Roller conveyor buffers SCLs for a continuous packaging process

Definition of the task

A manufacturer of packaging systems requires a reliable buffering section for the feeding and discharge of small load carriers (SLCs). The empty SLCs are supplied manually and must be fed to a loading station. At the same time, the SLCs that have already been filled must be made available again at a manual removal station. Loading and removal must be able to take place independently of one another over a certain period of time.

KLTs measuring 400 x 300 mm are used. The containers weigh around 1 kg when empty and are loaded with various small parts in plastic bags. When full, the weight is approximately 15 kg.

Solution from mk

Two RBF 2000 roller conveyors, arranged in parallel, each 5,000 mm long and 420 mm wide, were used for this task. The conveyors are fitted with driven 24 V DC motor-driven rollers with a diameter of 50 mm and a pitch of 75 mm.

The empty SLCs are initially fed onto the feed section manually. At the end of the line, a 90° transfer module transfers the containers to the parallel return line. There, they are stopped at the loading position and filled with the packaged small parts from the packaging machine via an KFG-P 2000 incline conveyor. The loaded SLCs are then transported back to the starting position via the return section, where they are made available for manual removal.

To ensure zero-pressure accumulation during buffering of the SLCs, both conveying paths are divided into 13 zones each. Each zone has its own motor-driven roller and can accommodate one conveyed product at a time. If the next zone is occupied, the SLC stops automatically. As soon as the zone is clear again, transport resumes.

The two buffer sections thus decouple the manual work processes from the packaging machine, thereby enabling the loading and unloading station to operate independently for periods of time.

Occupancy detection and clearance monitoring are carried out via photoelectric sensors integrated directly into the side rails of the roller conveyors. A controller with integrated logic for up to two motor-driven rollers is used for decentralised control. Cables and the controller are aesthetically integrated into the conveyor frame.

Customer benefits

• Continuous material flow: Several SLCs can be temporarily stored as required.
• Transport without build-up of pressure: The ZPA controller prevents the containers from piling up unnecessarily.
• Decentralised controller: No complex integration into the existing machine control system is required.
• Flexible and modular: Standardised RBF-2000 modules allow for easy adaptation to different plant configurations.
• Reliable in operation: Robust construction and integrated components ensure low-maintenance material flow.

Used Products

> Roller conveyor system RBF 2000