Rapistan Conveyors

SIEMENSDEMATIC

rII

I

I

t

ItII

I

··--I~'~=··~~~····~··~'-·'r·~"~-·_~·_·_····-

Appli~ation GUi~eII

1,- - - i, I

Model 7900 MAGSTMf IIIj

SIEMENSDEMATIC

Application Guide

Model 7900 Series

Model 7900 SeriesModular Assembly Conveyor System (MACSTM)

Application Guide

Figure 1

Modular Assembly Conveyor System (MACSTM)

MACSTM Product Line

2001-September-28 1

Model 7900 Series

Modular Assembly Conveyor System (MACSTM)Application Guide

2

SIEMENSDEMATIC

2001-September-28

rSIEMENSDEMATIC Model 7900 Series


2001-September-28

Important: Prior to applying any of the equipment or performing any of theapplication procedures described within this manual, it is strongly recommended thatthe Systems and Application Engineers read the information provided within theapplicable sections of this manual. All personnel shall pay particular attention to thenotes, cautions, warnings, dangers and safety information presented in this manualand posted on or in the area of the equipment. This equipment has been designedfor use by trained and qualified operators. Every possible effort to prevent injury tothe engineer, operator or maintenance personnel has been taken in the preparationof this manual. Damage to the equipment is possible when the procedures containedwithin this manual are not followed.

Information in this document is subject to change without notice. No part of thisdocument may be reproduced or transmitted in any form or by any means, electronicor mechanical, for any purpose, without the express written permission of SiemensDematic Corporation, Rapistan Material Handling Automation Division.

© 2001 Siemens Dematic Corp.

This document contains confidential information, trade secrets and/or know-howwhich is the property of Siemens Dematic Corp., and may not be disclosed to anythird party without the written permission of Siemens Dematic Corp.

Other product and company names herein may be the trademarks of their respectiveowners.

Siemens Dematic Corporation

Rapistan Material Handling Automation Division

507 Plymouth AvenueGrand Rapids, MI 49505616-913-6200

www.rapistan.com

3

Model 7900 Series


Sections/Release Dates

SIEMENSDEMATIC

This sheet will be changed with each section revision. If your manual sections andpages do not match the section dates below, you are using outdated applicationengineering information. The latest electronic Adobe Acrobat PDF file is the onlyModel 7900 Series MACS Application Guide that is controlled under ISO 9000guidelines. As of this printing, the PDF file is available on the Siemens DematicCorporation, Rapistan Material Handling Automation Division internal network andFTP site.

Section Title Release DateDescription

Front Matter

09/28/01Initial Release

General Information


Equipment Description


Application Information


•Model 7905 Workpiece Carriers (WPCs) 09/28/01Initial Release

•

Model 7910 RST 150 Wheeled Track 09/28/01Initial Release

Conveyor •Model 7915 Chain Conveyors 09/28/01Initial Release

•Model 7920 Dual Belt Conveyors DG 40,09/28/01Initial Release

DG 50/5, DG 50/1.5, DG 130, DG 160, DG 250•Model 7922 Single Belt Conveyors EG 09/28/01Initial Release

60, EG 70, EG 150, EG 180, EG 300 •

Model 7925 Diverters 09/28/01Initial Release

•

Model 7927 Transfer Units 09/28/01Initial Release

•

Model 7930 Vertical Lift Units 09/28/01Initial Release

•Model 7935 Gappers and Non-Return 09/28/01Initial Release

Devices •Model 7940 Positioning Units 09/28/01Initial Release

•Accessories (Includes Models 7945, 09/28/01Initial Release

7950 and 7952) •

Index 09/28/01Initial Release

4 2001-September-28

rI

SIEMENSDEMATIC

Table of Contents

Model 7900 Series


2001-September-28

General Information 13Introduction 13

Safety Informati on 15Material to be Handled 15

Trai ning Information 15Calculating Air Consumption 16Definition of Terms 16

Definition of Terms (continued) 17Receiver Tank Sizing 18Piping / Tubing Sizing 19Air Consumption Calculations for MACSTM-Compressor Sizing 20Air Consumption Calculations for MACSTM-Receiver Sizing 21

Equivalent Weights and Measures 22Weights 22Measures 23

Terms, Abbreviations and Acronyms 24

Equ ipment Descri ption 25System Components 27Model 7905 Workpiece Carriers (WPCs) 27Model 7910 RST 150 Wheeled Track 28

Model 7915 Accumulating Roller Chain Conveyors 29Model 7920 Dual-Belt Conveyors 33Model 7922 Single-Belt Conveyors 37Model 7925 Diverters 41Model 7927 Transfer Units 45Model 7930 Vertical Lift Units 49

Model 7935 Gappers and Non-Return Devices 51Model 7940 Positioning Units 59

Model 7905 Workpiece Carriers 63PWT 64

Specifications and Calculations 66RWT 67

Specifications and Calculations 69

Determine Required Live Load 71

Model 7910 RST 150 Wheeled Track 73

Model 7915 Chain Conveyors 75SK 200 Accumulating Chain Conveyor 76

5

Model 7900 Series


SIEMENSDEMATIC

6

SK 500 Accumulating Chain Conveyor 77



Model 7920 Dual-Belt Conveyors 81DG 40 Dual-Belt Conveyor 82

DG 50/1.5 Dual-Belt Conveyor 83

DG 50/5 Dual-Belt Conveyor 84

DG 130 Dual-Belt Conveyor 85



Model 7922 Single-Belt Conveyors 89EG 60 Single-Belt Conveyor 90

EG 70/1.5 Single-Belt Conveyor 91

EG 70/5 Single-Belt Conveyor 92

EG 150 Single-Belt Conveyor 93

EG 180 Single-Belt Conveyor 94

EG 300 Si ngle-Belt Conveyor 95Single-Belt Conveyor Layouts 96

Model 7925 Diverters 97UL 90 Tu rn 98

UL 180 Tu rn 99

ES 90 Infeeder 100

AS 90 Outfeeder 101

ZV Two-Way Merge/Divert 102

PV Parallel Merge/Divert 103

Model 7927 Transfer Units 105HT 80 Lifting Transfer Unit 106

HT 230 Lifting Transfer Unit 107

HT 500 Lifti ng Transfer Unit 108

HTS Lifting Transfer Line 109

HL 120 Lifting Stop 110

Model 7930 Vertical Lifts 111DVH Verti cal Lift 112

VL Verti cal Lift 113

Model 7935 Gappers and Non-Return Devices 115

2001-September-28

r

SIEMENSDEMATIC Model 7900 Series


2001-September-28

VED 70, VED 200 and VED 400 Gappers 116VE 200 and VE 800 Gappers 117RSP Non-Return Device 118

Model 7940 Positioning Units 119P 60 and P 120 Positioning Unit 120PH 80 Positioning Lift Station 121PH 150 Positioning Lift Station 122HD 100 Lift and Turn Station 123HD 170 Lift and Turn Station 124

Accessories 125Model 7945 Supports (SST, LST, DSE, DSW) 127Model 7950 Compressed Air Ducting and Distribution System 128Air Ducting System, Flange Kits, Pressure Gage, Filter Pressure Regulator andValves 128

Extension Kits, Consumer, Coupling and Pressure Switch Connections 129840 Valve System 130Model 7952 Control Devices 131SHV Switch Mount for Vertical Fixing 131SHH / SH P Switch Mount for Lateral Fixing 132Cable Conduits for the Transfer System 133Frequency Converter 134Switches for Workpiece Carrier (WPC) and Cylinder Interrogation 135

Transfer Profile Sections (TPS) 136Belt Conveyors 136Accumulating Roller Chain Conveyors - One-Row Track 137Accumulating Roller Chain Conveyors - Two-Row Track 138Track Wheel Edge Profile 139

Fastening and Bracing Materials 140Motors and Reducers 141USA 141Canada · 142

Index 143

7

Model 7900 Series


8

SIEMENSDEMATIC

2001-September-28

./

rSIEMENSDEMATIC

List of Figures

Figure 1Figure 2Figure 3Figure 4Figure 5Figure 6Figure 7Figure 8Figure 9Figure 10Figure 11Figure 12Figure 13Figure 14Figure 15Figure 16Figure 17Figure 18Figure 19Figure 20Figure 21Figure 22Figure 23Figure 24Figure 25Figure 26Figure 27Figure 28Figure 29Figure 30Figure 31Figure 32Figure 33Figure 34Figure 35Figure 36Figure 37Figure 38Figure 39Figure 40Figure 41Figure 42Figure 43Figure 44Figure 45Figure 46

2001-September-28

Model 7900 Series


MACSTM Product Line 1

Different Conveyor Principles 25PWT Workpiece Carrier (WPC) 27RWT Workpiece Carrier (WPC) 28RST 150 Wheeled Track 28

Tension Spring and Rollers 29Transfer Profile Sections 30Return Units 30

SK 200 Accumulating Roller Chain Conveyor 31SK 500 Accumulating Roller Chain Conveyor 31SK 1000 Accumulating Roller Chain Conveyor 32SK 2000 Accumulating Roller Chain Conveyor. 32Transfer Profile Section 33

DG 40 Dual-Belt Conveyor 34DG 50/1.5 Dual-Belt Conveyor 34DG 50/5 Dual-Belt Conveyor 35DG 130 Dual-Belt Conveyor 35DG 160 Dual-Belt Conveyor 36DG 250 Dual-Belt Conveyor 36Transfer Profile Sections 37

EG 60 Single-Belt Conveyor 38EG 70/1.5 Single-Belt Conveyor (without take-up) 38EG 70/5 Single-Belt Conveyor 39EG 150 Single-Belt Conveyor 39EG 180 Single-Belt Conveyor 40EG 300 Single-Belt Conveyor 40UL 90 Turn 41UL 180 Turn 42ES 90 Infeeder 42AS 90 Outfeeder 43

ZV Two-way Merge/Divert 43PV Parallel Merge/Divert 44HT 80 Lifting Transfer Unit 45HT 230 Lifting Transfer Unit 46HT 500 Lifting Transfer Unit 46HTS Lifting Transfer Unit.. 47HL 120 Lifting Stop 47DVH 2S Vertical Lift 49VL Vertical Lift 50

VED 70 Gapper 51VED 70 Gapper 52VED 200 Gapper 52VED 800 Gapper 53VED 800 Gapper 54VE 200 Gapper 54VE 200 Gapper 55

9

Model 7900 Series


SIEMENSDEMATIC

10

Figure 47Figure 48Figure 49Figure 50Figure 51Figure 52Figure 53Figure 54Figure 55Figure 56Figure 57Figure 58Figure 59Figure 60Figure 61Figure 62Figure 63Figure 64Figure 65Figure 66Figure 67Figure 68Figure 69Figure 70Figure 71Figure 72Figure 73Figure 74Figure 75Figure 76Figure 77Figure 78Figure 79Figure 80Figure 81Figure 82Figure 83Figure 84Figure 85Figure 86Figure 87Figure 88Figure 89Figure 90Figure 91Figure 92Figure 93Figure 94Figure 95

VE 800 Gapper 56VE 800 Gapper. 56RSP Non-Return Device 57

HD Rotating Lift Station (HD 100 shown) 59HD 100 Lift and Turn Station 60HD 170 Lift and Turn Station 60

P 60 and P 120 Positioning Modules 61PH 80 Positioning Lift Station 62PH 150 Positioning Lift Station 62PWT Workpiece Carrier Dimensions 65RWT Workpiece Carrier Dimensions 68RST 150 Wheeled Track Specifications 73SK 200 Accumulating Chain Conveyor Specifications 76SK 500 Accumulating Chain Conveyor Specifications 77SK 1000 Accumulating Chain Conveyor Specifications 78SK 2000 Accumulating Chain Conveyor Specifications 79DG 40 Dual-Belt Conveyor Specifications · 82DG 50/1.5 Dual-Belt Conveyor Specifications 83DG 50/5 Dual-Belt Conveyor Specifications 84DG 130 Dual-Belt Conveyor Specifications 85DG 160 Dual-Belt Conveyor Specifications 86DG 250 Dual-Belt Conveyor Specifications 87EG 60 Single-Belt Conveyor Specifications 90EG 70 Single-Belt Conveyor Specifications (without take-up) 91EG 70/5 Single-Belt Conveyor Specifications 92EG 150 Single-Belt Conveyor Specifications 93EG 180 Single-Belt Conveyor Specifications 94EG 300 Single-Belt Conveyor Specifications 95Single Belt Layout Example 96UL 90 Turn Specifications 98UL 180 Turn Specifications 99ES 90 Infeeder Specifications 100AS 90 Outfeeder Specifications 101ZV Two-Way Merge/Divert Specifications 102PV Parallel Merge/Divert Specifications 103HT 80 Lifting Transfer Unit Specifications 106HT 230 Lifting Transfer Unit Specifications 107HT 500 Lifting Transfer Unit Specifications 108HTS Lifting Transfer Line Specifications 109HL 120 Lifting Stop Specifications 110DVH Vertical Lift Specifications 112VL Vertical Lift Specifications 113VED 70, VED 200 and VED 400 Gapper Specifications 116VE 200 and VE 800 Gapper Specifications 117RSP Non-Return Device Specifications 118P 60 and P 120 Positioning Unit Specifications 120PH 80 Positioning Lift Station Specifications 121PH 150 Positioning Lift Station Specifications 122HD 100 Lift and Turn Station Specifications 123

2001-September-28



2001-September-28

Figure 96 HD 170 Lift and Turn Station Specifications 124Figure 97 Supports 127Figure 98 Air Ducting System, Flange Kits, Pressure Gage, Filter Pressure

Regulator and Valves 128Figure 99 Extension Kits, Consumer, Coupling and Pressure Switch Connections

....................................................................................................... 129Figure 100 840 Valve System 130Figure 101 SHV Switch Mount for Vertical Fixing 131Figure 102 SHH / SHP Switch Mount for Lateral Fixing 132Figure 103 Cable Conduits for the Transfer System 133Figure 104 Frequency Converter 134Figure 105 Switches for Workpiece Carrier (WPC) and Cylinder Interrogation .135Figure 106 Transfer Profile Section (TPS) for Belt Conveyors 136Figure 107 Accumulating Roller Chain Conveyors - One-Row Track 137Figure 108 Accumulating Roller Chain Conveyors - Two-Row Track 138Figure 109 Track Wheel Edge Profile 139Figure 110 Fastening and Bracing Materials 140

11

ISIEMENSDEMATIC Model 7900 Series


Model 7915 Accumulating Roller Chain ConveyorsThe Accumulating Roller Chain Conveyors run at constant speed to transport theWorkpiece Carrier (WPC) on stationary rollers to its destination. Theaccumulating roller chains are carried in the transfer profile section andtensioned at the drive end. In accumulating mode, the accumulating rollers rollunder the stopped WPC. The accumulating chain support rollers are made ofsteel or low-wearing plastic. These conveyors have a line load of 450-kg/m (steelrollers) or 300 kg/m (plastic roller) and range in transfer speeds of 0.08 to 0.32m/s.

The conveyor consists of a drive unit, a return unit and a line section. The motorcan be mounted either horizontally or vertically, on the left or to the right, and asan inboard or outboard unit.

In the case of bi-directional conveyors, the chain is tensioned by two screw-fixedtension rollers (1), which slide in mounting slots. In the case of non-reversibleconveyors, the chain in the return strand is tensioned by a spring take-up (2).(See Figure 6.)

Figure 6 Tension Spring and Rollers

2

2001-September-28

The conveyor line consists of two parallel transfer profile sections. (See Figure7.) So that the rollers rotate freely, the carrying strand of the accumulating rollerchain (1) runs along the upper chamber of the transfer profile section on twoinserted round silver steel rods (2). In the lower chamber, the rollers run onprofiled plastic bars (3). The flange ensures effective guidance of the WPC.When using a metal WPC, a polyamide WPC guide can be slid onto the flangeas a protection against wear. The profile extension (4) is retained in the centerhole and connects the conveyor lines or the drive and return units to each other.

Equipment Description 29

.===========================-~==================~~~=~=========~-----~~~-==------

Model 7900 SeriesModular Assembly Conveyor System (MACSTM)Application Guide

SIEMENSDEMATIC

Three profile holes for positioning pins (5) prevent the twisting of the transferprofile section to ensure precise guidance. The slots (6) provide the connectionpoint between the line and the supports. These enable the attachment of otherequipment (e.g. covers, gappers etc.).

Figure 7 Transfer Profile Sections

o 5

The return units (See Figure 8.) contain the return pulley (1), mounted on rollerbearings that rotate around the shaft (2). The bearing assembly is clamped onboth sides by covers (3). The transfer profile section end is covered with a profilecover (end cap) (4).

3

4/11 1

Figure 8

30 Equipment Description

Return Units

2

--e---0j----

2001-September-28



SK 200 Accumulating Roller Chain Conveyor

The SK 200 Accumulating Roller Chain Conveyor (See Figure 9.) is designed forlive loads of 200-kg in the accumulating mode. This conveyor is designed for usein transfer systems where end-mounted drive units are not feasible. The drivecan be fixed anywhere between the return pulley units. Reverse operation ispossible if a fixed roller replaces the spring take-up.

Figure 9 SK 200 Accumulating Roller Chain Conveyor


The SK 500 Accumulating Roller Chain Conveyor (See Figure 10.) is designedfor live loads of 500-kg in the accumulating mode. This conveyor is designed foruse in transfer systems where end-mounted drive units are not feasible. Thecenter drive provides a transfer direction that is towards or away from the drive,and not bi-directional.


2001-September-28 Equipment Description 31

Model 7900 Series


SIEMENSDEMATIC


The SK 1000 Accumulating Roller Chain Conveyor (See Figure 11.) is designedfor live loads of 1000-kg in the accumulating mode. Transfer is performed in thedirection towards the end drive.



The SK 2000 Accumulating Roller Chain Conveyor (See Figure 12.) is designedfor live loads of 2000-kg in the accumulating mode. Transfer is performed in thedirection towards the end drives. One motor drives each individual side of the

conveyor track. ,-j


32 Equipment Description 2001-September-28



Model 7915 Chain ConveyorsOne advantage of chain conveyors is the application; it is better suited for longerruns than belt conveyors. Graphite is added to all belts to minimize static load,making belt conveyors inappropriate for any type of clean room application (e.g.computers). Most chain models run in only one direction and loose hardwaremay become lodged in the chain, causing damage to the system. A take-up isavailable in all non-reversible units. Live load capabilities are increased if there isno accumulation. Before applying under these circumstances, be sure that thecustomer does not intend to accumulate product in the future.

Use Table 14 for model comparison to determine which chain conveyor yourcustomer should use. Calculate Live Load on page 71 before selecting a chainconveyor for any system.

Table 14 Comparison Chart of all Chain Conveyors

SK 500/ SK 1000 / SK 2000

Motor Type: WAF30*-S-pe-e-d~1Power I I(A) I jRatio* SpeedOutput

Driveshaft*

11 0-6000

Other RST 150 Specs.

Friction Coefficient: !l =ca. 0.07

SK 2000

,,2000,,1000

,,1500

SK1000

End

Towards Drive

0,270

,,500

,,750

SK 500

" 200

" 300

" 450

" 300

480-6000

SK 200

160-1500

Reversible I Either0,180,270

90 only on outsideCenter

Selectable

(M1 " kg/m)

(M2 " kg/m)

(NL = mm)

(MA =)

(FB = mm)

(FR =)

(ML = 0)

Model 7915 Chain ConveyorsData I MeasurementLive Load/Drive: (kg)

Accumulating ModeTransfer Mode

Live Load:

Steel Support Roller

Plastic Support Roller

Nominal Length

Drive TypeMotor Distance

Conveying WidthTransfer Direction

Motor Angle

Speed/Motor VariablesSK 200

Motor Type: WAF20*Power I I(A) r--- I Ratio* I Output

Driveshaft*

(kW) 460VRPM*i(1/min)m/s(kW)460VRPM*

0.15

0.678060.00 130.090.250.74105675

0.15

0.59165675.00 22.10.15• 0.371.12108048

0.15

0.59165660.00 27.60.190.3711656 60

0.25

0.7165648.00 34.50.240.551.52165648

0.25

0.7165639.00 42.50.300.741.48108025

* These are the criteria that SEW Eurodrive GmbHCo. needs to identify each motor. ** Identifies Siemens Dematic mounting flange.

(1/min)

14.1

22.5

27.6

34.5

44.1

m/s

0.10

0.16

0.19

0.24

0.31

2001-September-28 Model 7915 Chain Conveyors 75

Model 7900 Series


SIEMENSDEMATIC

SK 200 Accumulating Chain ConveyorThis conveyor has a reversible center drive.

Figure 59 SK 200 Accumulating Chain Conveyor Specifications

Nominal length NL

Motor distance MA ~ NL - 225)

Supports, see Chapter "Accessories 3" ]

126

'''' "

258

FB + 26

FB + 2

160 < FB < 1500

l::~,?.~:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:...~: j

102w-"-

126

Speed IPower IFull Load Current(400V, 50 Hz)

V (m/s) P (kW) In (A)

0.08 0.12 0.58

0.16 0.12 0.39

0.20 0.12 0.39

0.25 0.12 0.39

0.29 0.18 0.55

0.38 0.18 0.55

1Speed increase at idle:::; 12%

SK 200 Transfer Speeds 1

270·

max. 2000

..~

Motor positionfrom FB ~ 250 mm

only outside possible

Motor angle MLMotor inside Motor outside

90·

~{~E'-K1~'

o :'lTtT, 0180 U.R. 0

tfi( EfIT~I;;;':>

270·

76 Model 7915 Chain Conveyors 2001-September-28



SK 500 Accumulating Chain ConveyorThis conveyor has a nonreversible center drive that may be driven in eitherdirection, but not both. A spring take-up is included with this component.


_ ::!: / ~~: '., I "-, ::!i ./

, ,'" .. .' ' ' .. , '"1:11""',,· 'IT!!!! 102 300 !!!!j:, .:.Tt,

I 0 Supports, see Chapter "Accessories 3" , [

Nominallenqth NL

Motor distance MA ~ NL - 225)

aco

126197126


Speed lPower IFull Load Current(400V,50 Hz)


0.08 0.25 0.85

0.16 0.37 1.24

0.20 0.37 1.24

0.25 0.37 1.24

0.32 0.55 1.61

1Speed increase at idle::;; 12%

Motor angle MLMotor inside Motor outside

90',--,;::/-i',tfi

">"\ t,~.u•••180'r:'tiiL.l~ 0' 180'1":1,H 0'~_~u~.~ ',J-fB ::::~ 'fiffi ..,,· •..",nj'..:~J r~~~"-~

max. 2000

~"'IIII,,!!li~

Motor positionfrom FB ~ 285 mmonly outside possible

270' 270'




SK 2000 Accumulating Chain ConveyorThis conveyor has two end drives which signifies the direction of transfer.


FB + 26

FB + 2

160 < FB < 1500

oo orn

MM


Speed Ipower IFul1 Load Current(400V,50 Hz)


0.08 0.25 0.85

0.16 0.37 1.24

0.20 0.37 1.24

0.25 0.37 1.24

0.32 0.55 1.61

1Speed increase at idle::; 12%

rC\JC\J

439

166

Nominal length NL

126

j!! ,/" !!L,--

Jt', 'Jf

1, Supports, see chaper "Accessories 3' " rmax. 2000

_ FR :~:~-_._-.-:;::

Motor positionfrom FB 5. 285 mmonly outside possible

·""1:::

~o'a~~~;;~270'

Motor angle ML90'




Model 7922 Single-Belt ConveyorsSingle-Belt Conveyors transport the Workpiece Carrier (WPC) by the drag actionof a constantly driven conveyor belt on one side, and a non-driven wheeled trackon the other side. With the low-wear conveying belt, individual WPCs can bestopped individually and buffered on the moving conveyor. Transfer by positivefriction is guaranteed where the length, called dimension FBQ, of the WPC isequal to or greater than 0.8-times the conveying width, called dimension FB. Thenon-driven side of a single-belt conveyor may be a steel carrier roller, plasticroller or gravity roller chain. The conveyor live load is 100-kg/m and ranges intransfer speeds of 0.07 to 0.37-m/s.

The transfer line (6) consists of two, parallel transfer profile sections. (See Figure20.) One section is provided with a belt support (5) and belt (6) for transferringthe WPC. The second profile section provides the support for the non-drivenwheeled track (7). The flange edge (8) ensures positive guidance of the WPC.The flange edge can also be provided with a clip-on guide strip of polyamide foradded wear protection.

The upper chamber holds the belt (EG 60, 70 and 300 only) while the bearingportion is carried by the belt support; or the upper chamber may hold the rollerchain that is supported by two round-section bars (10) retained at the end by abolt. The center bore (11) is provided for profile section extensions. Theseextensions enable transfer section interconnections and drive and return pulleyassembly connections. Three fixing pins (12) prevent the transfer profile sectionfrom twisting. The longitudinal grooves (13) provide the means for connectingthe transfer section to the upright supports. The grooves also enable mountingfurther accessories (such as gappers, positioning units, etc.). The remainingsingle-belt conveyors differ in design as the belt is returned through the lowerchamber.

Figure 20 Transfer Profile Sections

2001-September-28

12

13


Model 7900 Series


SIEMENSDEMATIC

EG 60 Single-Belt Conveyor

The EG 60 Single-Belt Conveyor (See Figure 21.) is designed for a maximumlive load of 60-kg in the accumulating mode. The EG 60 is bi-directional anduses a Dunker Motor center drive. The motor's small size provides an advantageover the other single-belt conveyors.

Figure 21 EG 60 Single-Belt Conveyor

EG 70/1.5 Single-Belt Conveyor

The EG 70/1.5 Single-Belt Conveyor (See Figure 22.) is designed for a live loadof 70-kg in the accumulating mode. This conveyor has a maximum nominallength of 1500-mm and does not require a spring take-up. The EG 70/1.5 is bidirectional and uses a center drive.

Figure 22 EG 70/1.5 Single-Belt Conveyor (without take-up)


r



2001-September-28

EG 70/5 Single-Belt Conveyor

The EG 70/5 Single-Belt Conveyor (See Figure 23.) is designed for a live load of70-kg in the accumulating mode. This conveyor has a nominal length of 1501 to5000-mm and requires a spring take-up. The EG 70/5 is bi-directional and usesa center drive.

Figure 23 EG 70/5 Single-Belt Conveyor


The EG 150 Single-Belt Conveyor (See Figure 24.) is designed for a live load of150-kg in the accumulating mode. The EG 150 is bi-directional and uses acenter drive.



Model 7900 Series


SIEMENSDEMATIC


The EG 180 Single-Belt Conveyor (See Figure 25.) is designed for a live load of180-kg in the accumulating mode. This conveyor offers increased motor powerand greater nominal lengths. The transfer operation is performed by belt tractiontowards the drive station, which is arranged at the end of the conveyor track.



The EG 300 Single-Belt Conveyor (See Figure 26.) is designed for a live load of300-kg in the accumulating mode. The conveyor offers increased motor powerand greater nominal lengths. The transfer operation is performed by belt traction'-/towards the drive station, which is arranged at the end of the conveyor track.





Model 7922 Single-Belt Conveyors

The single-belt conveyor will only be applicable in approximately 10% of all beltapplications. Only light pallets should be used when applying this equipment(maximum=18-kg). The carrier position and size is very important when usingthis model. FBQ must be larger than FB and maintain a 60:40 relationship.

Use Table 16 for model comparison to determine which belt conveyor yourcustomer should use. Calculate Live Load on page 71 before selecting a beltconveyor for a system.

Table 16 Comparison Chart of all Belt Conveyors

Model 7922 Single-Belt ConveyorsData

1 MeasurementEG 60EG 70/1.5EG 70/5EG 150EG 180I EG 300

Live load/drive:

(kg) " 110

Accumulating Mode

" 60,,70 ,,150,,180,,300

Transfer Mode

" 90,,110 ,,230,,270,,450

Line Load

(kg/m)" 100,,100 ,,100,,100,,100

Nominal Length

(NL = mm)160-2000204-1500 11501-5000499-1 2000383-200001-30

'~

I Conveying Width(FB = mm)160-1500

Transfer Direction

(FR =)Reversible

I Traction towardsdrive stationMotor Angle

(ML = 0)0,2700,180,2700,270

90 only on outside

90 only on outside90 only on outside

Motor Distance

(MA=)Selectable

Drive Type

CenterI CenterI Centerw/Take-up

Speed/Motor VariablesEG70

EG 150/ EG 180/ EG 300

Motor Type: WAF20*

Motor Type: W AF30*

Power II(A)I

IRatio* l~utPutSpeed

PowerI(A) Ratio*Output ISpeedDriveshaft*

Driveshaft*

(kW)

460VRPM*i(1/min)m/s(kW)460VRPM*i(1/min)m/s

0.15

0.678060.00 130.070.250.74105675 14.10.12

0.15

0.59165675.00 22.10.110.371.1210804822.50.19

0.15

0.59165660.00 27.60.140.3711656 6027.60.23

0.25

0.7165648.00 34.50.180.551.5216564834.50.29

0.25

0.7165639.00 42.50.22

0.15

0.678014.33 54.40.28

* These are the criteria that SEW Eurodrive GmbHCo. needs to identify each motor.

** This part number includes a Siemens Dematic inclusive flange that must be added to the SEW motor.

2001-September-28 Model 7922 Single-Belt Conveyors 89

Model 7900 Series



SIEMENSDEMATIC

This conveyor is driven by a Dunker Motor, which is much smaller than thedrives used on the other single-belt conveyors. The wheeled rail on this modelmay be a steel or plastic carrier roller, or gravity roller chain.

Figure 69 EG 60 Single-Belt Conveyor Specifications

FB + 26 , 85FB + 2

160 ~ FB ~ 1500

EG 60 Transfer Speeds 1

Speed Ipower IFull Load Current(400V, 50 Hz)


0.21 0.09 0.31

0.27 0.09 0.31

0.34 0.09 0.31

1Speed increase at idle::; 12%

90 Model 7922 Single-Belt Conveyors

Nennlange NL

Moto~bstand (MA '" NL-80) MAmin=80

28 .1

StUtzen s. Kapitel Zubehor

~~~-f!l---~imax. 2000

~ ~-ffi-~--~Motorpositionab FB < 160 mm nur auBen moglich

Klemmenkasten-Lage

28

Motorlage ML900 (nur auBen)r,

~~

1800 rh'i -"(nur auBJnV ~ 00

[lJL...J

2700

Motorlage ML 1800 gedrehtum Motorlangsachse

900 (nur auBen)r,~~

Hl ~ 00 (nur auBen)180"[ _"-. c5L~

"~L...J

2700

2001-September-28

Model 7900 Series


SIEMENSDEMATIC

Single-Belt Conveyor LayoutsFigure 75 represents the only layout where the single-belt conveyor has anadvantage over double-belt conveyor. The single belt is used to transport on theinside track, while wheels are used on the outside.

I~

Figure 75 Single Belt Layout Example

WDRK PIECECAHR.!ER

96 Model 7922 Single-Belt Conveyors 2001-September-28

II

I

rK'api4la«.- Systems

Tab

Materials Handling Products

Page

Air Cargo Handling Systems

Air CargoCooler Room (CR) CR1Elevating Transfer Vehicle (ETV) ETV.1Powered Conveyor (PC) PC.1Warranty (Air Cargo) Warranty. 1

Automatic Guided Vehicle Systems (AGVS)

AGVSAGVS Vehicle Manager (VM) VM.1DemAGView AGV System Monitor DemAGView.1Constant System Monitor™ CSM.1DC-20 Automatic Guided Vehicle-Unit Load Carrier DC-20.1DC-40 Automatic Guided Vehicle DC-40.1DC-200 Automatic Guided Vehicle-Heavy Duty Unit Load Carrier DC-200.1DC-600 Automatic Guided Vehicle-Heavy Duty Unit Load Carrier DC-600.1DL-40 Automatic Guided Vehicle DL-40.1DT-24 Automatic Guided Tow Vehicle DT-24.1DT-40 Automatic Guided Tow Vehicle DT-40.1DT-60 Automatic Guided Tow Vehicle DT-60.1DT-100 Automatic Guided Tow Vehicle DT-1 00.1DX-40 Automatic Guided Vehicle-Unica,YY DX-40.1

Warranty (AGVS) Warranty.2

Automated Storage/Retrieval Systems (AS/RS)

AS/RSAKL 50 Automatic Miniload AKL50.1AKL 300 Automatic Miniload AKL300.1Destamat I Automatic Unit Load Destamat1.1Destamat 1224 Automatic Unit Load Destamat1224.1AKL Multistore ™ Miniload AS/RS AKLmultistore.1AKL Automatic Miniload Storage Module AKLamsm.1Transfer Cars - Storage and Retrieval TC.1Warranty (AS/RS) Warranty.3

8/5/99 Copyright © 1999 Mannesmann Dematic Rapistan Corp. TOC.1

Tab


K'Qpi4/44I... Systems

Page

Baggage Handling Systems

BaggageSlope Plate Claim and Makeup Device SPC.1Flat Plate (Type A) Claim/Makeup Device FPC.1High Speed Low-Impact 2000 Pusher System Pusher.1Slider Bed, 45 Degree Merge and Power Belt Curves SB.1Warranty (Baggage Conveyors) : Warranty.4

Distribution Conveyor Systems

Conveyors

100

Gravity Wheel (2 pages) 100.1

200

Gravity Roller 1.4" Diameter Galvanized Steel. 200.1Gravity Roller 1.9" Diameter Galvanized-1/4" Round Axle 200.2Gravity Roller 1.9" Diameter Galvanized-7/16" Hex Axle 200.3Gravity Roller Tapered Gravity Roller Curve 200.4

300

Gravity Conveyor AccessoriesStops (Fixed Angle and Hand Case) 300.1Inline Work Station Plate 300.2Neutral Converging Spu r and "V" Cu rves 300.2Spur and "V" Curve Switches 300.36-Way Combination "V" and Spur Switch 300.3Spur Curves and "V" Curves 300.4Beds Punched on 5-foot Centers 300.5Plastic Coated Roller. 300.5Case Counter and Guard Rails 300.5Gate Sections : 300.6Ball Transfers (Table, Plate and Strip) 300.7Extendable Gravity Conveyor 300.8

TOC.2 Copyright © 1999 Mannesmann Dematic Rapistan Corp. 8/5/99


Tab


Page

400

Belt Conveyor405 Slider Bed (2 pages) 405.1406 Walk Pick (2 pages) 406.1407 Bulk Package Belt Conveyor (2 pages) 407.1410 Belt-On-Roller (2 pages) 410.1460 Empty Carton (2 pages) 460.1

900

Curves and Junctions

960 180 Degree Tapered Live Roller Curve 960.1973 V-Belt Live Roller Junction (2 pages) 973.1975 Flat Belt Turn 975.1976 Spiral Belt Turn 976.1977 Flat Belt Turn (2 pages) 977.1985 V-Belt Live Roller Curve 985.1996 Round Belt Live Roller Curve and Junction (3 pages) 996.1

1100

Live Roller1102 Live Roller. 1102.11110 Continuous Chain Live Roller 1110.11176 Padded Chain Live Roller 1176.1

1200

Accumulation1211, 1221, 1230 V-Bottom Belt Wheel APC® (3 pages) 1200.11254 Lineshaft Conveyor (2 pages) 1254.1

1256 Lineshaft Conveyor (3 page~ 1256.11265 Narrow Belt Liv~ Roller APC ~ pages) 1265.11274 V-Bottom Belt live Roller APC (2 pages) 1274.11276 Padded Chain Live Roller APC® (2 pages) ..· 1276.11277 V-Bottom Belt Live Roller APC® (2 pages) 1277.11278 Narrow Belt Live Roller APC® (2 pages) 1278.1


Tab


K'alti4.1441- Systems

Page

1800


Accessories

Guard Rails and Roller ActivatorBelt.. 1800.145 Degree Wheel Sweep Plate 1800.2Sweep Rail 1800.2Guide Drums and Guide Wheels 1800.2Traffic Controllers (LD, MD and HD) 1800.3Hold Down Strips and Counterbalanced Wheel Gate 1800.3Return Belt Roller Assemblies 180004

Product (Case) Stops 1800.4

2000

Sortation

2305 Meter Belt (2 pages) 2305.12310 Single Line Induction 231 OSLI.12310 Single Line Dual Servo Induction 231 OSLDSI.1 '--.-/2310 Multiple Line Induction (2 pages) 231 OMLI.12311 Multiple Line Induction (2 pages) 2311.12420 RS200 PLUS ™High Rate Sorter (2 pages) 2420.12421 RS200E PLUS™ High Rate Sorter (2 pages) 2421.12422 RS200T PLUS ™High Rate Sorter (2 pages) 2422.12450 Pusher Diverter (2 pages) 2450.12455 PS-140 Positive Sorter (2 pages) 2455.12459 Pop-Up-Wheel Belt Sorter (2 pages) 2459.12460 SR 150 Steerable Roller Belt Sorter (2 pages) 2460.12462 Crossbelt Sortation System (3 pages) 2462.12472 Tilt Tray Sortation System (4 pages) 2472.12475 Pneumatic (Bullfrog) Tilt Tray Sorter (2 pages) 2475.1

3000

Ancillary Products3010 Flow Track and Flow Rack ( 2 pages) 3010.13020 Fixed Trailer Loader (2 pages) 3020.13021 Retractable Trailer Loader (2 pages) 3021.13025 Trailer Unloader 3025.13050 Cantilevered Extendable Conveyor (3 pages) 3050.13055 Gravity Extendable Loader (2 pages 3055.1

TOCA Copyright © 1999 Mannesmann Dematic Rapistan Corp. 8/5/99

K'ap.i41a«- Systems

Tab


Page


3500

SupportsTrussing and Spacing Kits 3500.1Supports (R1400, RCL, R200 Short, Multi-level and Ceiling Hangers) 3500.2R3000 HD Supports 3500.3Portable Supports (S-Stand and Straight) 3500.4Connector Angles and Plates, Splice Plates 3500.5

3600

ControlsPhotoelectric Controls 3600.1Mounting Brackets and Scanner Support 3600.2RapidVI EW2 Reports Option 3600RRO.13640 RapidSORT™ Controller-Crossbelt (2 pages) 3640.13640 Sorter Control System-Crossbelt (3 pages) 3640SCS.13645 Sorter Control System-Tilt Tray (3 pages) 3645.1

Heavy Unit Load Conveyors

4000

Gravity RollerGravity Roller Conveyor. 4000.1

4200

Live Roller4215 Padded Chain Live Roller Conveyor 4215.14222 Roller-to-Roller Chain Live Roller Conveyor 4222.14223 Roller-to-Roller CDLR 4223.1

4300

Chain4310 Chain Transportation (2 pages) 431 0.14320 Chain Transportation 4320.1


Tab


K'api4kut... Systems

Page

Heavy Unit Load Conveyors

4400

Accumulation4415 Padded Chain Live Roller APC® 4414.14456 Lineshaft Conveyor (2 pages) 4456.1

In-Process Conveyor Systems

4500

Demag Transfer System (DTS)Modular Assembly Conveyor Systems (MACS) Engineering Brochure

Distribution Conveyor Systems Appendix

Appendix

Common Equipment InformationBelts (2 pages) BEL TS.1Chutes (4 pages) , CHUTES.1Horsepower, Motors and Reducers (5 pages) HP.1Rollers and Wheels (2 pages) RLRS.1Safety (8 pages) SAFETY.1Warranty Warranty.5

Automated Electrified Monorail Systems

MonorailsOverhead Automated Electrified Monorail-DSB Track Track. 1Overhead Automated Electrified Monorail-DSB Two-Way Track Switch Switch. 1Overhead Automated Electrified Monorail-DSB Vehicle Vehicle.1Inverted Automated Electrified Monorail IMS.1

Warranty (Monorails) Warranty.6

Paperless Order Fulfillment

Paperless Picking .

RapidPICK2 Table of Contents RP.1 ~

TOC.6 Copyright © 1999 Mannesmann Dematic Rapistan Corp. 8/5/99


• 200 Cartons Per Minute

• Up to 540 FPM Sorter Speed

• Four Variable Speed Belts Per Line

• One Fixed Speed Belt Per Line

3-Belt Unit

Model 2311 Multiple Line Induct (MLI) includes twoparallel induct lines joined with a belt merge. TheMLI allows low speed, economical conveyor to feeda high speed sorter with the required spacing. Model2311 operates with the RS200 PLUS sorter.

Automatic Pressure Conveyors (APC) with dynamicaccumulation feed both induct lines. Next, thepackages enter the first pair and then the secondpair of induct belt sections. Each pair of belt sectionshas variable speed belts mechanically coupled tomaintain a constant speed ratio between belts. Thenthe fifth belt, which runs at a constant speed equal tothe sorter, feeds packages onto a belt merge. Themerge shifts packages into single file and feeds thesorter.

MASTER SECTION

DRIVE (AC SERVOMOTOR)

MECHANICAL

COUPLING

(FIXED BELT RATIO)

ELECTRICAllYCONTROllED VARIABLESPEED RATIO BETWEENBEL T 2 AND 3

DlSC-2 CABINETS ~(1 PER l~EI c:!::J 6

APC RUNNINGIN DYNAMIC

ACCUMULATIONMODE

SlA VE SECTION

DRIVE (AC SERVOMOTOR)

SlA VE SECTION

(PREGAPPING)

BelT ~O.4

MASTER SECTION

(FINAL GAPPING)

CONSTANT ~

SPEEDBELT

I2 TO 1 BELT MERGE

(SLAT OR VERTIBEl T)

6500B26A.CGM

11/20/98 Copyright © 1998 Mannesmann Dematic Rapistan Corp. 2311 .1

Maximum Rate:


Drives:

K'D~i4lac..Systems

200 cartons per minute (16" cartons, 1-waydivert).

160 cartons per minute (16" cartons, 2-waydivert).

Widths Available: 24", 30", 36".

Quantity Variable Speed Belts: Four (belts 1, 2, 3,and 4) in each induct line.

Quantity Fixed Speed Belts: One (belt 5) in eachinduct line.

Maximum Sorter Speed: 540 fpm

Lengths: 28' total for belt units 1-4. 4' for belt unit 5.27' for belt merge.

Conveyable Package Widths: From 6" to 34" wide.

Conveyable Package Heights: From 1" to 30" high.

First Four Belts: One AC Servo-Motor per paircontrolled by a Dual Servo Controller.

Fifth Belt: Electric motor, sized per job.

Merge Bed: 7-1/2 hp and 2 hp electric motors.

Package Stability: Must tolerate .4g acceleration.

Control: Programmable Sort Controller.

Safety Pull Cord: Provided along entire length ofthe induction conveyor for emergency shutdown.

Maximum Package Weight: 50 Ib per foot, 100 Ibper package

Minimum Package Weight: 2 lb.

Conveyable Package Lengths: From 9" to 42"long.

FLOW --.

r 39-112-

~B

J

BELT SERVO INDUCT4THr 3-3/4-

....---,

-BELT

ICl

~:*~B_LY- ;QRTE:

~

~

-IJc f I:20'

HIGH SPEED I

A

1276 APC

•... CL

'SORTER

6500639A

A (ft.) Servo B (in.)CD

Length of Assembly

1° Side3° Side

24

1-1/24' 6-1/2"4'8"

26

1-3/44'8"4' 9-3/4"

28

2-1/84' 9-1/8"4' 11-114"

30

2-5/84' 10-3/8"5' 1"

2311 .2 Copyright © 1998 Mannesmann Dematic Rapistan Corp. 11/20/98

~


• Quieter Diverts

• 200 Plus Cartons Per Minute

• Interleaving Aluminum Slats

Durable Divert Shoes

Reliable, Quiet Divert Switch ModuleDesigned for Minimum Maintenance andLong Life.

The RS200E PLUSTM sorter/conveyor providesreliable tracking and sorting of product regardless ofcarton size and shape. At divert points, anelectromagnetic divert switch automatically activates,and a group of divert shoes slide across theconveyor flights, pushing the appropriate carton ontoan outbound conveyor.

•

•

Package Weight: 100 Ib maximum (50 lb. per ft.), 2Ib minimum. Applications up to 150 lb. are possiblein certain applications.

Maximum Sorter Length: 650' for single units.Multiple units may be installed end to end.

Standard Drives: C-face mounted 7-1/2 to 25 hp, 3phase motor with parallel gear reducer, and cog beltdrive.

Maximum Rate: Capable of sorting more than 200cartons per minute (average length 16").

TRANSITION BELT ASSEMBLY

96"CHARGE

BEDASSEMBL Y

200 GRAVITY WHEELJUNCTION

700 GRAVITY WHEELCURVE

6500311A

TRANSITION BELTASSEMBLY

CHAIN, SLAT ANDSHOE ASSEMBLY

96"DISCHARGE

BEDASSEMBL Y

11/20/98 Copyright © 1998 Mannesmann Dematic Rapistan Corp. 2421.1

.-============================================~=============---= ••••••••••••••••••••••••-- •••I

~n.p.i4ID«- Systems


Divert Switch: An electrically-operated magneticdivert switch diverts shoes at each divert point. Thisdivert switch uses an electromagnet to re-directshoes to divert product whE?nturned on by themagnetic divert switch (MDS) controller. Themagnetic divert switch is easily removed through theside frame for inspection without disassembly of thesorter slats.

Standard Package Heights: 1" to 30" for photo eyeread.

Standard Sorter Widths: Slat surface widths from46-9/16" to 59-9/16".

Speed: 275 fpm minimum speed. 540 fpm maximumfor 20° sorter and 340 fpm maximum for 30° sorter.Speed control set for maintenance, jog and normalmodes.

Carrying Surface: Flat, anodized aluminuminterleaving slats make up the conveying surface ofthe sorter. These slats are driven by two strands ofASA RC-100 roller chain. A slat isolation insertconnects the roller chain to the slats to reduce noise.The roller chain is carried on polyurethane wheelswith shielded precision bearings.

Controls: Emergency stop pull cord, full length jamphoto eye. Microprocessor control provides lost shoedetection, slack chain detection, and missing pindetection. The MDS controller provides visible LEDfault detection, and line fault output is available.

Charge Bed: Supports the tail shaft and chainsprocket. Charge bed includes a transition belt,which transfers cartons onto the sorter from theconveyor feeding it.

Intermediate Bed: Provides transition betweenother types of beds. 3/16" formed side channels.Bolted, formed channel cross members.

Divert Beds: One or two-way divert beds which ~include magnetic divert switch/switches with controlsmounted near each switch. Controls equipped withquick disconnect fittings. Bed frames the same asintermediate beds. Magnetic divert curves at the endof the divert angles for noise reduction.

Catenary Bed: Includes a one-way or two-way divertand lost shoe sweep angle assembly. A catenarytake-up is located in the bottom of the bed tocompensate for any slack that may develop in theslat chains.

Divert Shoes: Attached to the slats and free to slide

along the length of the slats. When shoes passthrough a divert switch, they can be re-directed toslide across the slats to divert a carton. While

diverting, the shoes are magnetically guided througheach divert switch by rolling on a precision ballbearing, to reduce noise. On two-way diverts, aguide vane is located under the ball bearing to steerthe shoe through the crossover point. Divert shoescan sort to the right, left or both sides of theconveyor at either a 20° or 30° angle .

Discharge Bed: Supports the head shaft and sorterdrive. Discharge bed includes a transition belt,which transfers cartons from the sorter to nextdownstream conveyor.

Options:

• Divert left, right or two-way

• Low Support Assemblies

• Oil Pans

• Sound Dampening Panels/

-------

2421.2 Copyright © 1998 Mannesmann Dematic Rapistan Corp. 11/20/98

r


• Sorts Up to 120 Cartons Per Minute

• Two Rows Diverter Wheels

• Handles Wide Product

Model 2459 sorter consists of a belt conveyor withtwo rows of wheels at divert points. The wheels areskewed (set at an angle to conveyor flow), and theypop up pneumatically to steer cartons onto outboundlive roller junctions. This conveyor is suitable forgrocery and dry goods warehouse cardboard cartonsthat have been glued, banded, tied, heat-shrinkwrapped in a cardboard tray, or products containedin plastic tote pans.

Auxiliary Take-up: Air-operated belt take-up with18" of travel; provides 36" of belt take-up. Maintainsproper belt tracking on the sorter beds.

Skewed Wheels: Aluminum wheels have urethanetreads. Power for wheels comes from main line belt,transmitted by round belts through shaft and idlersheaves. Wheels are raised and lowered by an aircylinder.

When wheels are in the down position, cartonsconvey across divert sections on round belts ridingon special grooved rollers with high-quality sealedfor-life bearings.

60 0 SLAVE DRIVENLIVE ROLLER CURVE

15-11/16"

DOUBLEEND CAP

CENTER DRIVEASSEMBL Y

AIR OPERA TED

TAKE-UP

-r0-r -r0-r, ... ..

300 SLAVEDRIVEN LIVEROLLERJUNCTION

INTERMEDIA TESUPPORTS AT

BED JOINTS6500274A


K'~.p;4Uz«- Systems


Belt Conveyors: Formed box channel beds. Bedsection is of required length to span distancebetween pop-up diverters.

Standard Carrier Belt: PVK 100, Brushed xBrushed/FS 1 Ply, 3/32" thick with one lacing (notake-outs).

End Pulley: Machined pulley, 3" diameter, mountedin high quality sealed-for-life bearings, 1-7/16" shaft.

Drive: Center drive with 800 Ib maximum pull. 121/2"-diameter drive pulley with lagging, 2-7/16"diameter shaft, with high quality, self-aligning ballbearings. Available with chain-driven or quieter beltdriven drive pulley.

Motor: Totally enclosed C-face motor with parallelshaft gear reducer. Horsepower and output speed tosuit application in 3, 5 or 7-1/2 hp sizes.

Take-away Junctions: Products divert to a slavedriven or self-driven, 30 or 45 degree live rollerjunction. Roller speed for slave-driven junctions: 45°is 40 percent faster than sorter speed and 25percent faster for 30°.

Cartons can divert off the sorter onto the Model 2490

high speed 30° live roller junction and curve forconveyors running parallel to the sorter.

Divert Direction: Right hand or left hand.

Diverter Widths: 24-1/4" or 30-1/4"

Maximum Divert Capability: 120 cartons perminute with the average carton length of 16" at 350fpm (based on a 19" carton-to-carton gap).

Carton Weight: 4 lb. min.l100 Ib (50 Ib/ft) max.

Conveyable Carton Lengths: 9" to 36" long.

Conveyable Carton Widths: 6" to 26" wide.

Conveyable Carton Heights: 3" to 30" high.

Maximum Air Operating Pressure: 80 psi for popup-wheel and 45 psi for belt take-up.

Options:

• Carrier Belt: Cold Room and Quiet Applicationsuse the .074 thick Georgia Duck PRL-2-90SMFUB x BB quiet belt.

• Pop-up-Wheels: Available with a carbideabrasive grit surface for high speed applicationsand to grab poor carton surfaces.

• Junction Roller Surfaces: Available with

polyurethane coating (30° and 45° junctions) orgrit rings (45° junction only).

Pop-Up-Wheel with Integral Drive and SlaveDrive

The decision point to use an integral drive pop-upwheel sortation system over a center drive system iswhere there is a need for multiple drives. Theadvantages of the integral drive system are:

1. Uses only one carrier belt to eliminate speedvariances associated with a multiple center drivesystem.

2. Eliminates separate drives in one sortationsystem, reducing costs.

3. With less drives, fewer belt take-ups are needed,further reducing costs.


r


• 17,000 Packages per Hour at500 fpm (283 cpm)

• Low Acoustic Noise Level

• Modular Sorter EquipmentAllows Flexible Layouts Over,Under, and Around Obstacles

• Works with Model 3640

RapidSORTTM ControllerCrossbelt 6500504B.CGM

Straight Track Length: From 48" to 144"

Sorter Velocity: From 50 fpm (0.25 meters persecond [m/s]) to 500 fpm (2.5 m/s)

Curves: 140" and 180" radii in 45 degree increments(45,90,135,180).

Sorter Safety: (3 speeds and automatic mode)Sorter jog panel gives the operator direct control ofthe sorter speed, overriding all computer commands,to move the carriers to a convenient place to removeunsortable packages.

Pitch20"24"30"30"

Lenqth24"24"24"32"

Throughput Rate: At 500 fpm sorter velocity.Carrier Type RateXB-4060-50 17,000 pkgs/hour (283 cpm)XB-4060-60 14,200 pkgs/hour (237 cpm)XB-6060-75 11,400 pkgs/hour (190 cpm)XB-6080-75 11,400 pkgs/hour (190 cpm)

Carrier Sizes: Up to 1,440 carriers can be in onesortation system.Carrier Type WidthXB-4060-50 16"XB-4060-60 16"XB-6060-75 24"XB-6080-75 24"

The Crossbelt Sortation System consists of inductionstations, a sorter, take-away conveyors or chutes,supports, and computer control cabinets.

Maximum Package Weight: 66 Ib (30 Kg)

Maximum Package Length: Up to 48" (1200mm)using two sorter cells for over-sized packages. Thisis the largest package loadable on the XB-60-80-75carrier.

The Model 2462 Crossbelt Sortation System handlesa wide variety of break-pack goods, flat goods, andpliable packages. This sortation system canaccommodate a wide variety of package weightsfrom 1.6 ounces to 66 pounds, as well as packageshapes and materials like shirts, envelopes, videotapes, foodstuffs, polybags and tools.

Positive control of the product is the key feature ofthe Crossbelt Sortation System. Individual carriers,each with their own belt conveyor, allow productdelivery to a particular destination with pinpointaccuracy. Linear Induction Motors (LlMs) positionedevenly around the loop drive the sorter. The LlMscan move the carriers at velocities up to 500 feet perminute with no moving parts.

Package Dimensions: From 3" long x 3" wide x .2"high (75 mm x 75 mm x 5 mm) to 35" high x 63" longx 32" wide (900 mm x 1600 mm x 800 mm) using theXB110-120-135 cell. Contact Product Developmentbefore quoting the XB11 0 application.

. Track Widths: 25" (640 mm)

Track Height: From 48" to 161.75"

Take-away Conveyors/Chutes: A minimum of twoto a maximum of 2,000 package destinations.

11/20/98 Copyright © 1998 Mannesmann Oematic Rapistan Corp. 2462.1

K'api4la«-. Systems


Operating Temperature: +32°F (+O°C) to +122°F(+50°C); 5% to 90% relative non-condensinghumidity.

Induction Station: Up to four in-feed areas with upto four induction stations. Maximum 16 inductionstations on one sorter loop. All drives are BrushlessServomotor operated and timing belt driven. Theinduction station includes the following mechanicalsub-systems:

Orientation Belt (Optional): Used at infeed of theinduction station to automatically orient packagesat a 45 degree angle prior to loading onto theinduction station.

Coding Belt Speed: 600 fpm (3.14 m/s) MAX;Used for start/stop operations during scanning ofpackages.

Buffer Belt Speed: 600 fpm (3.14 m/s) MAX; Actsas a staging area before entering the nextinduction belt phase.

Synchronization Belt Speed: 600 fpm (3.14 m/s)MAX; Changes velocity to synchronize thepackages with the sorter.

Loading Belt Speed: 875 fpm (4.45 m/s) MAX;Shaped at a 45 degree angle to optimize loadingpackages to the sorter.

Induction Station Widths: 26" (650 mm) and 32"(810 mm)

Induct Length: 142.5" (3619.5 mm); 209" (5309mm) with loading conveyor assembly.

Induction Station Throughput: Up to 3,300packages per hour

For more information, contact the Crossbelt ProductManager at Rapistan Systems.

DATATRACKI I I 1\

ISOLA TOR

~II!II!II!II!II!II!II!! !! !

I

1111 \

LOAD ABILITYPHOTO

J UUUU1 3

5 79 1113 1517 1921 2325 276500648B.CGM

RECENTERING

STATION

SCANNER

VERIFICA TIONOFF-LOADINGPHOTO



Double Level Cell Carriers (DXB)

Double level cell carriers are composed of atraveling structure caTrying two belt conveyors (ableto load and unload products perpendicular to thesorter transport direction) installed one above theother.

The main feature of this application is to double thethroughput and chute quantity with the samefootprint of the single level sorter.

The double level cell sorter loop uses the wider 840mm horizontal track (modules). The double cellloading and automatic code reading of products shallbe performed on the upper level only with thescanners installed, in most applications, on inductionstations. As in the XB carrier style, there are masteras well as slave carriers.

NOTE: Loading on more than one cell on the lowerlevel is not possible due to the support structuresbetween the lower and upper carriers.

3270 mm

2635 mm

g.

RECENTERINGSTATION RECENTERINGSTATION

DXB Carriers

o

I • 4000 mm •• I

6500998A.CGM

7.63" (194mm)

ALLIGATORVDT ASSEMBLY

ALLIGATOR ASSEMBLY

345.51" (8776mm)

Induction Conveyor Assemblyused to induct items onto theDXB Carriers.

FLOW •••••••.

35.43"(900mm)

6501060A.CGM



• Quiet Linear Induction Motors

• Split Tray Design Available

The Tilt-Tray sorter is designed for automaticdistribution and sorting of packages, parcels,containers, baggage, and a variety of other articles.This high-performance sorter will operate at speedsof up to 2 m/s. Products are carried horizontally by aTray to a specified destination, where they are tippedonto a gravity chute or some other poweredconveyor system. The Tilt Tray is typically used inpostal or mail-order distribution centers, the foodindustry and airports.

• The system is capable of carrying loads between0.05 and 50 kg.

• At a peak speed of up to 2 mis, sorter throughputmay be as high as 12,000 units per hour perInduct Area.

• Standard Tray pitches include 500 mm, 600 mm,750 mm, 900 mm, and 1300 mm.

• Track design is highly flexible and may includeboth horizontal and vertical curves and bends.

Inclined sections may be at 5°, depending on thefriction between the product and the tray surface.

• With the additional Tray-leveller feature, inclinedsections may be up to 20°.

• The Tilt Tray Sorter conforms to currentEuropean CE standards as well as to the.requirements of DIN, VDE, and UL.

Safety: Vertical side guards, on each side of thesorter, are provided to prevent accidental contactwith the moving trays.

An induction area side guard is installed, oppositeeach induct station, to prevent parcels and itemsfrom falling off the trays as they are inducted.

For more information, contact the Tilt Tray ProductManager at Rapistan Systems.

o

Component -AverageMax.

Number Of Carriers

2501400

Number of LlM drive units

1056

Number of Induction

464Stations Number of Loading

1No LimitStations

-

Number of Offloading1No Limit

Stations Number of Repositioning

1No Limitstations Number of Sorter Scanners

1No Limit

Number of Overflow

1No LimitStations Number of destinations

50500

Number of Filling Factors per destination (weight,13

volume, number of items) Number of I/O

14

Operating Temp range

32-122°F0-50°C


K'api4la«- Systems


Track Module

Track modules are made from two aluminum, hightensile strength, extrusion profiles connected bycrossmembers. Track modules have provisions forinstalling the Drive Units, the bottom and lateralcovers and the Diverts.

The track modules are suitably supported on 6000mm centers with negligible deflection and twist angle(Less than one degree).

The curved track module is similar to the straightone and is made from bent profiles.

Bracing is provided as necessary.

o oStraight Track Module

Curved Track Module

Drive Unit

The sorter is composed of a series of mechanicallylinked carriers driven (transport motion) by LinearInduction Motors (LlM). The bottom part of thecarriers are the secondary side of the motor(conductor plate), while the primary side (stator) isinstalled on a straight track module of the sorter.

The driving unit has a Linear Induction Motor with anair cooling system and supports to fit into a straighttrack module.

The units are evenly spaced along the sorter track(Approximately every 30 carriers) and are managedby Frequency Converters that assure equal loaddistribution.

~~.~~-.'. -

//'

...•.••••~~~~~>~:::>. " .. , .. ·r~~t)...~

l,;.:;~:-:J~~~...~;'~""-.:

..~-,"':1"

.1", '

:'.,....:':~ " / ".•....•..,." ...- II "" ~~ ..-:;;;



Induction Conveyor

The induction station is the injector of the sorter.Induct station specifications include choice of width,length, weighing and, measuring features, codingand rate selections.

Induction parcel or item codes can be entered by akeyboard, by a hand-held scanner, or by a fixedscanner mounted to/above the unit.

Before the first unit of the induct area, a photoeyeLoadability Station checks that the sorter trays areempty and in an upright position to avoid doubleloading on trays.

In addition, the induction station is equipped with aswitch for full automatic or semi-automatic modeselection.

The unit can start and stop automatically or byoperator intervention.

COOl(; InT

r--=

'CL.-.;,.... ,

...

0

0•••

..

..

..

..... ..

-0

I I

.--s • ~ m

D••aaa. ~"",. m

Induct Station Belt Width (mm)Coding Belt L (mm)Buffer Belt L (mm)Synch. Belt L (mm)

IS-65 100-4 MB

6501000; 140010001000

IS-80 100-4 MB

8001000; 140010001000

IS-100 100-400

1000120012001200

Induction Station Throughput RatesCoding Method

Product Oriented?Max. Throughput (p/h)Notes

Keyboard (Manual)

No / Yes800-1600 / 400-1500The lowest values are relevant to carton

Laser Gun (manual)

No / Yes2000-2300 / 2000processing. The highest to 3 digit ZIPcode keyingInduct Station Scanner

No / Yes2800 / 2500Full automatic induction

Scanner on the Loop

-3300Full automatic induction


K'6pi4[a«... Systems


Carriers

The carrier is the transportation element of thesorter. The carrier is mainly composed of two parts:the undercarriage and the tilting mechanisms withtray.

The tilt angle of the tray is 100% controlled duringhorizontal position, tilted position and during thetilting movement.

The tilting axis is parallel to the traveling direction ofthe sorter.

If two trays are occupied with an item, the tilting ofthe two trays will take place at the same time or in asequence .

Undercarriage

The undercarriage is the portion of the carrier in thechain that supports the tilting mechanisms and trays.Additionally, the chain profile, which is comprised ofextruded aluminum, forms the secondary conductorof the Linear Induction Motor of the drive unit.

Supports and guide wheels are made ofpolyurethane elastomer and fitted with life-timelubricated ball bearings.

The chain links have ends fitted with a ball joint balland a ball socket.

Axles are aluminum die-cast, carrying both thesupport and lateral guide wheels.

Tilting Mechanism

The Tilting Mechanism is connected to theundercarriage by a support plate for easy removaland replacement.

The Tilting Mechanism consists of a series of camsand levers made by high tensile self-lubricatingplastic material, requiring no preventivemaintenance.

When the Tilting Mechanism is engaged by a Divert,it is unlocked from the horizontal position first, thenpositively driven to the tilted position and thenlocked.

Tray

The tray is comprised of pressured bondedlaminated marine plywood. It is bent with a suitableradius to keep the item stable during transportation.

The tray is fixed to the swinger arm of the tiltingmechanism and it can be easily removed.

The two trays installed on a "split carrier" have aminimum gap between them and are shaped in suchmanner to minimize the gaps between the adjacenttwin trays.

Maximum Product Length:

• Single Tray is 1000 mm

• Double Tray is 2200 mm

Minimum Product Length: 75 mm

Maximum Product Width: 800 mm

Minimum Product Width: 75 mm

Maximum Product Height: 800 mm

Minimum Product Height: 10 mm

Optional Scale: Can be installed in the InductionBuffer Belt Unit. The scale has a standard length of1000 mm. If the scale unit is used and the product islonger than 800 mm, a 1200 mm long belt must beused. If the product length is greater than 1000 mm,the scale must be located upstream of the inductionstation.

Maintenance: Preventive maintenance is not

required; however visual inspection is recommendedon a monthly basis. Servicing may be facilitated byusing a modem for access to diagnostic checks,program updates, and configuration parameterchanges.

For more information, contact the Tilt Tray ProductManager at Rapistan Systems.



• Maximum Throughput is 6000 Productsper Hour

• 240 Maximum Destinations

• LH and RH Sorting

• Jam Forgiving

• Economical

The Pneumatic Tilt Tray (PTT) Automated SmallSorter is an automated package sorting machine.The sorting system is also referred to as the Bullfrog.The PTT is designed to be a low volume, manualinduct and low cost small item sorter. RapistanParcel, Freight and Cargo Operations is the Productand Design Center for the PTT .

The Sorter system allows sorting small packages tomultiple destinations using a singular linear conveyorbelt. This belt is provided with side dischargingtrays. Small packages are sorted on each side ofthe machine and accumulated in either totes or

bags. The totes are emptied during sorts and thesmalls bagged by sort baggers.

Product Size and Weight:

• Length: 1" up to 16"

• Width: 1" up to 20"

• Height: 1/8" up to 12"

• Weight: 4 ounces to 25 pounds

Normal Air Pressure: 2.0 psi to 3.0 psi

Belt Speed: 140 fpm (35 m/s)

Maximum Destinations: 152 with 5 hp motor or 240with 7.5 hp motor.

Bed Width: 18"

BeltlBellowsfTray Assembly: The belt is a GeorgiaDuck and Cordage Mill part number PHR2-160BB xBB. Lx W Tol. = ± 1/8. The tray is .093" black ABSsmooth finish plastic. The bellows are made byGange, Inc. and are vulcanized to the belt and trays.The bellows are square and constructed of highquality polyurethane known for its flexibility, abrasionand tear resistance and very long cycle life. Thebellows are heat sealed using RF welding.

• Polyurethane Bellows comes in materialthickness from .005 to .040 with a temperaturerange of -GO°Fto +225°F. This material is veryresistant to oils, water, ozone, and ultraviolet.The material has a very high abrasion resistanceand has high tensile strength.

Inflated Height: 12" max.Deflated Height: 1-1/2"

~ ~

Belt Segment Lengths: 56" with 4 trays and 112"with 8 trays.

Tray Size: 12" by 18" at 14" pitch.



Blower Specifications: The PHA-1101 Blower is aframe mounted system serving as a continuous dutyair supply to the belt/bellows/tray air system. Theunit includes a single blow~r and modular reliefcircuit. The system includes the Siemens 2BH18series regenerative blower, intake filter and silencer,back-flow prevention valve, relief valves, electricalfield junction box, and PVG schedule 40 pipe andfittings. The components are assembled, painted,and mounted within a tubular steel frame.

No. of Blowers: 1 for every 32 destinations.

Drive: 230/460 VAG, 60 Hz,S or 7.5 hp paralleloffset Sumitomo Gearmotor.

Chute Inclination: l' 4" at 34 degrees plus l' 8" at23 degrees.

System Power Requirements: 480 VAG, 3 phase,150 amp service electrically fed from a 150 ampmain distribution board or MGG compartment.

Dimensions "A", "B", "C" and "D" depend on thenumber of destinations a particular system requires.

INTERMEDIATE ASSEMBLY

ONE REMOTE PANEL EVERY

3 INTER MEDIA TES

INTERMEDIA TE

ASSEMBL Y, CAMERA

FLOW ••

RECYCLE

CONVEYOR

ONE BLOWER REQUIRED I-EVERY 2 INTERMEDIATES I

1ST REMOTE

PANEL ON 2NO

INTERMEDIA TESECTION

CHUTE RH OUTPUTSLIDE

DRIVE

SIDE

LH OUTPUT

SLIDE

7' -6"

(2286

mm)

9"-6-3/4"

(2915 mm)9'-4"(2845 mm)INDUCT

2475.2

7' -0-1/2"

(2146 mm)9'-4"(2845 mm)

3'-1"(940

mm)

10' -6"(3200 mm)

C CHUTES ® 18'-8" (5690 mm)

OVERALL LENGTH = A

B INTERMEDIATES®18'-8" (5690 mm) = D -I7'-6"(2286 mm)

INTERMEDIA TE

EL. 4'-7-3/4" (1416 mm) TOP OF BELT HOLDING GUIDE ASSEMBLY,140 FPM •• BLANK

REMOTE PANEL

NEARSIDE, REF.

9'-4"(2845 mm)

Copyright © 1998 Mannesmann Dematic Rapistan Corp.

3'(914 mm)

DRIVE

ASSY.

L

11/20/98


• Rugged

• Versatile

• Wide Range of Widths

• E-Z Trac® Pulleys

Model 405 Slider Bed conveyor is an economicalchoice for widely varying load sizes and shapes. Inaddition to mixed loads, slider beds can handle hardto-convey products such as crates, bags, bundles,rolls, and unpackaged goods.

Operation: Two-way, horizontal, incline, or decline.No accumulation.

Capacity: 1581b/ft max. with 12-1/4" wide bed.

Speeds: 40-200 fpm fixed in 10 fpm increments.

Drives: 500 Ib series drives (520 Ib and 522 Ib pullcenter drives) with 8" diameter pulley on a 2-7/16"

,_/ diameter shaft with 1-3/16" diameter bearings andinput (520) or 1-7/16" bearings & 1-3/16" input (522).Chain final drive (520) or cog belt final drive (522).1050 Ib pull center drive with 12" diameter pulley on2-7/16" diameter shaft with 1-15/16" diameterbearings and input.

For each drive, pulley has molded-on, flat lagging,and self-aligning bearings in which the shaft mounts.

Take-up in Drives: 4" diameter (6" for 1050)E-ZTrac belt take-up pu11eywith lifetime grease packed,sealed ball bearings mounted to a 1-7/16" diameter(1-15/16" for 1050) fixed shaft.

t 12-1/4",18-1/4",24-1/4",30-1/4"136-114",42-11'",48-11'""-1I'"1I~

~ Y l~r55DD017A

Take-up pulley: Mounts on parallel take-up screws;adjusts manually. Maximum belt take-up:

• 26" with 520 Ib (Center Drive)

• 16" with 522 Ib (Center Drive)

• 24-1/2" with 1050 Ib and 2050 Ib Center and EndDrive

Drive AB520lb

14"54"5221b

17"59"1050lb

27"65"

522# CENTER DRIVE OPTIONAL GUARD _l

5500018C


~np;4/~ Systems


Accessories

Gravity Wheel Feeder

Slave Drive: Model 996 curves and junctions.

Auxiliary Horizontal Take-up: 4" diameter pulleysprovide 24" or 48" of belt take-up.

Options

Speeds: Higher speeds available.

5221b Center Drive: With chain final drive.

Beds: Galvanized roller slider has 1.9" diameter

rollers projecting 7/16" above the top surface of bed,with roller centers varying from 14" to 30". Availablewith single or double lanes. Wheel slider alsoavailable.

Conveyor and Drive Weights: Ask your SalesEngineer for weight information.

End Pulley (underslung):

• 260 Ib: 4" dia. drive pulley, 1-7/16" dia. shaft



,II)

~D

_ /""0\..,; ,J - -_

5200031A.CGM

Belt: PVC-impregnated polyester carcass. Withhorizontal, both sides low-friction surfaces. Withincline/mete rib rake, low-friction on bottom, roughtop. Belt width is 4" less than bed width of 30"through 54". -

Bed: Painted, 12-gage steel, 5-1/4" deep box type,bolted-in crossmembers.

Motor and Reducer: 1/3 through 7-1/2 hp, C-face.Brake motor on incline/decline units.

Bed Lengths: 12'. Other lengths available.

End Pulley: 4" diameter with 1-7/16" diameter fixedshaft or 6" diameter pulley with 1-15/16" diameterfixed shaft. Has precision, grease-packed ballbearings mounted in machined bores, spin formedinto the ends of the pulley shell.

Return Rollers: 1.9" diameter, 16 gage, galvanizedsteel with 7/16" hex SR bearings.

Nose-over: Painted, 10 gage, one piece laser cutside channels, 5-1/4" deep with 2-3/16" diameter,12-gage carrier rollers.

Power Feeder: Box type bed with 4" or 6" diameterend pulleys. A 4" or 6" diameter main line end pulleydrives power feeder end pulley by chain andsprockets.

A5200030A.CGM

Drive Widths (Nominal)Pulley Dia

12"

18-24"30"36"42"48-54"

4"

3'7-4'1-5'7-6'7-9'1-1/8" -1/8"

1/8"1/8"1/8"

6"

-4'2"5'8"6'8"9'2"9'4-1/16"

Drive A (in.)BC (in.)D (in.)

260lb

7-1/16*19-3/444

520lb

15-1/2*19-7/857

1050lb48-1/2-2569

* 2-1/2' or 10' Bed



o

• Rugged Welded Construction

• Versatile Bulk Product Conveyor forParcel Handling Industry

The Model 407 Belt Conveyor is designed for theParcel Handling Industry with integral side guardsand externally mounted bearings for the mainpulleys. This conveyor is an economical choice forwidely varying load sizes and shapes. In addition tomixed loads, a bulk package belt conveyor canhandle hard-to-convey products such as crates,bags, bundles, rolls, and unpacked goods.

37" OR 43" -Ir'1&~ 10"

OR

~ 24"

]-0 ---'r~t9200138A.CGM

Bed: Welded construction, 10-gage steel.Galvanized steel slider plates, painted steel sidechannels, 15" or 29" total height with 10" or 24" highside guards.

9200095A.CGM

Operation: Horizontal, incline, or decline. Noaccumulation.

End Pulley: 3" diameter pulley with 1-3/16" diameterfixed shaft. Has precision, grease-packed pillowblock ball bearings.

Return Rollers: 2-3/4" diameter, 10 gage,galvanized steel with 1-3/16" diameter shaft.

Capacity and Speed: 20 Iblft at 450 fpm, max.

Bed Lengths: 12'. Other lengths available.

Material to be Handled

LengthWidthHeightWt. (Ib)

(in.)(in.)(in.)

Min.

961 1

Max.483030100

-

END BED

INTERMEDIATE BED

SORTERDRIVE UNIT

NOSE-OVER BED

POWER FEEDER

CENTERDRIVE

9200136A.CGM


~api4.la«...Systems


Nose-over: Painted, 10 gage, welded channelsegments,S" deep with 2-3/4" diameter, 10 gagecarrier rollers.

9Z00055A.CGMKD078-80

Drive Bed Assembly: This drive comes with a 125/8" diameter drive pulley on a 2-7/16" diametershaft with 2-7/16" diameter bearings. Cog belt finaldrive or RC60-2 chain drive. Center and End Drivesavailable.

The drive pulley has molded-on, flat lagging, andself-aligning bearings in which the shaft mounts.

Motor and Reducer: 7-1/2 hp, 230/460v, C-faceparallel gear box. Brake motor on incline/declineunits. Reducer is an APG-4, 11.4: 1 ratio, 210DM4A.

Take-up in Drives: 16" of belt take-up.

Power Feeder Assembly: A power feeder is a shortslider bed that is slave driven from the main

conveyor and normally mounts only to the low end ofa belt conveyor. It pushes products onto the mainconveyor with inclining flow and pulls products offthe main conveyor with declining flow, allowing forsmooth product transition.

The drive pulley, attached to the end of the mainbed, powers the driven pulley through chain andsprockets. The end pulley assembly returns thepower feeder belt to the driven pulley.

End Caps: An end cap has two 3" pulleys whichallow the carrier belt to be returned at the correctheight.

.~

Belt: 150 PIW PVC-impregnated polyester carcass;with horizontal, both sides low-friction surfaces; withincline/meter/brake, low-friction on bottom, frictiontop. Belt width is 1" less than bed width.



• Economical

• Flexible

• Quiet

• Safe

This is a transportation and variable pressureaccumulation conveyor with a wider range offlexibility than conventional belt or chain driven liveroller conveyors. Straights, curves, junctionassemblies, right angle transfers, pop-up wheeldiverters, and gates can all be powered by one drive.

Operation: Two-way (with extra spool clips),horizontal.

Accumulation: Variable line pressure, or zero linepressure through straight sections.

"--/ Capacity: 20 Ib per roller.

Speeds: 30 through 200 fpm. Over 120 fpm requirescomponent upgrade.

Motor and Reducer: 1/2-2 hp Gearmotor.

Shaft: 1" diameter, cold rolled steel with self-aligningpillow block bearings. 1-15/16" diameter spoolsmounted on shaft. Shafts joined by delrin couplings.

Belts: 3/16" diameter, 83A durometer polyurethane.

Bed: 10 gage, 7-1/2" deep, painted, 1-1/8" flanges,bolted construction.

Bed length: 10' standard. The minimum length forintermediate beds is 2'.

Curve Degrees: 30, 45, 60, and 90

Junction Assembly: 30 degrees with 3" rollercenters. Includes a junction bed and junction spur.

Rollers: 1.9" diameter, 16 gage galvanized steelwith 7/16" hex SR bearings. Rollers are doublegrooved at one end and driven from the shaft of anadjacent roller. Rollers on curves are 14 gage, 2.25",2.5",2.75", or 3" diameter tapered to 1-5/8" with7/16" hex FZ bearings. High speed HQ bearings areavailable.

Roller Centers: 3" (4-1/2" and 6" available)

Zero-line-Pressure Accumulation: Available with

slug or singulation discharge. Field retrofit alsoavailable.

Accessories

Pop-up Wheel Diverter: Maximum rate is 35cartons per minute. An air cylinder raises and lowerstwo rows of powered wheels skewed at 16 and 26degrees. Requires 80 psi, clean, dry air. Rollerdiverters also available.

15'MIN.

"T L'"-1-

11/20/98

I ' 4' MIN.

r:'""~_~ 10' MAX1\1.0~,1.:~pr----·-----I ,,"'~\i II: I,I 'IJ'O - C ....

Copyright © 1998 Mannesmann Dematic Rapistan Corp. 1256.1

K'api41a«- Systems


Air Operated Brake: a 34" friction pad actuated bytwo actuators.

Powered Gate: A 4' frame hinges on a 2' stationaryframe. When the gate is closed, the two shafts areconnected through a drive sheave arrangement.Power is automatically removed as the gate isopened. The locking gate latch bar safely locks thegate open. The gate is counterbalanced and has thesame general construction as a straight bed withrollers on 3" centers.

5800187 A.CGM

~R1

L2

JUNCTION SPUR

(L2 CONFIGURATIONSHOWN)

V L1*

* HALF-COUPLING LOCATION

Spur Assembly: For merging onto a main line. Spurassemblies driven by upstream lineshaft conveyorwith no shaft connection to the main line. A junctionspur attaches to a junction .bed. A spur assemblytypically attaches to a non-1256 bed.

Junction Spur or Spur Assembly Dimensions

A (in.)D* (in.)G* (in.)H* (in.)

min.min.min.

18-1/4

39-3/41323

24-1/4

48-3/414-7/826-3/8

30-1/4

57-3/416-3/430-7/8

36-1/4

69-3/420-1/835-7/8

* Standard minimum lengths are listed. Longer spurs areavailable in 3" increments up to 117-3/4".

Crossover: Transmits power to the opposite side ofthe conveyor by chain and sprockets. Optional onbeds, and spurs. One or two included with junctionbed and wheel diverter beds. An external crossover

is available which transmits power to an adjacentparallel unit.

Air Operated Case Stop: A blade type stop thatraises 1-1/2" above the rollers when actuated by anair cylinder.

Spool Clips: One clip is provided for each spool toprevent the spools from creeping along the shaftduring operation. For two-way operation anadditional clip is required on the opposite side ofeach spool.

Speed-Up Spools: Used in certain areas to create agap between cartons. The larger spool diameterincreases roller speed by approximately 40 percent.

Slave Drives: Available for slave driving a 90 degreelineshaft unit from a lineshaft unit or slave driving alineshaft unit from a Model 405 or 410.

Right Angle Powered Transfer: Moves productsON and OFF the main line conveyor at a 90 degreeangle. Consists of a 36" long, 7-1/2" deep bed withrollers on 4" centers. Belts are raised and lowered

between the rollers by air actuators. Air requirementsare 35 psi, clean, dry, not lubricated.



~. ---------- C ---------

12-1'16' --'-JUNCTION BED

(L3 CONFIGURATION SHOWN)

DRIVECROSSOVERS

5800154B.CGM

1S'

JUNCTION SPUR(L2 CONFIGURA TlON

SHOWN)

Curves

5800147B.CGM

Junction Assembly & Wheel Diverter Dimensions

A (in.) B (in.)C (in.)·D (in.)·F (in.)18-1/4

18-1/45439-3/422-3/3218-1/4

24-1/46648-3/42418-1/4

30-1/47857-3/425-7/818-1/4

36-1/49069-3/429-9/3224-1/4

18-1/45439-3/425-3/3224-1/4

24-1/46648-3/42724-1/4

30-1/47857-3/428-7/824-1/4

36-1/49069-3/432-9/3230-1/4

18-1/45439-3/428-3/3230-1/4

24-1/46648-3/43030-1/4

30-1/47857-3/431-7/830-1/4

36-1/49069-3/435-9/3236-1/4

18-1/45439-3/431-3/3236-1/4

24-1/46648-3/43336-1/4

30-1/47857-3/434-7/836-1/4

36-1/49069-3/438-9/32

"'Longer junction beds and spurs are available in 3" increments upto 10-foot (Spur length is 2" less than "D" dimension).

~ F •

5800148B.CGM

Curve Dimensions

Width D (in.) E (in.)FG (in.)H-CenterJ-(in.)

(in.)InsideOut30°

45°60°90° 30°45°60°90°Roller Centers tonearest 10th (in.)18-1/4

36-1/26-1/813-22-45-54-22-31-1/839-3/845-5/8 3.64.23/8

15/165/83/413/1624-1/4

36-1/26-1/214-24-48-60-24-1/434-1/44248-5/82-3.84.71/4

5/165/83/4 15/1630-1/4

36-1/26-15-25-51-66-25-3/436-7/1644-51-5/8 4.05.115/16

1/813/165/83/4 9/1636-1/4

36-1/27-5/161627-54-72-27-38-9/1647-1/454-5/8 4.35.65/16

5/83/45/16


rK'api4/a«... Systems


• Quiet at High & Low Speeds

• Durable at All Speeds

• Handles Many Product Sizes

• Low Maintenance

• Zero Line Pressure

This Automatic Pressure Conveyor provides airoperated roller accumulation. Roller driving force issupplied by a 45mm flat belt which presses againstthe bottom of the carrier rollers. An air actuator

raises each pressure assembly, which raises the beltto drive the carrier rollers. Air actuators are

controlled by sensor assemblies located on 36"centers.

r---- Required Air Pressure: 45 psi minimum.

Operation: One-way, horizontal, accumulation.

Accumulation: 2' and 3' zones, with zero-linepressure accumulation.

Motor and Reducer: 3/4-5 hp, C-face motor with 90degree shaft gear reducer.

Capacity: 100 Iblft and 200 Iblproduct maximum.

Minimum Weight Product: With 3" roller c-c, 1.0 Ibof force on a single sensor to depress the sensor;2.0 Ib of force on a dual sensor to depress thesensor.

Speeds: 50-350 fpm in approximately 10 fpmincrements.

Drive: 350 Ib pull end drive with 44" for belt take-up.

Drive Pulley: Solid steel; in diameters from 5-9/32"to 6-9/16", depending on speed.

Bed Lengths: 12' standard with 2' and 3' zones.Other lengths are available.

Belt: flat 45mm, 1.77"-wide belt, with polyurethanebody and Armid fiber reinforcement with anti-staticnylon back.

1-31/32"

11-15/16"

44" BELT TAKE-UP

1.77" WIDE BELT

END DRIVE

ASSEMBL Y

42"

66"

71-9/16"

8-3/4"

10-3/4"

PRODUCT

rLOW "-......

DISCHARGE

END PULLEY

5800604A.CGM

IIII



Bed: 10 gage, 6-7/16" deep side channels, boltedconstruction.

Bed Width Dimensions (in.)Outside

EffectiveInsideMountingInside FrameBed

CarryingFrameHole c-cWidth withWidth

SurfaceWidth rollers low

18-1/4

141617-1/418-3/4

24-1/4

202223-1/424-2/4

30-1 14

262829-1/430-3/4

38-1 14

323435-1 1436-3/4

End Pulley: 5-1/2" diameter at charge anddischarge ends.

Roller Safety: Finger guard strips between carrierrollers.

Sensor Assembly: 7/8" diameter counter-weightedroller supported by plastic arms that pivot on the axleof a carrier roller.

Rollers: 1.9" diameter, 14 gage, galvanized steelwith 7/16" hex axle with SR or high speed HQbearings (for quieter operation). The tops of rollersare 1/4" above the top of standard side channels,and are captured for reduced wear and longer life.

Roller Centers: 3"

Options

Dual Sensors: A second sensor 6" upstream,mechanically linked to existing sensor.

Retractable Sensors: Provides sensors-down

conveying for quiet operation (standard for skewedbeds).

Solid Slug: Every zone or selected zones can beactivated to live roller mode by means of anelectrical signal.

Skewed Rollers: Provides 2" or 3" skew for edgealignment of product to a specific side of theconveyor (available with 12'-long beds only).

Controlled End Cap Assembly: The end capassembly transforms an intermediate bed into acharge end bed or discharge end bed. A controlledend cap assembly allows accumulation of productover the charge bed with no additional controls (suchas photoeyes and electrical solenoids).

Rollers Low: The tops of rollers are 7/8" or 3-5/16"respectively, below the tops of the side channels, "which serve as integral guardrails.

Intermediate Zone Control W/Brake: Deactivates '-'two adjacent intermediate zones. A 2' brake iscentrally located.

Controlled End Cap Brake: Used when products atthe discharge end must not coast beyond thedischarge bed.

Accessory

Slave Drive: Model 996 curves and junctions atcharge end; available with end drives only.

5800237A

996 BED

R-SUPPDRT REQUIRED AT THISPOSITION. 996 SUPPORT TO BEPLACED CENTERED ALONG LENGTHOF 996 BED

5600258A.CGMK0066-25



• Speeds Shipping

• Power Driven

• Power Steering

• Integrated Controls

• Retractable End Section

Model 3021 is a mobile power belt conveyor with aretractable gravity discharge section which can bedriven into a semi-trailer. This allows product to beconveyed into the trailer for shipping.

Total live load on the loader at any time is 1,000 Ibmax.

Product Specifications

LengthWidthHeightWeight (Ib)

(in.)(in.)(in.)

Min.

963 2.5

Max.

36263050 Ibltt or 100 Ibmax

Frame: 12" structural channel with weldedcrossmembers.

Extended Lengths: 52' 8-7/8" or 55' 8-7/8"

Retracted Lengths: 40' 9-7/8" or 43' 9-7/8"

Height: 36" at charge end, 22" discharge end.

Transition Section: Gravity roller ramp locatedbetween the power and gravity conveyors.

Power Conveyor: 30-114" or 36-1/4" wide sliderbed.

Belt: 24" or 30" wide, PVC-impregnated polyestercarcass with low-friction surface both sides.

Belt Speed: 100 fpm _

Conveyor Motor: 1-1/2 hp

Mobile Drive Unit: 1 hp motor, 60 fpm (.68 mph)travel speed, and two 20" diameter foam-filled tires.

Travel Length: 36' or 39'

Mobile Drive Unit: 1 hp motor, 60 fpm (.68 mph)travel speed, and two 20" diameter foam-filled tires.

3 '4" APPROX (50' TRAILER WITH 55' 8-7/8" TRAILER LOADER)4 '4" APPROX (48' TRAILER WITH 52' 8-7/8" TRAILER LOADER)

TRAILER

TRAILER LOADERA T MAX TRAVEL

GRA VITY RETRACT ABLESECTION EXTENDED

TRAILER CENTERLINE

./ BUILDING WALL

U _ ~H~~ l~A~S~V - :;:f-- GUIDEE-:-:-=:::: ~ ~A~H TRACK

o r= LH TRAILER LOADER ASS'Y I3' SUGGESTED GUIDE TRACK LOCATION L~ (BE SURE TO CLEAR DOCK PLATE) _

l' -0" GUIDE TRACK LENGTH +6-1/2' = TOTALSPACE REQUIRED FOR LOADER LENGTH --1 7000028B.CGM


r IC'DItHIa«... Systems


Loader Weight: 4125 Ib (largest unit). Guidance: Front wheels steerable, rear wheelsguided and centered by floor-mounted track.

Front Wheels: 16" diameter solid rubber.

Gravity Conveyor: 12'-lon'g retractable wheelsection with aluminum wheels on 1-3/4" centers. 37

wheels per foot with 30" wide; 44 wheels per footwith 36" wide.

Voltage: 208-230/460-480 volts, 3 phase, 60 Hz.

Product Length Capacity: Sixty 16" long cpmsustained and solid slug at peak.

Controls:Power Steering: Approximately 5 degrees in eitherdirection.

• Emergency stop buttons on both sides of thedischarge end of the power belt conveyor.

• Discharge end stop bar to stop loader travel.

• Control panel on side of gravity section. Includesstart and stop buttons for the slider bed andoverhead conveyor, joystick control for forward,reverse, left, and right steering, and a toggleswitch for the lights.

• Decline conveyor cabinet interlock.

Lights: 13W fluorescent tube.

Options

Fan: 12" diameter, 3 speed.

Charge end stop bar

* CAN ALSO BE LOCATED ALONGSIDE LOADER NEAR CHARGE END

~---~-=TI 11-- II

S'-NO ;';;CTIONS IN THISAREA. I40' 9-7/8" OR 43' 9-7/8" •. ~~\~~",TO TOPOF BED

14"

21"NORMALSTOPPINGPOSITION

30" MINIMUM FROMTIP OF GUIDE TRACKTO NEAREST OBSTRUCTION

BEL T CONVEYORDRIVE

TRAVERSING (LOADERTRAVEL) DRIVE

CABLE TRACK

36' OR 39' TRAVEL DI5T ANCE

CONVEYOR BELT

~ 100 FPM

39' 4" OR 42' 4"

36' 6-15/16" OR 39' 6-15/16"

52' 8-7/8" OR 55' 8-718"

18" OR 21" MINIMUM

[FROM LOADER C/L TO

NEAREST OBSTRUCTION

GUIDE TRACK

~:=$

30-1/4"

OR L36-1/4"

PIVOT RAMP

12' RETRACTABLEl '"hJ..~ ~ ~ ~ =-=:::!

L-t-~

116",22", OR 24"

4"

APPROX

7000022A


~npi4kuL. Systems.1111:.1 •.••.•


Level 2

Ethemet TCP/IP

Level 1

SorterControl System

Architecture

InterBus-S

Dispatch

RCMs

RS422

ScannerRS422

RS422

BMU

scs

~I"'''I~VDU, Keyboards, Hand held scanner

• Industrial Grade IBM-PCComputer

• Video Display Terminal(VDT) Menus arePassword Controlledwith Seven AccessLevels

• Works with Model 2472Tilt Tray SortationSystem

The SCS is based on a two-level

system principle; the processcontrol is managed by the SorterControl Computer (SC) andexecuted by the Remote ControlModules (RCM).

The SC computer runs the RCMsthrough a Backup ManagementUnit (BMU) and a Bus system.

The BMU provides a Full WarmBackup (Hardware andSoftware). In case of crash of theSorter Control PC, the BMU willtell the Operator the procedure toresume the operationsimmediately.

The Sorter Control functionality can be resumed inless that 5 minute through the BMU while the RCMelectronic can be changed in even less time. Thisgives the SCS a very high system availability and avery low Mean Time To Repair (MTTR).

The SCS has a built-in self-check system whichinforms the operator if there is anything wrong in anyof the controlled functions/devices. Errors, if any, areshown on the system terminal with text informationof the error status.

The system architecture is characterized bysimplicity; no preventive maintenance, simple cablingsystem, easy diagnoses of the complete system andvery fast network communication.

The Level 2 of the system is the Sorter Controller.This computer uses the Intel RMX OperatingSystems.

11/20/98 Copyright © 1998 Mannesmann Dematic Rapistan Corp. 3600SCS.1

K'npula«-. Systems


The Sorter Control functions are:

• Management of items information on sortercarriers and Induction Stations

• Items sortation based on sorting process andchute availability

• Management of the sorter velocity and position

• Management of Remote Control Modules (RCM)through InterBus-S industrial bus

• Communication with Dispatch System

• Communication with Graphic System

• Presentation of system diagnoses

• Execution of commands given by operator(Human-Machine Interface [HMI])

• Update of all data to the Backup Sort Controller.

• Login and Password management

• RUN menu

Dispatch System-Physical Structure

The Dispatch System may be comprised of thefollowing components depending on application:

A master Dispatch PC with its own printer, which isthe heart of the Dispatch System, with the followingconfiguration:

• Desktop PC with Windows NT Operating System

• 200 MHz Pentium processor

• 32 Mb SDRAM

• 2.1 Gb Hard Drive

• 2 network cards

• System Maintenance.

The level 1 of the system is comprised of RemoteControl Modules (RCM) located at the mechanicalfunctions that are controlled. Each RCM has its ownelectronic to control the mechanical and the

electrical devices. As previously said, the logicalcontrol of the sortation is managed by the SorterControl Computer.

This way, before start-up and after power loss, thesystem can restart immediately since no reinitialization procedure has to be performed.

The following system components are controlled byRCMs:

• Induction Stations

• Sorter movement

• Sorter Sensing Devices

• Divert and Discharge full control

• 1 UPS

• 1 network printer

• A standby Dispatch PC, to provide a warmbackup in case of failure of the master one

The locations of the various PCs and cabinets are

expected to be as follows depending on application:

• The DS master, stand-by, UPS, and printer maybe located in the computer room.

• The SC and ISC are located inside the MainSorter Cabinets.

The following illustrations, on the next page, show anexample of the physical connections among theDispatch System (SC, ISC, Customer Host).

3600SCS.2 Copyright © 1998 Mannesmann Dematic Rapistan Corp. 11/20/98

i

K'npiJa«... Systems

RSCT

ETHERNET Tcpnp


RICT

ETHERNET Tcpnp

InterBus-S

HostLEVEL 4

VDTIDI{ \

VDT II II{"'''\

8 SCANNERS

ETHERNET TCP/IP

LEVEL 3

ETHERNET TCP/I

LEVEL 2

RSCT

DSSTAN BY

CUSTOMER NET

RapidVIE# System

SORTEC NElWORK

11/20/98 Copyright © 1998 Mannesmann Oematic Rapistan Corp. 3600SCS.3


Allinterbus-S Remote I/O devices are operated from120 VAC. This is provided by the computer cabinet

SC and ISC Computer Assemblies: Eachcomputer assembly consists of an industrial-gradepersonal computer (PC), serial I/O interface,Interbus-S board, and LAN adapter boards. Thesecircuit boards are installed in the chassis where

there are specific slot assignments for each circuitboard. A crossbelt sortation system may have fromone to six computers in the cabinet.

Power for SC and ISC Computers: Each computerchassis requires 120 VAC supply voltage. This isobtained from one or more Uninterruptible PowerSupplies (UPS). When the commercial power sourcedrops below a specified voltage for a specifiedperiod of time, the UPS generates a signal telling theSC computer to shut down the computer system inan orderly fashion.

(LEVEL CONVERTERS.VDTS. SCANNERS)

(VDTS. SCANNERS)

SERIAL I/O

(1-16)

SERIAL I/O

(1-16)INTERBUS-S

8000070B.CGM

LlM

CONTROL

INTERBUS-S INDUCTIONSTATIONS

INTERBUS-S SORTER ELEMENTS

(ENCODER. CHUTE GROUPCONTROLLER. ETC.)

REMOTEJOG

PANELS

LlM

ANALOGDRIVE

R

E

LA

Y

INDUCTIONCOMPUTER

• Illuminated Start and Stop buttons

Basic System Controls: The basic system controlsare in the computer cabinet. The principle localcontrols are:

SUPERVISIONETHERNET

Manual Control Functioning: To provide forsmooth installation and maintenance, the sorter canbe moved around the track without the computersrunning at all. A hand-held control unit can be movedto a clear area where one can see the sorter, andcontrol the speed-safely.

Remote Control Functioning: A special controlmode is provided for operators to move the sorterwhen they must unload non-sortable packages. Thisrequires an operator to plug a jog panel into one ofmany jog connectors located throughout theCrossbelt area. The sorter will then operate in asemi-automatic mode where the computer iscontrolling the enabling functions, and the operatoris controlling the speed.

and distributed throughout the Crossbelt system asneeded.

CONTROLRELA YS

CONTROLPCB

SORTCOMPUTER

CABINETSWITCHESANDINDICATORS

RS-232

TO UPS

ETHERNETTERMINA TION

The Model 3640

RapidSORTfM Controllercontains the central

processing unit, which is theheart of the Crossbelt system.This unit executes the

appropriate instructions (theprogram) stored in the harddisk memory unit, in responseto incoming input device signals. The CPU finallysends out control signals as required to the outputdevices.

• Industrial Grade IBMPC Computer

• Video Display Terminal(VDT) Menus arePassword Controlledwith Seven AccessLevels

• Works with Model 2462Crossbelt SortationSystem



~ap.i4ku&...Systems

• Audible Warning Horn for start-up

• Emergency Stop (E-STOP) button

• Speed Selector

• Linear Induction Motor (L1M) Spacing WarningIndicator.

The principle Remote Controls are:

• Start and Stop signals

• E-STOP signal

• Fault Reset.

Other Controls: Up to 4 scanners on the loop with:

• Manual coding or code label reading interface forscanners installed on induction stations and/orsorter loop

• Long parcel orientation during loading

• Parcel loading on single or double carrier

• Long parcel automatic orientation during 011

loading from double cell

'--.-'• Parcel re-destination capability

•

Online diagnostic and equipment availabilitystatistical data

•

Self diagnostics examine and display status ofSC and ISC

•

Error messages displayed on VDTs for system

monitoring•

Network connection to supervisory system

•

Induction station parameters and maintenance

passwords•

Carrier activation velocity for sorting according to

parcel code•

Code translation program

•

Chute verification reporting for each destination

chute and reject chute•

Supervision computer lo~ding and changing oftranslation tables.


K'ap;4/a«-. Systems


BMU

Level 2

Ethemet TCP/IP

D

Dispatch

scs


system principle where theprocess control is managed bythe Sorter Control Computer (SC)and executed by the RemoteControl Modules (RCM).

• Industrial Grade IBM-PC

Computer

• Video Display Terminal(VDT) Menus arePassword Controlled withSeven Access Levels

• Works with Model 2462Cross belt SortationSystem

VOU, Keyboards, Hand held scanner


Level 1

InterBus-S

RCMs

RS422

Scanner

Management of items information on sortercarriers and Induction Stations

Items sortation based on sorting process andchute availability

Management of the sorter velocity and position

Management of Remote Control Modules (RCM)through InterBus-S industrial bus

Communication with Dispatch System

Communication with Graphic System

Presentation of system diagnoses

•

••

•

•

•

••

RS422RS422

~I""·I~

The SCS has a built-in self-check system whichinforms the operator if there is anything wrong in anyof the controlled functions/devices. Errors, if any,are shown on the system terminal with textinformation of error status. The system architectureis characterized by simplicity, no preventivemaintenance, simple cabling system, easy diagnosisof the complete system and very fast networkcommunication. The Level 2 of the system is theSorter Control PC. In this computer Intel RMXOperating Systems is running.

The SC computer runs the RCMsthrough a Backup ManagementUnit (BMU) and a Bus system.The BMU provides a Full WarmBackup (Hardware and Software).In case of a crash of the SorterControl PC, the BMU will tell theOperator the procedure to resumethe operations immediately. TheSorter Control functionality can beresumed in less that 5 minutes

through the BMU while the RCMelectronic can be changed in lesstime. This results in a very high system availabilityand a very low Mean Time To Repair (MTTR).

11/20/98 Copyright © 1998 Mannesmann Oematic Rapistan Corp. 3640SCS.1

K'apUi/a«-. Systems


• Execution of commands given by operator (Man-Machine interface)

• Update of all data to the Backup Sort Controller


• RUN menu


The Level 1 of the system is made of RemoteControl Modules (RCM) located at the mechanicalfunction that are controlled. Each RCM has its ownelectronic to control the mechanical and the


This way, before start-up and after Power Loss, thesystem can restart immediately since there is no reinitialization procedure to be performed.

The following system components arecontrolled by RCMs:


• Sorter movement



System Technical Characteristics

SorlerConuolCompuffir

The Sorter Control is based on an industrial PC with:

• Pentium 200 MHz processor

• 32 MB RAM

• 2.1 GB hard disk

• Floppy disk driver.

The following additional boards are installed:

• Ethernet network card

• Serial I/O card (16 channels)

• InterBus-S card.

Backup Sorler Control (BSC)

This computer is identical to the Sorter Control fromhardware and software standpoints.

Backup Management Unit

The Backup Management Unit is a MannesmannDematic proprietary assembly used to automaticallyswitch the entire sortation control from the Sorter

Control computer to the backup one, in case the firstone crashes. After resuming, all items on Inductionand on the sorter trays will be diverted properly tothe discharge chutes. From this moment on, theBSC will manage the entire system. This gives themaintenance operator the possibility to restore theSorter Control PC at deferred time.

SCS Console

The SCS console is a standard 15" Monitor and

keyboard. This console is switched from SC to BSCby the Backup Management Unit.

Modem

The modem connection is a standard feature ofMannesmann Dematic SCS. This connection is

used by the Rapistan, on customer demand, toretrieve Log files and to perform RemoteMaintenance. After connection, all maintenancemenus available on site will be accessible by theRapistan Service Department.

Encoding Unit

Each Induction Station can be equipped with arobust VDU. A Hand-held scanner can be also

connected. This unit is used for encoding purposesand to start, stop and test the induction and sorter.

Remote Control Module (RCM)

As shown on the SCS architecture, the RCMs arelinked to the InterBus-S. This sensor/actuator bus

system is a worldwide standard in industrialapplications. More than 50,000 system are currentlyrunning! This system has been developed to

3640SCS.2 Copyright © 1998 Mannesmann Dematic Rapistan Corp. 11/20/98


robustly connect sensors and actuators likephotocells, lamps, frequency converters, encodersetc., through a single bus instead of complex,expensive parallel wiring. The RCM is a unit thatincorporates the electronic and the terminal block,suitable to manage inducts, diverts, chutes etc., andhas LEDs for local diagnostic as well as remotediagnostic on the Sorter Control.

Power Supply for Computers

Each computer requires 230/120 Vac supply voltage.This is obtained from one or more UninterruptiblePower Supplies (UPS). When the commercial powersource drops below a specific voltage for a specificperiod of time, the UPS generates a signal telling theSC computer to shut down in an orderly fashion.

AlllnterBus-S remote I/O devices (RCMs) areoperated from 230/120 Vac. This is provided by theMain Sorter Cabinet and distributed throughout thesystem as needed.

Manual Control Functioning

To provide for smooth installation and maintenance,the sorter can be moved around the track without thecomputers running at all (Manual Mode). A handheld unit can be used for this purpose even if theaccess door of the Maintenance area is open.

Remote Control Functioning

A special control Mode (Maintenance Mode) isprovided for operators to move the sorter at lowspeed (0.3 m/s). This requires an operator to plug aJog Panel into one of the many jog connectorslocated in the sorter access areas. In this mode, it ispossible to exercise diverts and to collect nonsortable packages that are not unloaded. The sorterwill operate in a semi-automatic mode where the SCis controlling the enable functions.

11/20/98Copyright © 1998 Mannesmann Dematic Rapistan Corp. 3640SCS.3


VDU

ISC2

Keyboards

Level 2

Hand held scanne

VDU

Keyboards

Hand held scanner

Ethernet TCPIIP

r - - --

Interbus-S

t- ---~

UPS

The system architecture is characterized bysimplicity; no preventive maintenance, simple cablingsystem, easy diagnoses of the complete system andvery fast network communication.

1--

I

I Level 1

I Interbus-Sr ---~8 ..GGJ ..·GJI L _. ~~ I

I RS 422 I ', RS 422

SC

1 Interbus-Sr --r- -- -I -- -I

DODD

L - 1

Printer

Modem

The Sorter Control functionalitycan be resumed in less that 5minute through the BMU whilethe RCM electronic can be

changed in even less time. Thisgives the SCS a very high systemavailability and a very low MeanTime To Repair (MTTR).

The BMU provides a Full WarmBackup (Hardware andSoftware). In case of crash of theSorter Control PC, the BMU willtell the Operator the procedure toresume the operationsimmediately.

The SC computer runs the RCMsthrough a Backup ManagementUnit (BMU) and a Bus system.


system principle; the processcontrol is managed by the SorterControl Computer (SC) andexecuted by the Remote ControlModules (RCM).

• Industrial Grade IBM-PCComputer

• Video Display Terminal(VDT) Menus arePassword Controlledwith Seven Access

'. Levels

• Works with Model 2472Tilt Tray SortationSystem

The SCS has a built-in self-check

system which informs the operator if there isanything wrong in any of the controlledfunctions/devices. Errors, if any, are shown on thesystem terminal with text information of the error

\....-I status.


l<'<rp;4la... Systems




• Management of items information on sortercarriers and Induction Stations;







• Execution of commands given by operator(Human-Machine Interface [HMI])

• Update of all data to the Backup Sort Controller.


• RUN menu


functions that are controlled. Each RCM has its ownelectronic to control the mechanical and theelectrical devices. As previously said, the logicalcontrol of the sortation is managed by the SorterControl Computer.




• Sorter movement



• 1 UPS










• 32 Mb SDRAM


• 2 network cards


The level 1 of the system is comprised of RemoteControl Modules (RCM) located at the mechanical

•

•

The DS master, stand-by, UPS, and printer maybe located in the computer room.

The SC and ISC are located inside the MainSorter Cabinets.


r

K'np;4la«-. Systems

Materials Handling Products~



• Management of items information on sortercarriers and Induction Stations







• Execution of commands given by operator(Human-Machine Interface [HMI))

.~ Update of all data to the Backup Sort Controller.~


• RUN menu






• 32 Mb SDRAM


• 2 network cards


'-.-,e level 1 of the system is comprised of RemoteControl Modules (RCM) located at the mechanical

functions that are controlled. Each RCM has its ownelectronic to control the mechanical and the





• Sorter movement



• 1 UPS





• The DS master, stand-by, UPS, and printer maybe located in the computer room.

• The SC and ISC are located inside the MainSorter Cabinets.




Dispatch System

ETHERNET TCP~P

LEVEL 4

ETHERNET TCP/IP

LEVEL 3

RSCT

InterBus-S

Host

DSSTANBY

RICT

ETHERNET TCP~P

VDT II II("'00\

VDT II II(00' ,\

CUSTOMER NET

RapidVI EW2 System

8 SCANNERS

ETHERNET TCP/I SORTEC NETWORK

LEVEL 2

412199 Copyright © 1999 Mannesmann Dematic Rapistan Corp. 3645.3


System Overview

The RapidPICK2 system has been designed to be anelectronic warehouse picking system which offersincreased picking productivity and reduced errorrates. The RapidPICK2 system has been designedto be versatile, with many configurations possiblewithin the same installation. The diagram belowillustrates basic system architecture.

THE FiberLiNK PROVIDES

THE FIRST 750 mA OF

POWER TO PICKING DEVICES

TO NEXT SubCONTROLLER

ZonePANEL 3D

JL[8]8JI

I 0

EJ I2J I2J [§] 0

[§] [§] 0

P-TAP

~ II

oo

P-TAP

RP2NET CABLE

BARCODE SCANNER

~I'

\5

Fiber

LINK

SubCONTROLLER

12VAC

120V AC

TO PREVIOUS

Sub CONTROLLER OR

RapidPICK2

SystemCONTROLLER

MaxiPICK

D~I:88881 0 D

CONNECT UP TO 30 TwinPICK DEVICES

D~ 1:888810 D <;

CONNECT UP TO 50 SinglePICK DEVICESr-ooPowerSPLICE

BayCOLOR

8000054B.CGM

4/2/99 Copyright © 1999 Mannesmann Dematic Rapistan Corp. RP.3

Rapistan Conveyors

Documents

siemensdematic model

diverters41 model

dualbelt conveyors33

singlebelt conveyors37

wheeled track28 model

dualbelt conveyor82dg

singlebelt conveyors89eg

vertical lift units49