Vacuum conveyor for higher production volume
Task
Preventing production downtime with a conveyor solution
An adhesive technology manufacturer wants to significantly increase the productivity of its cutting machines for adhesive films. Currently the cutting machines must be switched off when employees enter the danger zone to replace filled storage boxes that collect the cut films. The engineers therefore sought a conveyor system that would automatically remove the stickers from the danger zone, eliminating the need for employees to enter the zone. mk came up with the perfect solution.
Solution from mk
Timing belt conveyor with vacuum function transports films out of the danger zone
The experts at mk have designed a 2,000-mm long ZRF-P 2000 timing belt conveyor with a protruding infeed end that extends 800 mm into the danger zone. It boasts one special feature, vacuum chambers in the conveyor frame. A special hole pattern in the conveyor belt and the negative pressure generated in the conveyor frame suck the films onto the conveyor belt. The conveyor is divided into three zones in the direction of travel. In the first zone, or receiving zone, the products are sucked in and transported out of the cutting machine while suspended. Zones two and three are located outside of the danger zone. Here, a compressed air pulse is activated so that the stickers fall into the corresponding storage boxes under the conveyor belt. Employees can safely replace the boxes without interrupting production.
Another advantage is that the ZRF-P 2000 operates particularly quietly. mk has divided the vacuum zone into nine separate chambers – three longitudinal and three transverse. Sensors detect the position of the films and switch the individual zones on and off. Thanks to this zone control, there is no longer a need to operate one single large vacuum area, constantly drawing air through all the holes in the belt. This allows the vacuum system to be operated more effectively, with reduced power, lower energy consumption and lower noise emissions.
The adhesive film manufacturer also benefits from the flexibility of the ZRF-P 2000. The conveyor's lightweight aluminium frame is mounted on castors, allowing employees to easily position the system next to other cutting machines as needed. The profile system allows the conveyor height to be continuously adjusted in just a few steps for a smooth connection. The vacuum area can also be flexibly adapted to different production lines. If the films leave a cutting machine in two lanes, the vacuum is only created in the two middle perforated tracks of the conveyor. The two outer tracks can be switched on when the cutting machine outputs the adhesive film in four lanes.
Since this is a pilot system for testing various application scenarios, the vacuum operation was initially controlled manually. During the test phase, the conveyor's cycle paths are measured, among other things. These can be precisely determined using a timing belt conveyor. To activate further optional chambers, blind plugs for additional connections were also provided to the rear of the conveyor.
Benefits for the customer
- Uninterrupted operation increases system availability: Thanks to automation, the cutting machine can run continuously
- Rapid return on investment: Increased productivity quickly amortises the investment costs
- Flexibility: The timing belt conveyor is mobile and can be easily adapted to different cutting machines in terms of height and performance
Products used
> ZRF-P 2000 AF timing belt conveyor with vacuum function
> Option with a belt conveyor is also available
