Conveyor Systems

Different applications require different conveyor technologies:

Belt Conveyors:
Continuous belt wrapped around pulleys:
- General purpose, most versatile
- Handle packages, bulk materials, unit loads
- Flat, troughed, or cleated configurations
- Incline/decline capability with cleats
- Speed range: 20 to 400+ feet per minute

Roller Conveyors:
Series of rollers in a frame:
- Gravity Roller: Slight decline, no power required
- Powered Roller: Belt or line-shaft driven
- Motor-Driven Roller (MDR): Each roller has motor, zone control
- Best for flat-bottom loads (cartons, totes, pallets)
- Accumulation capability without pressure

Chain Conveyors:
Chains carry loads or drive rollers:
- Heavy loads (pallets, drums, large equipment)
- High-temperature and harsh environments
- Slower speeds typically
- Durable for demanding applications

Overhead Conveyors:
Utilize vertical space:
- Enclosed Track: Clean, quiet, versatile routing
- I-Beam (Trolley): Heavy loads, industrial environments
- Power and Free: Accumulation, diverting, flexible routing
- Automotive paint lines, garment handling, meat processing

Specialty Types:
- Flexible Conveyors: Expandable for truck loading
- Spiral Conveyors: Vertical elevation change, compact footprint
- Magnetic Conveyors: Ferrous metal parts, inverted applications
- Vacuum Conveyors: Thin, flat items (paper, labels)

High-speed sortation is critical for distribution centers:

Sortation Technologies:

Divert Types:
- Popup Wheel Sorter: Wheels rise to divert at angle
- Sliding Shoe Sorter: Shoes slide across belt to push items
- Tilt Tray Sorter: Trays tilt to discharge items
- Cross-Belt Sorter: Individual belt segments change direction
- Bomb Bay Sorter: Tray bottoms drop open

Performance Considerations:
- Rate (items per hour): 2,000 to 20,000+
- Accuracy: 99.5% to 99.99%
- Gentle handling for fragile items
- Gap control for varying package sizes
- Recirculation for unread items

Induction Systems:
Getting items onto sorters:
- Manual induction (operator places items)
- Automated singulation (separate items from bulk)
- Dimensioning/scanning for identification
- Gap optimization for sorter efficiency

Sortation Control:
- WCS (Warehouse Control System) integration
- Scanner/vision-based identification
- Real-time destination management
- Exception handling
- Performance monitoring

Conveyor reliability depends on proper installation and maintenance:

Installation Best Practices:
- Level and align frame precisely
- Proper belt tracking from initial tensioning
- Motor alignment with drive components
- Electrical connections per codes
- Guard all pinch points
- Test all safety devices

Preventive Maintenance:
Regular tasks prevent failures:
- Belt/chain tension and tracking adjustment
- Roller/bearing lubrication
- Motor and gearbox oil levels
- Sprocket/pulley wear inspection
- Clean sensors and photoeyes
- Inspect guards and safety devices

Common Issues and Solutions:

Belt Tracking:
- Check frame alignment
- Verify pulley parallelism
- Adjust tracking idlers
- Inspect for belt damage

Roller Failure:
- Listen for bearing noise
- Check for seized rollers
- Verify load distribution
- Replace worn bearings/rollers

Motor Issues:
- Check electrical connections
- Monitor temperature
- Verify gear oil condition
- Listen for unusual sounds

Sensor Problems:
- Clean lenses regularly
- Check alignment
- Verify wiring connections
- Replace failing units

Safety Considerations:
- Lockout/tagout procedures
- Guard all moving parts
- Emergency stop placement
- Training for all personnel
- Regular safety audits

Conveyor expertise supports multiple career directions:

Maintenance Roles:

Conveyor Technician:
- Troubleshoot and repair systems
- Perform preventive maintenance
- Emergency response
- $45,000-$65,000

Maintenance Supervisor:
- Lead maintenance team
- Schedule and prioritize work
- Parts inventory management
- $60,000-$85,000

Engineering Roles:

Application Engineer:
- Design conveyor layouts
- Select appropriate equipment
- Customer interface
- $65,000-$95,000

Project Engineer:
- Manage installations
- Coordinate with contractors
- System commissioning
- $70,000-$100,000

Controls Engineer:
- Program PLCs for conveyor control
- Integrate with WCS/WMS
- Optimize system performance
- $75,000-$110,000

Industries:
- Distribution and fulfillment centers
- Manufacturing plants
- Airports (baggage handling)
- Postal/parcel carriers
- Food processing
- Mining and aggregate

Skills Development:
- Mechanical maintenance fundamentals
- Electrical troubleshooting
- PLC basics for controls understanding
- Conveyor-specific training (vendor certifications)
- Safety training (OSHA, ANSI standards)

Career Progression:
Entry-level technician → Lead technician → Supervisor → Maintenance manager
or
Technician → Application engineer → Project manager → Operations director

Conveyor knowledge provides foundation for broader material handling and automation careers.