions and Robotunits have worked together for a number of years. Robotunits has a sterling reputation for the prompt and reliable delivery of its products. Simon Ward, director of Ward Material Handling Solutions was very impressed with the dedication of the staff at Robotunits and their attention to detail in getting tasks accomplished.

Mr. Ward said that “Robotunits always goes the extra mile and that there is nothing that they won’t attempt in order to get the job done on time. They are always able to develop innovative solutions to tough problems and they always adhere to deadlines. They are priced very competitively and they over deliver their services, which makes them stand out in their field.”

Belt Conveyors from Robotunits used to build Checkweighers

WMH Checkweigher System built with Robotunits Modular Automation System

New Conveyor Safety Feature

Safety is continuously an issue in any manufacturing environment and safety features in any production machinery become more and more critical. Robotunits has just released a small but very effective product update for all belt conveyors. An additional stainless steel cover will be added to each side plate of the conveyor. This minimises the gap between roller and slide deck to a distance well below the allowable standard.

For our customers this new safety feature can bring cost savings as well. Depending on individual onsite safety specifications, additional safety barriers around conveyors may not be needed with this new feature.

Conveyor Safety Feature

This is the new safety feature on all Robotunits Conveyors.

 

Belt Conveyor Tracking

Belt Conveyor Tracking is imperative for the smooth operation of a belt conveyor unit. There are a number of things to consider in regards to belt conveyor tracking. Most tracking issues can be eliminated from the start with the proper design considerations. Once the belt conveyor is installed onsite there are also a few basic steps to be undertaken to make sure the belt tracks nicely.

Design Considerations

Rollers Design

All drive rollers, as well as idler rollers need to be crowned to allow belt conveyor tracking. Most of our rollers are about 1mm bigger in the centre and tapered towards the outside. All Robotunits rollers are also made from steel with large wall thicknesses to guarantee that rollers will not bend when tensioning the belt. Bending of a roller would offset the crowning and create all sorts of belt tracking issues.

Aspect Ratio

A belt conveyor should be at least twice as long as it is wide to have a minimum ratio of 2:1. Anything lower makes belt conveyor tracking very hard. Here at Robotunits we generally keep to these ratios. There are a few scenarios when we can go a little below this ratio without the need for a tracking strip.

Tracking Strips

Should a ratio below 2:1 be required we design the belt with a tracking strip. This is a PVC strip bonded to the underside of the belt. The rollers have the relating groove turned into them. This will guarantee belt tracking. It has to be said that the belt should track on it’s own as much as possible without relying on the tracking strip. If it doesn’t then the constant side force applied to the tracking strip will eventually tear it of. So even with a tracking strip a belt conveyor needs to be set up correctly to make sure it runs smoothly.

Conveyor Belt Tensioning

The manufacturer of the conveyor belts specifies certain tensioning criteria to maximize efficiency. Generally a belt needs to be stretched by about 0.3%. This can vary slightly depending on the belt material. The belt stretching is needed to ensure that the drive roller cannot slip and also to ensure belt conveyor tracking.

Direction of Travel

A belt conveyor should generally be run in a “pulling” fashion. This means that the belt travels from the idle roller towards the drive roller. This is mainly to eliminate roller slippage but also greatly influences tracking. It is much easier to track a belt conveyor if run in a “pulling” rather then a “pushing” fashion.

Onsite Setup and Maintenance

Generally a belt conveyor is tracked from the idler roller end. All Robotunits conveyors have adjusting screws on each side of the idler roller. These are used to tension the belt and also to fine-tune tracking. Should a belt wander to one side simply tension the belt on that side a little bit more. A small adjustment often makes a large difference so start with quarter turns. Do this while the conveyor is running. Allow the belt to settle in for a while and readjust accordingly. There are further details in the conveyor manual supplied with each of our conveyors.

Maintenance

Please check your conveyors at least once a week to make sure the belt conveyor tracking is still maintained. It will guarantee a smooth and trouble free operation of your conveyor unit.

PDF of Belt Conveyor Tracking from the Robotunits Operations Manual.

Belt Conveyor Tracking

Extract from the Robotunits Conveyor Manual describing the belt conveyor tracking procedure.

The Robotunits Philosophy – Our Promise to You!

We are committed to help our clients succeed by providing clever automation solutions that streamline their production processes. Ultimately this will save time and money resulting in improved profits.

 Specifically we are committed to deliver:

Outstanding Quality. Our large R&D Team makes sure we always listen to market feedback and design innovative products accordingly. We customise each solution according to exact requirements and we make sure that everything we deliver fits the lean philosophy eliminating waste wherever possible.

Uncompromising Service. We believe that we can stand out from the crowd by delivering outstanding service. We endeavor to be personal, competent and fast. We value relationships, call us at any time, we are here to help. This is our promise to you.

Fastest Delivery Times. We know that every holdup in manufacturing is costly to our customers. That is why we keep everything you find in our catalog in stock. We ship small orders on the same day we receive an order. Conveyors are designed, built and shipped within 5 business days with express options for 3 days. Assembled constructions are shipped within 5 business days or faster.

We are continuing to invest into R&D, training and internal systems to make sure we can deliver on our core promises.

We are human too and we do make mistakes from time to time. When that happens we promise to keep you in the loop and to work with you to ensure the best possible outcome.

The bottom line for us is this. We can only succeed if we help our customers to succeed. Therefore we do everything in our power to make sure we help our customers to achieve just that.

wishing you lots of success

Jurgen Mennel, Robotunits Australia

As always, we would love to hear your feedback below.

Robotunits Philosophy

Belt Conveyor Safety

When installing a conveyor in your manufacturing environment it is of course of utmost importance to make sure that the belt conveyor safety is considered in every possible way. This includes the safety standards the conveyor was built to but also includes the way it is installed onsite. After all, even a belt conveyor built to the highest standards and adhering to all the relevant safety standards can be installed onsite in a way that creates unsafe situations. These can lead to injury or worse and of course need to be avoided at all cost.

Manufacturing Standards regarding Belt Conveyor Safety

Here at Robotunits we can only control the manufacture of the conveyor itself. We do this by designing and building all our conveyors according to a number of European as well as International Standards. All of these standards are listed in the operating instructions, which we ship with every conveyor. Please make sure you read the manual from front to back and consider all aspects of the Belt Conveyor Safety.

Onsite Installation Standards regarding Belt Conveyor Safety

We want to make sure you consider all the belt conveyor safety issues that may arise when installing the belt conveyor. Belt Conveyor Safety once the unit is in operation also need to be considered. We do recommend installing your belt conveyor according to the Australian Standard “AS 1755 – 2000 Conveyors – Safety Requirements” and all other as well as newer Safety Standards that may apply at the place of installation. Again we ask you to thoroughly read the Belt Conveyor Operating Instructions. You can download them here. The operating instructions do not only list the specific standards each belt conveyor has been built to but also outline the following safety tips and considerations in relation to

-       Intended use

-       Improper use

-       Normal operation

-       Electrical safety advice

-       Mechanical safety advice

-       Cleaning advice

-       Transport advice

We do recommend you conduct a Risk Assessment once the conveyor has been installed. This will reduce the likelihood of incidents and injuries even further and will reduce the likelihood of prosecution in the unlikely event of an incident. It will also lead to more efficient business processes, which will ultimately increase your bottom line.

Disclaimer

We wrote this post as a guide to get you started when considering Belt Conveyor Safety. It is my no means comprehensive and is not intended as a legal document. You MUST conduct your own research and make sure you get legal as well as technical advice when installing belt conveyors. The correct installation according to all relevant laws is your responsibility.

Belt Conveyor Safety Guard

New Belt Conveyor Safety Guard installed on Robotunits Conveyors.

Industrial Linear Motion System

Our Industrial Linear Motion System has long been a star performer as a standalone product and many customers appreciate the advantages the Robotunits Linear Motion System brings. Where the Robotunits Industrial Linear Motion Systems stand out from all other offerings on the market is the easy integration into existing assemblies. This will save the user an excodinarry amount of time in design and assembly and of course will boil down to outstanding cost savings overall.

Robotunits Industrial Linear Motion Systems come as a standard based on our 50 x 100 or 100 x 100mm Aluminium Extrusion. They can also be build with other extrusions from our system 50 ranges like the 100 x 200 mm extrusion for example. The hardened guiderails are inserted into our standard aluminium extrusions and they align themselves to one datum edge to assure the highest accuracy.  The sliding plate is also a standard extrusion from the Robotunits range of Aluminium Extrusions, measuring 200mm x 25mm.  They are also comprising the standard Robotunits T-Slots making it easy to add standard components even to the sliding part of the Industrial Linear Motion System.

Bearings and rollers are all designed to withstand high loads. Standard units are rated at 3000 Newtons of payload in radial as well as axial direction. Higher loads are possible with special designs. The guide rollers are also mounted on adjustable eccentric bolts making it very easy to adjust the play or accuracy of the unit. The system is driven via a steel reinforced T8 timingbelt. This makes high acceleration and deceleration possible.

Because all industrial linear motion systems are designed based on our standard aluminium extrusion system they fit perfectly into the Robotunits Modular Automation System. The below picture is a perfect example of this. A customer needed to build an enclosed  X-Y-Z Gantry System over a roller conveyor. As you can see the complete solution was built with the Robotunits Modular Automation System. This has reduced the design, build and assembly times to a bare minimum. The customer had this solution up and running in a very short amount of time, saving him thousands of dollars compared to a traditionally build system.

If you do have a project where a industrial linear motion system is needed or indeed a complete X-Y-Z Gantry System then please call us on 03 9334 5182. We are eager to help you design a solution that will not only save you time and money but will also look great once installed.

This X-Y- Z Gantry System uses Robotunits Industrial Linear Motion Systems which integrate perfectly with the rest of the Robotunits Modular Automation System

This X-Y- Z Gantry System uses Robotunits Industrial Linear Motion Systems which integrate perfectly with the rest of the Robotunits Modular Automation System