Streamlining Pallet Handling: A Chain Conveyor System Design
Case Studies
Efficient pallet handling is crucial for any warehouse or manufacturing operation. Recently, we tackled a project requiring a robust and precise system to move heavy pallets loaded with paper through a loading and packaging process.
The challenge: heavy pallets, precise movement
Our customer needed a conveyor system capable of handling substantial pallet weights while concurrently maintaining accurate positioning for subsequent operations. The key requirements were:
- Pallet Dimensions: 1200 x 800mm
- Throughput/Speed: 12 meters per minute
- Pallet Weight: 1000 kg
- Orientation: Wide edge leading
- Integration: Seamless transfer to a customer-supplied pallet loading station with a servo drive (a sophisticated electronic motor that controls a very precise movement), followed by a two-way strapping and wrapping station.
- Discharge: Presentation of finished pallets for forklift truck (FLT) offloading.
These specifications presented a number of challenges. The heavy pallet weight demanded a robust conveyor design. Furthermore, the required speed and precise transfer to the loading station meant accurate control and smooth movement. Finally, integration with the customer’s existing servo drive and subsequent packaging equipment was essential.
The solution: robust design and complete control
Our proposed solution was a combination of proven technology and careful design:
- Low Profile Triple Chain Conveyors: We specified heavy-duty, low-profile triple chain conveyors using 5/8 pitch chains. This design gives the strength and durability to handle 1000kg pallets while the low profile simultaneously makes for easy loading and unloading. The triple chain configuration ensures even weight distribution and smooth pallet movement.
- Compact 180-Degree Rotation Turntable: A compact, 180-degree rotation turntable was incorporated to precisely orient the pallets. In addition, the turntable features an externally mounted gearbox and motor for easy maintenance and accessibility.
- Braked Motors: Braked motors were included to ensure precise stopping and positioning of the pallets.
- Customer Servo Drive Integration: Seamless integration with the customer’s existing servo drive was a key element of the solution. For the most part, this was to allow precise control in placing the pallets where they were needed in the operation.
- Conveyor Bridging Transfers: To facilitate smooth and seamless pallet transfers at conveyor intersections we introduced conveyor bridging transfers to add additional support and regulation.
The turntable section design
The outcome
This comprehensive solution addresses all of the customer’s requirements to provide a significantly robust, efficient, and accurate pallet handling system. The combination of heavy-duty components, precise control mechanisms and seamless integration undeniably ensures a smooth operation and optimal throughput.
In summary, we have delivered a great solution that has been a game changer for this customer’s pallet handling by carefully considering their needs and applying our expertise in conveyor system design.
The design becomes a reality
Need help with pallet handling?
We have the brains and the muscle to get you the perfect tailored solution that can handle even the heaviest pallet. Call us on 01623 354473 or see the other ways you can get in touch.