Non-Powered Conveyors

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1 Non-Powered Conveyors HB /03

2 To contact FKI Logistex, Automation Division: For service: Customer Service and Support Group (CSSG) Hotline On the World Wide Web: By mail: FKI Logistex, Automation Division International Boulevard Cincinnati, Ohio (513) The information presented in this document is correct at the time of publication. FKI Logistex Automation Division has made every effort to ensure that the information presented is correct and free from error. However, some errors or misprints may occur. Please contact FKI Logistex, Automation Division with any corrections. This document is copyrighted 2001 by FKI Logistex, Automation Division, all rights reserved. No Part of this Users Guide may be reproduced and/or distributed to parties other than the customer and the customer s employees for whom it was originally produced. Direct questions and comments concerning the information contained in this manual to: productmanagement@fkilogistex.com or Product Management FKI Logistex, Automation Division International Boulevard Cincinnati, Ohio (513) HB /03

3 Table of Contents Non-Powered Wheel Conveyor Application Data Grades Components Frames Couplings Standard - Hook and Rod Coupling Optional - Universal Coupling Straight Sections Curve Sections Curve Sections How to Select Rate of Speed Package With a High Center of Gravity Paper Bags Cleated Boxes, Cans, Etc Live Storage Rails Selection Guidelines Product Loading Roller Centers Conclusions Gravity Grades Considerations Controlled Gravity Proper Grade Conveyor Width Gravity Curves Curve Types Curve Design Considerations Frame Selection Frame Types Cross Brace Requirements Angle Frames Channel Frames Roller Position - High or Low Frame Rail Variations Calculating Frame Capacities Frame Rail Punching HB /03 TOC - 1

4 Table of Contents Couplings Plain End - PE Universal - U Hook and Rod - HR Welded Butt - B Bolted Butt - BB Strap - 2S Strap - 4S Heavy Strap Support Selection Accessories Bearings Non-Powered Straight Sterling Edition Dia. x Dia. x.065 (16 ga.) Roller - Series B Bearings - CR Frame (3-1/2 x 1-1/2 x.120 galvanized formed channel) - All bolted construction Dia. x.065 (16 ga.) Roller - Series B1000 Bearing AR Frame (2-1/2 x 1 x.109 formed steel channel) Z Dia. x.049 (18 ga.) Roller - Series B1000 Bearing AR Frame ( Frame (2-1/2 x 1 x.109 formed steel channel A Dia. x.049 (18 ga.) Aluminum Roller - Series B1000 Bearing ARA Frame (2-1/2 x 1 x.125 aluminum channel Dia. x.065 (16 ga.) Roller - Series B1020 Bearing CR Frame (3-1/2 x 1-1/2 x.120 formed steel channel) Dia. x.065 (16 ga.) Aluminum Roller - Series B1020 Bearing CRA Frame (3-1/2 x 1-1/2 x.120 aluminum channel) Dia. x.109 (12 ga.) Roller - Series B1020 Bearing CR Frame (3-1/2 x 1-1/2 x.120 formed steel channel) Dia. x.065 (16 ga.) Roller - Series B1020 Bearing CR Frame (3-1/2 x 1-1/2 x.120 formed steel channel) Dia. x.148 (9 ga.) Roller - Series B1050 Bearing w/shot Guards HR Frame (4 x 2 x.179 formed steel channel) Dia. x.120 (11 ga.) Roller - Series B1060 Bearing HR Frame (4 x 2 x.179 formed steel channel) Dia. x.180 (7 ga.) Roller - Series B1060 Bearing HR Frame (4 x 2 x.179 formed steel channel) Dia. x.180 (7 ga.) Roller - Series B1070 Bearing w/shot Guards HR Frame (4 x 2 x.179 formed steel channel) Dia. x.148 (9 ga.) Roller - Series B1060 Bearing HR Frame (4 x 2 x.179 formed steel channel) Dia. x.300 Roller - Series B1080 Bearing KR Frame (6 x 2 x.179 formed steel channel) Dia. x.438 Roller - Series B1100 Bearing F (Frame (7 x 4 x.5 structural steel angle) Dia. x.750 Roller - Series B1120 Bearing F Frame (7 x 4 x.5 structural steel angle) TOC - 2 HB /03

5 Table of Contents Non-Powered Curve 1-5/8 to 1 Dia. Tapered Roller - Series B1000 Bearing AR Frame (2-1/2 x 1 x.109 formed steel channel /2 to 1-11/16 Dia. Tapered Roller - Series B1020 Bearing CR Frame (3-1/2 x 1-1/2 x.120 formed steel channel) /2 Inside Radius Straight Roller - 18 rollers per 90 curve /2 Inside Radius Straight Roller - 22 rollers per 90 curve Inside Radius Straight Roller - 18 rollers per 90 curve Inside Radius Straight Roller - 22 rollers per 90 curve Non-Powered Telescoping Supports C10 Tripod Support pound capacity For use with AR, ARA, CR and CRA Frames C11 Tripod Support pound capacity For use with AR, ARA, CR and CRA Frames C13 Single Leg Support pound capacity For use with AR, ARA, CR and CRA Frames C690 Double Deck Floor Supports Pounds Capacity For Use with CR and PR Channel Frame Rails C691/C1231 Caster Mounted Supports For Use with AR and CR Channel Frames C1571 Sterling Edition 1500 pound capacity - Floor Support For Use with CR Frame Sterling Edition Sections C1231 Floor Support pound capacity C1230 Floor Support (single leg) pound capacity For use with AR and CR Formed Channel Frames C690 Series pound capacity Floor Supports For use with CR Formed Chjannel Frames C680 Series pound capacity Floor Supports For use with HR and H Channel Frames C698 & C pound capacity Floor Supports For use with KR, K and F Frames C ,000/25,000 pound capacity Floor Support For use with KR, K and F Frames C pound capacity Hanger Support For use with AR, and CR Channel Frames C pound capacity Single Hanger Support For use with AR, and CR Channel Frames C pound capacity Hanger Support For use with AR, and CR Channel Frames Accessories C1303 Channel Guard Rail - Straight For Use with CR Channel Frame Rails C1443 Angle Guard Rail - Straight For Use with CR Channel Frame Rails C1276 Straight Adjustable Guard Rail For Use with CR and PR Frame Rails HB /03 TOC - 3

6 Table of Contents C1277 Curved Adjustable Guard Rails For 2-1/2 Tapered Roller Curves For Use with C1320 Tapered Roller Curves only Curved Angle Guard Rail For Use with CR Channel Frames C641 Adjustable Tubular Guard Rail - Straight For Use with CR Formed Channel Tubular Guard for Skate wheel Curves For Use with CR Formed Channel C9-200 pound capacity Manual Right Angle Transfer For Use with 1.90 dia. rolls in CR Channel Frames C pound capacity Right Angle Transfer (Air-Operated) For Use with 1.90 dia. rolls in CR Channel Frames C pound capacity right Angle Transfer (Air-Operated) For Use with 1.90 dia. rollers in CR Channel Frames C diameter Turning Wheel C1615 Rotating Roller Stop - (Air-Operated) For Use with 1.90 Dia. Rollers in CR Channel Frames C1265 Fixed Angle Stop For Use with CR Channel Frames C3595 Rotating Roller Stop - (Foot Operated) For Use with 1.90 Dia. Rollers in CR Channel Frames C3595 Rotating Roller Stop - (Hand Operated) For Use with 1.90 Dia. Rollers in CR Channel Frames D720 Stop Plate and Retarding Plate For Use with Wheel Conveyor and Gravity Roller Conveyor with 1.38 and 1.90 dia. rollers B4500 Ball Transfer Bed For Use with 1.90 dia. rollers in CR Channel Frames B4500 Ball Transfer Rail B4520 Ball Transfer Bed For Use with 1.90 dia. or 2.50 dia. rollers in CR Channel Frames B4520 Ball Transfer Rail Converging/Diverging Gravity Spur For Use with 1.90 Dia. Rollers high in CR frames Converging/Diverging Gravity Spur For Use with 1.90 Dia. Rollers high in CR frames C20107 Spring Balanced Hinge Gate Dia. x.065 wall Rollers on 3 Centers in CR (3.50 ) Frame C20108 Spring Hinge Gate dia. Zinc Plated x.049 wall Rollers on 1.50 Centers in ARR (2.50 ) Frame C91 Manually Operated Turntable C308 Air Brake Assembly C653 Work Tabl12 Wide and C654 Work Table - 18 Wide C311 Traffic Control C311 Traffic Control C8060 Manual Deflector TOC - 4 HB /03

7 Non-Powered Wheel Conveyor Non-Powered Wheel Conveyor Application Data Wheel conveyors are advantageous in the conveying of lightweight packages or when the system requires lightweight components. Wheel conveyor curves are often used in a roller conveyor system because the differential action of the wheels reduces the disorientation of the product which occurs with a straight roller curve, i.e., the product doesn t "turn" on the conveyor. When the product to be conveyed is light, the low inertia of a wheel system permits gravity operation on a lesser grade than a roller conveyor. The wheel units offer advantages of quick and easy assembly or disassembly. Wheel sections using aluminum wheels and frames are available when extreme lightness is required. Wooden or firm cardboard cartons with smooth, even conveying surfaces are easily conveyed by gravity on wheel conveyor. Cans with chimes, any false bottom packages (such as crates), damp or soggy cartons or soft-bottom cartons are not easily conveyed by wheel conveyors. Grades Grades required for conveying cartons will vary with the weight of the carton and the conditions of its conveying surface. Full cases and cartons will convey satisfactorily on grades of 3" per 10'-0" section or 3" per 90 curve. Empty cases or cartons require about 4" per 10'-0" section. Extremely light articles, loosely tied articles, and wire bound or soft-bottom articles require steeper grades. The wheel conveyor has been successfully used to convey bagged materials such as cement, lime, carbon, etc. The grade required is about 6" per 10'-0" section. A steep grade adequate to start movement may allow excessive speed to develop once the load is moving and in these cases, retarding plates inserted in the line offer sufficient braking to slow the packages down. HB /03 Non-Powered Wheel Conveyor - 1

8 Non-Powered Wheel Conveyor Components Frames Frames for wheel conveyor are available in steel or aluminum construction. Steel frames are designated "ARG" and are formed from.109" zinc plated steel. Also, the cross bracing of zinc plated steel is bolted, using self-locking nuts. The center rails are 1/8" x 1" zinc plated steel. The axle bolts are 1/4" diameter steel. The optional aluminum construction is designated as "ARA" and utilizes extruded aluminum channel and the B aluminum wheel. The center rails and cross braces are plated steel. Both zinc plated steel and aluminum are corrosion resistant. There are three plated steel cross braces per 10'-0" section in 10" W and 16" W and four in the 22" W sections. STEEL CONSTRUCTION ALUMINUM CONSTRUCTION These high quality wheels are manufactured with precision-ground balls and hardened steel races. They extend 3/8 above the frame. The wheels are axles set on 3 centers. These wheels are available with either steel shell (B4000-1), or aluminum shell (B4001-1). Non-Powered Wheel Conveyor - 2 HB /03

9 Non-Powered Wheel Conveyor Couplings Standard - Hook and Rod Coupling The Hook and Rod Coupling is shown in the illustration below. Hook and Rod Couplings are used for temporary installation when being portable is a necessity. The slotted design of the "H & R" coupling allows angling the sections 3" to 6" per 10-0" section. Optional - Universal Coupling. 12 Overall Width - 10 Between Frames 18 Overall Width - 16 Between Frames HB /03 Non-Powered Wheel Conveyor - 3

10 Non-Powered Wheel Conveyor 24 Overall Width - 22 Between Frames Non-Powered Wheel Conveyor - 4 HB /03

11 Non-Powered Wheel Conveyor Straight Sections HOW TO ORDER C1500 SERIES WHEEL CONVEYOR SECTIONS (Example): Quantity Code No. Section Length Options Couplings 3 C A HR WHEELS FRAME BETWEEN FRAMES (W) Standard /16 dia. - 1/4 dia. bore (B4000-1) plated steel. Option - (B4001-1) aluminum. Standard - 2-1/2 x 1 x.109 formed steel channel (galvanized). Option - Aluminum channel. Standard 10, 16 and 22 W only. SECTION LENGTH Standard Option AXLE CENTERS Standard - 3. WHEELS PER FOOT (See Chart on following page) COUPLINGS Standard - Hook and Rod (HR). Option - Plain End (PE) or Universal (U). OPTION CHART FRAME CAPACITIES A Aluminum Frame - Aluminum Wheels MAXIMUM ALLOWABLE LOAD GA Galvanized Frame - Aluminum Wheels Section Length Steel Aluminum AG Aluminum Frame - Galvanized Wheels # 80# PE Plain Ends (No Couplings) # 700# U Universal Couplings HB /03 Non-Powered Wheel Conveyor - 5

12 Non-Powered Wheel Conveyor CODE NO. SELECTION CHART Code No. W Wheels/Foot Wt. per 10-0 Section All Steel Aluminum STD C # 33# C # 35# C # 45# STD C # 48# C # 52# C # 55# STD C # 60# C # 63# C # 67# Non-Powered Wheel Conveyor - 6 HB /03

13 Non-Powered Wheel Conveyor Curve Sections HOW TO ORDER C600 SERIES WHEEL CONVEYOR SECTIONS (Example): Quantity Code No. Options Couplings 3 C632 A GR WHEELS Standard /16 dia. - 1/4 dia. bore (B4000-1) plated steel. Option - (B4001-1) aluminum. FRAME Standard - 2-1/2 x 1 x.019 formed steel channel (galvanized). Option - Aluminum channel. BETWEEN FRAMES (W) Standard 10, 16 and 22 W only. DEGREE PF CURVE Standard - 90 and 45 only. INSIDE RADIUS Standard (all W s). AXLE CENTERS Standard /16 at inside rail. WHEELS PER FOOT Standard - (Approx.) 10 W = 12, 16 W = 16, 22 W = 22. COUPLINGS Standard - Hook and Rod (HR). Option - Plain End (PE) or Universal (U). GUARD RAIL Option - for outside only (see Accessories section, topic C641 Adjustable Tubular Guard Rail - Straight HB /03 Non-Powered Wheel Conveyor - 7

14 Non-Powered Wheel Conveyor OPTION CHART A GA AG PE U Aluminum Frame - Aluminum Wheels Galvanized Frame - Aluminum Wheels Aluminum Frame - Galvanized Wheels Plain Ends (No Couplings) Universal Couplings CODE NO. SELECTION CHART Code No. W Angle Coupling Weight of 90 Curve All Steel Aluminum STD C HR 32# 18# C HR 19# 10# C U 32# 18# C U 19# 10# STD C HR 46# 24# C HR 27# 14# C U 46# 24# C U 27# 14# STD C HR 70# 36# C HR 42# 22# C U 70# 36# C U 42# 22# Note: Curves with HR couplings can only be connected to straight sections. Non-Powered Wheel Conveyor - 8 HB /03

15 Non-Powered Wheel Conveyor Curve Sections HOW TO ORDER C529 TELESCOPING CONVEYOR (Example): Quantity Code No. W No. of Sections 7 C /2 4 UNITS WILL NOT ADJUST FROM LOWEST INFEED ELEVATION TO HIGHEST DISCHARGE ELEVATION AND BE OPERABLE. \ How to Select Rate of Speed 1. Consider width of package to be conveyed. 2. Determine maximum extended length required. 3. Check loading and unloading heights. 1. If feed rate varies, the wheel-type is more efficient. 2. For rapid and continuous service, we recommend the aluminum roller -type which operates with less pitch. HB /03 Non-Powered Wheel Conveyor - 9

16 Non-Powered Wheel Conveyor Package With a High Center of Gravity Paper Bags 1. Recommend conveyor to be used fully extended. 1. We suggest handling tests before purchase. Cleated Boxes, Cans, Etc. 1. If the containers you handle have uneven bottoms we suggest you pre-test for the optimum type of conveyor. Roller type should be considered. TELESCOPING WHEEL CONVEYOR (16-1/2 W) No. of Sections Retracted Extended Model Number Capacity Per ft. (lbs.) Unit Wt. (lbs.) C /2-4 C /2-3 C /2-2 70# 638# 482# 326# Note: For units with aluminum wheels, use C529A in How To Order. Non-Powered Wheel Conveyor - 10 HB /03

17 Non-Powered Wheel Conveyor Live Storage Rails HOW TO ORDER C151 LIVE STORAGE RAILS 10-0 Long (Example): Quantity Code No. Style Wheel Centers 10 C HB /03 Non-Powered Wheel Conveyor - 11

18 Non-Powered Wheel Conveyor Styles #1 and #3 Style #2 WHEEL RATING 60# PER WHEEL Wheel Ctrs. A B Qy. of Wheels Wt. Qty. of Wheels 2 1-1/2 1/ # # 3 1-1/2 1-1/ # 80 39# 4 1-1/2 2-1/ # 60 35# 5 2-1/2 2-1/ # 48 32# 6 2-1/2 3-1/ # 40 31# Wt. ALLOWABLE LIVE LOAD 25 lbs. per foot 50 lbs. per foot 100 lbs. per foot Non-Powered Wheel Conveyor - 12 HB /03

19 Selection Guidelines Selection Guidelines The Selection Guidelines are presented to assist you with the selection of a gravity roller conveyor to match your requirement. You should also review other Mathews handbooks which provide related application data: HB-822, Bearings, Wheels and Ball Transfers and HB-823, Industrial Rollers. Product Loading The maximum load that the conveyor will encounter (live load) is a major factor in deterining the conveyor specifications. The conveyor loading, expressed in pounds per foot, can be obtained by any one of the following methods: 1. Divide the total maximum load on the conveyor by the conveyor length. Total load on conveyor( lbs) = Conveyor Loading lbs ft Conveyor Length ( ft) ( ) 2. When product is back to back on the conveyor, the conveyor loading is a function of product weight and product length. ( ) = Conveyor Loading( lbs ft) ( ) Product Weight lbs Product Length ft For shock loads consider higher capacity frame or supports at 5-0 centers, instead of the standard 10-0 centers. Live Load 500 lbs = 50 lbs./ft. Frame Capacity 1000 lbs = 100 lbs./ft. Less Conveyor Weight 200 lbs = (-) 20 lbs./ft. Maximum Live Load 80 lbs./ft. Note: When determing conveyor loading, always consider the worst possible condition. Many products have rigid bottoms or conveying surfaces and more often than not they are not exactly flat. In order to compensate for this, it is advisable to figure that only 2/3 of the rollers will support the full weight of the product. Therefore, it is necessary to take the weights of the various products being HB /03 Selection Guidelines - 13

20 Selection Guidelines conveyed and divide by 2/3 of the rollers under the product to determine the required capacity of each roller. Because of the variety of rollers available, see the individual specification pages. Example: 19" long product weighing 80 lbs. 19 Product = 6.33 roller centers 3 Rollers The closest standard will probably be 6". Therefore, there are three rollers under the product. 2/3 x 3 = 2 rollers supporting 80 lbs. 80 lbs. 2 rollers = 40 lbs. per roller required capacity. If the roller you have selected does not meet the capacity requirement using the 2/3 condition, there are alternatives available besides a larger diameter. You should consider closer roller centers, higher capacity bearings or a heavier gauge tubing. Mathews does offer standard rollers that have the same outside diameter but different wall thickness (gauge). A heavier gauge can withstand more abuse. For example, a 1.90" dia. x.065" wall roller may be fine for carton handling. It would not stand up well in handling steel drums, as they are apt to dent the thinner wall rollers. A 1.90" dia. x.148" wall roller would probably be a better selection. Roller Centers When selecting a roller conveyor, the most important consideration is roller centers. It is considered good engineering practice to have a minimum of three (3) rollers in contact with the conveyed package at all times. To calculate this minimum, divide the dimension of the package parallel to the direction of travel by three (3), then specify the closest standard roller center. As an example: Assume the conveying length of the package is 24". This dimension divided by three (3) indicates an acceptable roller center of 8". If we are considering AR or CR frames, which are punched on 1-1/2" modules, 8" would not be a standard center. With the 1-1/2" modules, standard centers would be either 7-1/2" or 9". In this case, we would specify 7-1/2" centers, since 9" centers would not provide for three (3) rollers under the package. The next consideration is load rating. Will three (3) rollers support the package weight? Let us assume that the weight of the package is uniformly distributed and weighs 400 pounds. The capacity of the roller being considered is 100 pounds per roller. This would mean a minimum of four (4) rollers are required under the package at all times. Taking the 24" package length and dividing by 4 rollers yields a requirement of 6" centers. For 6" centers to be acceptable, the following qualifications must be met: A. The conveying surface of the package must be near perfect. It is a rare occasion that we find a perfect conveying surface. Most packages have surfaces with varying degrees of irregularity. Depending on the degree of these irregularities, different load conditions will be imposed on various rollers. Selection Guidelines - 14 HB /03

21 Selection Guidelines B. The package length must be at least 24". In our example, if the 24" dimension is not rigidly held, or the conveyor surface has slightly rounded corners, we could have the entire load imposed on three (3) rollers. C. The frame rail must be able to support the load. The published frame rail capacities denote loads the frame rail will support without excessive deflection. If we have a "Perfectly Level and Perfectly Rigid" conveying surface we may satisfy condition "1", yet still deflect the frame. In reality, the fact that most conveying surfaces have some "give" to them helps us in overcoming frame rail deflection. There is another point to be considered when the load is equal to the full capacity of the roller. In the example of the 400 pound package conveyed on 6" centers, when the package is properly distributed. When the package is as shown in the illustration to the right, the load is properly distributed. Any other position will generate excessive loading on certain rollers. HB /03 Selection Guidelines - 15

22 Selection Guidelines All of the foregoing assumes a package of uniform loading. If we have a package that is not uniform, we must study the condition of eccentric loading to properly define roller spacing. If the adjoining sections of the conveyor are not adjusted to precise elevations, a condition that imposes excessive loads on certain rollers could be created. Impact loading is also a consideration. A 400 pound package dropped onto the conveyor would be equivalent to a load greatly in excess of the 400 pounds. Conclusions 1. An absolute minimum of three (3) rollers should be under a package at all times. 2. If three (3) rollers will not provide sufficient capacity to support the load, specify closer centers or a higher capacity roller. It is better to specify rollers with greater capacity. 3. Every conveyor application is unique to some degree. Be sure you have a thorough understanding of the product and the application before specifying centers. Example Roller Spacing: Load Length = Roller Spacing = 8 Roller Centers 3 Selection Guidelines - 16 HB /03

23 Selection Guidelines Use caution in selecting roller centers when the unit being conveyed does not have a solid bottom surface in contact with the rollers. HB /03 Selection Guidelines - 17

24 Selection Guidelines Gravity Grades Considerations For gravity to generate movement of a package, the force of gravity must be sufficient to overcome the resistance of the rollers or wheels involved. The force of gravity on a perfectly horizontal conveyor is exerted perpendicular to the conveying face. The direction of this force is vertical. (See Figure to the left). As the conveyor is inclined, the gravitational force continues to be exerted in a vertical direction. However it is no longer perpendicular to the face of the conveyor. (See Figure to the left). This force can now be broken down in to two vector forces, one perpendicular and one parallel to the face of the conveyor. As the degree of incline increases, the magnitude of the perpendicular force decreases, while the magnitude of the parallel force increases. (See Figure to the left). When the conveyor is declined sufficiently so that the parallel force of the conveyor is sufficient to overcome the resistance of the rollers at rest, the package will start moving. The degree of decline required for a gravity system to operate may vary under different conditions. If the package being conveyed has a "firm" conveying surface, less grade will be required than if the package has a "soft" surface. (See Figure to the left) The degree of decline will be affected by roller and bearing construction. Non-precision bearings require less grade than precision bearings. The internal clearances and tolerances of precision bearings increase the force required to make them rotate. Grease packed or regreasable bearings are normally not used for graded applications. The heavier the product, the less grade is required. Brakes or other speed control devices may have to be used for long runs of very heavy products. Selection Guidelines - 18 HB /03

25 Selection Guidelines Controlled Gravity Roller weight will influence the grade. It takes more force to start heavier rollers, but once they are turning they will continue to rotate for a longer period of time. If two rollers with different diameters have equal weight, the larger diameter roller will require less grade. If packages must start from rest after a lengthy dwell time, such as overnight, additional grade may be required to compensate for carton indentation. A grade sufficient to start a line flowing from a standing start will frequently cause excessive speed in subsequent packages. This is particularly true for long runs. After the first package has begun to move, the rollers over which it has passed are now in some state of rotation. A second package passing over these rollers will benefit from this rotation and would travel faster than the first package. This process could continue until a "train" of packages has been created traveling much faster than the grade was planned for. Some control can be made by inserting retarding plates or "roller brakes". If these are used, any product that stops on them may not restart without assistance. Another way to control speed would be to insert a short section of BDLR into the gravity line. This would tend to "pace" the speed of the line to the speed of the live roller unit. On long runs, multiple inserts of BDLR may be required so that the unchecked speed and weight of the product does not cause it to skid or slide over the controlled rollers. This type of speed control is not recommended for products weighing over 50 lbs. Another point to be considered is the effect a distributed load will have on the grade. If we consider one package on a conveyor, and determine a grade sufficient to generate movement of the product, this same grade may not be sufficient to move a train of products from a standing start. Depending on the frame rail of the conveyor and the spacing of supports, this grade may have to be increased. The deflection of the frame rail under multiple package loads might crease "dead spots" in the system. See illustration below. It is for this reason that in this catalog we provide you with two capacities, level storage and gravity flow. The capacity for gravity flow is always less, to minimize the occurrence of dead spots. HB /03 Selection Guidelines - 19

26 Selection Guidelines Proper Grade The proper grade of a gravity conveyor should be determined by actual field test of the conveyor, using the product that is to be conveyed. Approximate grades can be recommended, but finite grades for a given set of conditions should be resolved in the field at the time of installation. Our standard supports, properly specified, provide sufficient range to enable this adjustment to be made. To assist you in the selection process, the following chart shows the results of tests conducted at our factory. The tests were made using two different conveyors: 1. 10'-0" long section of 2CR-B " dia. x.065" (16 ga.) steel - 3" roller centers - 27" Between Frames '-0" long section of 2H-B " dia. x.120" (11 ga.) steel - 4" roller centers - 39" Between Frames. We tested the slope required to keep a product moving as well as the slope required to start a product from rest. Please remember that these tests should be used as a guide only. Product Being Conveyed Firm Cardboard Cartons Steel Drum Fibre Tote Pallet With Runners Product Weight (lbs.) SUGGESTED GRADES Slope Required to Keep Product Moving Slope Required to Start Product Moving From Rest 1.90 dia. x dia. x dia. x dia. x.120 Slope Inches/ Foot Slope Inches/ 10-0 Slope Inches/ Foot Slope Inches/ 10-0 Slope Inches/ Foot Slope Inches/ 10-0 Slope Inches/ Foot Slope Inches # 3/8 3-3/4 1/2 5 5/8 6-1/4 11/16 6-7/8 45# 5/16 3-1/8 1/4 2-1/2 1/2 5 7/16 4-3/8 100# 1/4 2-1/2 1/4 2-1/2 1/4 3-3/4 3/8 3-3/4 20# 1/8 1-1/4 1/4 2-1/2 3/16 1-7/8 3/8 3-3/4 55 1/8 1-1/4 1/8 1-1/4 3/16 1-7/8 1/4 2-1/2 120# 1/16 5/8 1/8 1-1/4 3/16 1-7/8 3/16 1-7/8 250# 1/16 5/8 1/16 5/8 3/16 1-7/8 3/16 1-7/8 10# 3/16 1-7/8 3/8 3-3/4 3/16 1-7/8 9/16 5-5/8 25# 1/8 1-1/4 5/16 3-1/8 3/16 1-7/8 3/8 3-34/ 50# 1/8 1-1/4 1/8 1-1/4 1/8 1-1/4 1/4 2-1/2 75# 1/8 1-1/4 1/8 1-1/4 1/8 1-1/4 1/4 2-1/2 50# 1/8 1-1/4 3/16 1-7/8 5/16 3-1/8 7/16 4-3/8: 100# 1/8 1-1/4 3/16 1-7/8 5/16 3-1/8 7/16 4-3/8 250# 1/8 1-1/4 3/16 1-7/8 5/16 3-1/8 3/8 3-3/4 500# 1/8 1-1/4 1/8 1-1/4 5/16 3-1/8 3/8 3-3/4 Selection Guidelines - 20 HB /03

27 Selection Guidelines Conveyor Width The next consideration for specifying roller conveyor is conveyor width. The width required should be specified in terms of between conveyor frame dimension (W). 1. First determine if the conveyor will require guard rail or product will overhang the conveyor. 2. Next select the W width required to convey product around curves. Refer to the Curve Selection Charts below. The W for straight sections should match the W of the curve. 3. Use this W to order conveyor sections, components and accessories. 4. Our standard widths are in 3" increments. Conveyors with formed channels have a minimum W of 6". Structural channel conveyors have a minimum W of 9". Between Frames Dimension for 2-81/2 and 4-0 Inside Radius Straight Faced Roller Curves Product Length Product Width Conveyor Between Frames Dimension HB /03 Selection Guidelines - 21

28 Selection Guidelines Product Length Between Frames Dimension for 2.50 to 1.69 diameter Tapered Roller Curves Product Width Conveyor Between Frames Dimension Between Frames Dimension for to 1.00 Diameter Tapered Roller Curves Product Length Product Width Conveyor Between Frames Dimension Selection Guidelines - 22 HB /03

29 Selection Guidelines ROLLERS SET HIGH Can handle loads wider than conveyor width. Maximum load width = W x 1.25 When guard rails are installed, allow extra width for curves to avoid friction from guard rail. When guard rails are installed on the conveyor frame allow a minimum 1 clearance on each side between product and guard rail. HB /03 Selection Guidelines - 23

30 Selection Guidelines Gravity Curves Curve Types 1. Wheel A wheel curve is an excellent means of turning a package, but use is limited to situations where the between frame (W) dimension of the conveyor is 10", 16" or 22". 2. Rail Construction With Straight Faced Rollers Straight faced roller curves are usually the most economical. As a general rule they are used when the W of the system does not exceed 51", and where precise package control is not critical. Where the W is in excess of 51", a 3-Rail curve should be considered Rail Construction With Tapered Rollers Tapered rollers are the best means of turning a package and delivering it properly oriented. The tapered roller is made on a die. The radius of the inside rail is designed so that the taper of the rollers in the curve will meet at a focal point. To make this construction economically practical, we try to obtain maximum use of one (1) set of dies. As a result, we use the same degree of taper for several lengths of rollers, leaving longer rollers with a partial straight face. Normally, this does not have an adverse effect on the curve. If packages on a curve are traveling side by side, this construction may not be acceptable Rail Construction With Straight Faced Rollers The 3-Rail curve, comprised of two (2) lanes of rollers, will provide a differential action enabling the package to turn on the rollers with less drag than on an equivalent 2-Rail curve. In addition, having two (2) sets of rollers with shorter axle length, increases the capacity of the curve. 3-Rail curves can be ordered with specially designed roller patterns to provide more rollers in the outside lane. As a result, the roller gap of the curve is held to a minimum. Curve Design Considerations 1. Package Characteristics There are several package characteristics which will effect how the package is conveyed through a curve. These include size, shape, weight, product uniformity and conveying surface of the package. 2. Product Width Many times curves in a system will dictate the width of the conveyor for the entire system, in that the product may require additional space to negotiate the turn. This "additional space" depends upon the width and length of the product. The charts shown on pages 9 and 10 show the conveyor widths required to convey product around a curve. Selection Guidelines - 24 HB /03

31 Selection Guidelines The conveyor widths listed are based on our standard radii for the various standard Between Frame dimension curves. These charts are also based on the formula shown below. You should also keep in mind the basic principle that the inside radius should be greater than the length of the product. Formula for determining distance Between Frames or Guard Rails: G = ( Radius + Package) 2 + PackageLength 2 ( Radius 2) 2 3. Product Length For curves, the roller centers on the inside rail are closer together than they are on the outside rail. In our standard construction, the wider the conveyor, the more rollers are required in the curve to keep the roller centers to a minimum. You must keep this "fanning" effect in mind when choosing curves. Due to the variations available, the roller spacing at various points on the curves are shown on the individual specification pages. 4. Product Weight It was stated earlier that the product weight determines roller selection, roller spacing and frame selection for straight sections. The same holds true for curves. The rollers and frames you select for the curve section should be compatible with the straight sections. Roller capacity should be checked in the same manner as you did for straight sections. The abuse factor also holds true for curves. You will note that tapered rollers are either 16 ga. or 18 ga., depending on roller size. The straight faced roller curves and 3 rail curves are available in the same assortment of diameters and wall thickness as sections. Supports are required at both ends of a curve, as well as at the midpoint if the curve is over 45 degrees. Full width supports and single leg supports are available. 5. Speed Of The Package Package speed should also be considered. The speed of the line could be so great that the package would be thrown from the conveyor as it enters the curve. HB /03 Selection Guidelines - 25

32 Selection Guidelines 6. Type Of Construction Of The Curve The construction of the curve will have an influence, as previously discussed. 7. Relative Grades Of The Curve As Compared To The Feed And Discharge Sections If there is a difference in grade between the feed and the curve, the package will be affected. The package will not be influenced by the curve until its center of gravity passes the transition point between the curve and the adjoining section. 8. Package Positioning If packages approach the curve "in train," a curve will not be able to turn the package properly. There must be package separation for the curve to properly function. If a curve discharges a package within 5 degrees of the relative position with which it was received, it is considered that the curve is effective. Precise package orientation can not be guaranteed. Any package negotiating a curve must undergo some physical twisting on the wheels and rollers to result in a turned package. As a result, a gravity curve should never be joined on a belt conveyor. The high friction between the belt and the package will not allow the package to be immediately influenced, thus preventing the required twisting. If a curve is to join a belt conveyor, there should be a length of wheel or roller conveyor, at least as long as the longest package, ahead of the curve. It is acceptable to directly join a curve to gravity or live roller conveyor. Selection Guidelines - 26 HB /03

33 Selection Guidelines Frame Selection Frame Types In order to simplify selection, this brochure contains roller and frame combinations that have been selected to offer compatibility in size and capacity. Having determined the roller size, you will find that roller in a specific frame. You will need to confirm that this frame has the required capacity. You need to determine the total load on the conveyor at the worst loading condition. Add to that the weight of the conveyor section, and check the frame capacity chart on each page. A composite of the frame capacities and the formulas used to calculate the capacities are also shown in the Calculating Frame Capacities section, page 35. The weight of the frame plus the rollers must be deducted from the rated capacity of the frames to determine the load the conveyor will carry. You will note that the capacities for the frames are based on support centers, either on 5'-0" or 10'-0". In some instances, it may be more economical to stay with a smaller rail and increase the number of supports to achieve the desired capacity. Mathews standard non-powered conveyors include a frame which we have pre-selected. Our selection is based upon compatibility in size and capacity of rollers and frames. If you require a non-standard combination of frame and rollers, the following guidelines should be considered when selecting a frame. There are many types of frames available. The most common are roll formed channels, structural channels, structural angles and flat stock. Usually the conveyor frames are the same on both sides and are connected with a welded cross brace. The cross brace is usually an angle. The illustrations below show some of the more common frame and cross brace configurations. Cross Brace Requirements The chart on the next page provides a guide for choosing a cross brace for all Mathews frame types. Between Frame width (W) is a major determining factor in the cross brace selected, as the chart indicates. HB /03 Selection Guidelines - 27