Tech Library

Design a Conveyor

Basic System Chain Selection

FlexMove provides a wide selection of chain sizes to cover a wide variety of product sizes and shapes. The following selection criteria will help you select the right chain size for your application.

Product Dimensions
A product can be wider than conveyor chain in two or three times the width of the chain as long as the center of gravity of product falls within the chain width. Extra supporting guide rails are required and testing are recommended.

Product Weight
Product weight is important in chain selection as each chain has its maximum traction force. Traction force calculation is required when there are several heavy products to be conveyed, and the traction force will be increased further if the products are accumulated on the conveyor.

Conveyor Functions Available
Most of the conveyor functions are available in all the FlexMove conveyor series. However there are differences with regard to the chain types, drive unit and idler unit variants. Selection of drive type is important as different drives have different traction forces.

Technical Calculation
It is important to calculate total load on conveyor based on product weight, distance between products, accumulation distance and conveyor length of the system. The frequency of start /stop, chain tension and service factor are important. If the calculated capacity is higher than the selected drive and chain series, the conveyor should be shorten or select system with high capacity.

Floor Space Available
Consideration of floor space available and utilization of smallest foot print for conveyor layout.

Compatibility With Other Machines
In certain applications, interfacing and integrating with other automation equipment can be made much easier by using FlexMove Conveyor system sizes rather than other sizes.

Standard Plain Chain
Friction Top Chain
Conductive Chain
Stainless Steel Top Chain

Conveyor Frame Product Overview & Selection

Intermediate Drive Unit
An intermediate drive is best utilized when space restriction prohibits the placement of the end drive unit. It required two idler end units at each end. The gear motor can be coupled directly or suspended underneath the drive unit at both right and left orientation. Adjustable torque limiter can be added to protect the conveyor system. The traction force is lower than other end drive units due to less engagement between drive sprocket and chain.

Catenary Drive Unit
Catenary Drives are designed to accommodate top-running chains. Commonly used in application of single loop or alpine conveyor system. Additional idler end unit is not required. Only suspended version is available.

Combined Drive and Idler Unit
A combined drive and idler consist of one end drive and one idler end unit mounted in a single assembly with transfer bridge for smooth transfer of products. It has a smaller footprint compared to side transfer design. Available in both direct and suspended drive versions, the gear motor can be coupled at both left and right orientation. Adjustable torque limiter can be added to protect the conveyor system.

Wheel Drive Unit
Wheel drive suits for the application of using single loop or alpine conveyor system without return chain. Both direct and suspended drive version are available with the gear motor mounted underneath. The traction force is lower than other end drive units as the gear wheel engages the side of the chain.

Idler End

Idler End Unit

The function of idler end is to change the direction of the moving chain. Available in both standard idler end unit (180º) and idler bend unit (90º), it comes with 2pc connecting strips at the connection end.

Idler End Unit (standard 180º) – The moving chain is transfered 180° from bottom of conveyor beam to the top through flange guide with minimal friction.

Idler Bend Unit (90º) – The idler bend unit converts and changes the chain direction in 90º perpendicular to incoming chain direction.

Bends

Bends are used to change the direction of chain movement of conveyors. There are 3 types of bends available as follow:

Wheel bends  – Designed with top and bottom wheels that rotate freely with the chain and are supported by a dual sealed ball bearing, it has the lowest friction, minimum bend force and smallest turning radius compared to other types of bends. Besides standard 30°, 45°, 60°, 90° and 180° configurations, special angle is also available upon request. Select a horizontal wheel bends whenever is possible.

Horizontal Bends – An alternative to wheel bends, horizontal bends are useful in conditions requiring large space, long products with large turning radius and twin – track bends applications. It has higher friction compare to wheel bend. Larger radius is recommended for lower friction and stress on slide rail.

Vertical Bends – A vertical bend provides vertical change of conveyor moving direction. It can be used either as convex or concave bends. Vertical bends increase the tension in the chain and cause higher stress on the slide rail. Avoid using more than four 90° vertical bends in one conveyor.

Wheel Bend Corner 180°
Horizontal Plain Bend 180°

Slide Rail

A slide rail provides low friction and wear resistance track for chain to slide on. It is mounted to a conveyor beam via screw or rivet. Various types of slide rails are available that cater to different requirements like normal operation, high speed, high load, conductive and accumulation applications.

Conveyor Beams

Conveyor beams are made of anodized aluminium extrusion that comes in standard length of 3 meter section. T-slot flexibly allow drives, idlers, bends, guide rail bracket, leg support and other accessories to be connected using connecting strips or bolts and nuts. Aluminium extrusion has advantages of high strength and light weight. 2 connecting strips are required for joining.

Conveyor Beam
Slide Rail
Guide Rail

Guide Rail Assembly System

Guide rail components are used to guide and contain products throughout the conveyor system and prevent them from falling off the conveyor. FlexMove® provides a comprehensive range of guide rails, covers and brackets either fixed or adjustable to cover many specialized product sizes and shapes.

Structural System

FlexMove structural support system consists of support beams, support brackets, foots and end caps that are interconnected to form robust support structure for every conveying need.

Conveyors Accessories, Gearmotors, & Stands

FlexMove offers a wide selection of conveyor accessories, gearmotor options and stands.

Accessories include special bolt & nuts, brackets, connecting strips, rivets, rollers, T-slot cover to washers for inter-connection between modules and components.

For more information on options and capability please refer to the product manual.

Gearmotor

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