Conveyor Manufacturer - OEM
Conveyors, as Roller conveyors and Belt conveyors, are constructed based on long term experience and tradition. Nevertheless these constructions often create unnecessary time to build and install, as well as cause problems for the operator in terms of safety and maintenance, modifications, spare parts and know how. Here we will discuss some points, compared with normal construction and show the solutions with avancon:
NEW: Different admospheres
Problem: Conveyor rollers made of Polymer materials can expand in size, between -10 °C (in Alaska) and +40° C (in Panama) or in a very dry room (in Arabia) or near by the sea (in Amsterdam). Therefore avancon rollers got a play of 2 to 3 mm on the spindle, depending on the length of the roller. This could lead to an unsightly appearance if there was a gap between the roller bodies.
Solution: avancon now puts a special bushing / tube of ca. 15 mm length on the spindle, which is elastic. (Instead of a hard tube) This compensates for expansion in different atmospheres and temperatures, so that the avancon rollers always work without play on the spindle. Although this is more of an aesthetic effect, it looks better, feels better and reduces noise. (See Rollers)
NEW: OTU
Problem: It may happen that the tolerances of an avancon OTU line in a seldom case/application or in different admospheres (cold:hot, dry:humid) expands some 10th of a millimeter, which can in a worst case - when accumulate - create a “banana effect”. In very seldom cases, where the convveyor width is tight to the good to be transported, it can cause a conveyed item to tilt or jam.
Solution: avancon has several solutions for that:
1) It is possible to overcome this by modifying the software (of a PLC-control or the software of the OTU line) so that the turning point of the
OTUs in a table is moved a few milliseconds later and further and the transfer or diverter avoid that the item touches a frame. construction.
2) We can put the OTU line into an aluminum profile, which holds the OTU line tight and close, so that the single OTU elements can’t move or
bend in a “banana effect”. (See OTU) This is more expensive.)
NEW: Break of polymere parts
Problem: The High Tech Polymere Materials used by avancon generally don’t break. They do noever break in the foreseen applications. - But if you program the system in a way, that goods or items push against a frame or against each other, peaces may break or wear at the time.
Solution: Never let goods touch each other or crash against a side frame. When you program your installaton with PLC, please stop softly before other items or the frame construction.
If you do, it’s the same effect as when you would drive your car against a wall !!! - You would never do this!
Gravity roller conveyor
Problem: The assembly of the basic design of a roller conveyor takes too long time and is therefore expensive. Rollers are fixed into the frame construction by whether using spring loaded spindles or screws to fix the spindles.
Spring loaded spindles, hexagonal are noisy and wear the holes in the frames.
Solution: avancon uses different rollers generally where the spindle rotates in the external bearings. These bearings are snapped into a bearing housing, which is also snapped into the patented rips of the frames. This is possible without any tools or automated.The spindles are simply secured with circlip rings. This is very fast and maintenance friendly.
Powered roller conveyor, or live-roller conveyor
Problem: Because the drive systems are driven from roller to roller with O-rings, timing belts or with chain or small, long belts underneace for long line and visible from outside, the assembly - and especially a replacement - takes more time to install each roller into the frame and the long drive with a big motor can only be assembled as a whole thing.
Any roller must be finger-protected and so the assembly is more complicated and time consuming and expensive to Build.
Solution: avancon instead divides the conveyor systems into zones. Each zone has its own BLDC Motor and its own control with a light barrier. These control boxes are hidden inside the closed frames..
So, each zones controls everything in itself, but communicates with the other zones. Generally the whole system is autonomous and uses as standard zero pressure accumulation, which is safer than other systems. It is very fast and maintenance friendly.
Conveyor Rollers
Problem: There are rollers with steel tube or plastic (PVC) tube or rollers with rubber or soft-PVC slaves on the market.
These rollers are available in different diameters to be used in relation to the length of the smallest goods to be transported. Depending on the width of the goods these rollers have to be made or purchased in the required length. In addition there are tapered rollers required for curves, also in different diameters and length.
Solution: avancon has simply only one roller corpus made of special Polyamide or with tires of Polyurethane. Always 50 mm diameter and 30/33 mm wide. These corpuses turn fix or loose on the special spindle (see rollers).
This special patented roller type can be used for all kind of roller conveyors, gravity roller conveyors, powered (live) roller conveyors, low pressure accumulation conveyors, zero pressure accumulation roller conveyors, roller conveyor curves and for incline and decline conveyors (instead of expensive belt conveyor).
There is only one roller diameter of 50 mm necessary for trasporting all kind and sizes of goods!
How simple!! - How easy!! - How flexible!! - avancon never uses PVC which is very toxic in case of fire,
Cables, wires and control. Big savings!
Problem: So far all systems have to be wired, to each motor and to each sensor and to each internal drive (or drive roller). In many cases this has to be done at site, where miles of cables are laid into cable channels to a central control cabinet, where also a PLC is installed and a gateway for all communication.
This is very cost consuming (min. 30% of the total installation) and uses much time.
Solution: avancon offers much simpler and patented solution. All elements, including the cables, which are just snapped into preformed rips inside the frame without tools (manually or semi automated). This reducess the assembly time and cost by half, because hourly cost in-house are generally half as costly as on the construction site.
In addition, a central control cabinet is unnecessary, cable channels are unnecessary! So, min. 30% of the systems investment cost is saved!
Motor and power supply. High Energy savings.
Problem: Normally any conveyor line of 5 to 10 m has a big motor to drive the powered rollers or a belt in a conveyor systems. These motors are mostly AC motors of 400 to 1000 Watt.
They run all the time. Only in a low peak time, when nothing has to be transported, they switch off after some time.
Generally this uses enormous energy for nothing.
Solution: avancon saves instead between 30% up to 84% energy, because all conveyors (roller. conveyors and belt conveyors) work in Zones and only these zones which have in this moment something to transport, use energy, but only 2 x 40 Watt per Zone. (see Power Supply)
The DC power is supplied by a invisible power supply which is used to drive up to 12 motors with 48 V DC and up to 100 control units with 30.5 V DC, and this with simultaneous data transfer. Easy and efficient. (See Energy)
Clean and Maintenance friendly
Problems: Generally conveyors shall be maintained and cleaned regularly, as any other machines.
Most conveyor systems are built of pre-punched profiles, where over time, dust and dirt settle in the open holes in the frame and stands, making them difficult to clean. Even maintenance, as exchange of a roller or a control unit, is more difficult when dirty.
Solutions: avancon’s design is all closed without any holes and inside the clodes frames. Dirt will not easily enter. Whith closed frames it is IP 53 protected. It looks outside clean and streamlined and feels like silk. Therefore operators are save when walking alongside the conveyors. Here are no pin-points.
Any maintenance or change of a unit is simple and very fast.
Security, hazard elimination
Problem: Most conveyors have external housings or motors or fasteners or screw heads or retaining bars for the guides etc.. All of these elements are unsafe for operators and people working on a conveyor. Therefore, the purchaser of such systems must also invest in an external safety fence to protect people from injury.
Solution: avancon's design is clean, sleek and fully enclosed, which also applies to the legs. There are no boxes or cables or attachments outside the conveyor frame. This increases safety enormously. The drives of the rollers and belts are also not visible from the outside. Finger protection is not necessary. In extreme cases where many people have to pass through the conveyor belts, e.g. in airports, we offer a roller pitch of 40 mm, which results in distances of only 2 mm from roller to roller.
In addition there is only low voltare (30,5 V and 48 V DC), which secures the elettrical part.
Maintenance, Spare parts
Problem: For a regular maintenance of all conveyors a regular control by a service person and eventual replacement of parts is inevitable. Therefore it is necessary to keep sufficient spare-parts in stock in order to avoid prolonged system downtime.
Solution: avancon uses less standardized parts for all their conveyor systems. Therefore much less spare parts need to be stored as with other conveyor systems. - Everything, the frames, the conveyor rollers, the legs/ (stands) can be easily cleaned with commercially cleaning liquids.
Lifecyle
Problem: Conventional conveyors wear and tear after several years in operation. Zinc plated rollers start getting black or rusty partly, where containers always run. Plastic tubes get dirty and wear on the sides, where containers touch the rollers. Frame construction get dust and dirt inside the frames and electronic controls have to be updated from time to time.
Solutions: avancon conveyors last longer. They are nice, clean and will feel always as silk. The roller corpuses are made of solid gray polyamide through and through. The grey color bleat. They are highly abrasion-resistant and glide easily and remain as they are.
Flexibility
Problem: Conventional conveyors are made fix for the goods you required. They can be prolonged or with additional modules modified. To replace or modify a diverter or a transfer is a nightmare, because it is heavy, bulky an may be it needs even pneumatics (tube and valeves)
Solution: avancon conveyors can be modified simple and fast with omnidirectional transfer tables. These exist of OTU lines and a special low aluminum basic frame, which allows, to put it into any position of the conveyor or ad additional OTU tables everywhere, as transfer, or as diverter, or corner, or even as sortation system.
Modularity, easiness
Problem: Also conventional older designed conveyors can be modified or enlarged. But may be more complicated and more expensive.
Solution: avancon conveyors are equipped with fast connection features (see platform) it connects the electronics, the cables, the legs and the frames - all in one snap!
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