A 'rotating tube system' overhead conveyor overcomes the problems of noise and power consumption associated with such equipment, says ITS.Overhead conveyor systems have previously not had a huge take-up in many sectors of British industry. Despite the obvious floor-saving advantages, overhead chain systems were seen as expensive, inflexible, noisy, power hungry, susceptible to chain-stretch and rapid wear. As a result, hand trucks, fork-lifts and floor based conveyor systems have predominated.
But the problems have now been overturned by a new type of overhead conveyor system that employs a patented 'rotating tube system', available from UK company Intern Transport System (ITS).
Flexibility improvements are attributable to a 'power and free' system.
Two conveyor tracks are employed, one powered and the other, located underneath, is unpowered to provide a buffer area, allowing queues at workstations until goods are needed.
Rotating aluminium tubes drive trolleys that are suspended from carriages that run freely along a supporting rail.
Each trolley has four wheels, mounted at an angle which make contact with the rotating tube.
Unlike chain systems, there is often no need for a return loop as the track is divided into short sections with their own motors which can power trolleys in either direction.
Trolleys, which are independently driven, can be easily directed to individual bays and can wait while parts are assembled.
Another major advantage is that different parts of the production line can be operating at different speeds and if one section needs to be halted or fails, the rest of the line can remain in operation for an extended period.
Additionally, it is possible to change from one model of vehicle to another frequently, reducing inventory and work in progress.
Goods can be transported for instance, from ground level up to a higher level and moved without conflicting with machinery or fork trucks.
Automatic buffering helps to balance different work outputs from linked processes.
Each process can therefore operate at peak efficiency.
Another advantage over the chain system, particularly to the automotive industry is that, because there is no chain to stretch, ITS can now offer trolleys with up to 500 kg carrying capacity.
This means that major items like engines and gearboxes can be handled with ease and without over-burdening the whole conveyor system.
The system also offers significant benefits over the conventional chain system in terms of running, maintenance, replacement and re-tasking costs.
The system has fewer moving parts and does not require oiling, ensuring no 'drips' on product and less cleaning (as oil collects dirt).
It is less prone to breakdown and it is impossible for carriages to drop, if a fault occurs, ensuring a safer workplace.
It is also virtually silent.
ITS can also supply the software for the system with full 'track and trace' capabilities.
By attaching electronic tags or barcodes to each trolley, they can be tracked through the system.
Scanning stations monitor what components are on each trolley and relay the information to a central computer.
The computer can tell it where to go next.
This allows manufacturers much more flexibility to 'build to order'.
The system manufactured by production partners OCS of Sweden, is already in use by Volvo, Saab, Dunlop and Lear Seating and over half the major high-street retailers employ this system for sorting and distribution.
ITS, based in Ilkeston, Derbyshire, has over 20 years experience as supplier and project manager on turnkey production projects for various sectors of industry.