OverviewAutomated Conveyor Systems In partnering with Smock Material Handling, a long time customer needed a large material handling system to help them meet demand while reducing cost. This system was broken down into zones and sub-divided into station. Smock supplied a system that utilized time proven technologies and the latest cutting edge technologies to provide a system that will last and meet the demands of the future. This system consists of a load station, runs of straight conveyor, 90 & 180 degree rollovers, turntables, gates, and a main control panel for each zone. An operator control station with pushbuttons and indicator beacons is located at each station. These custom designed and fabricated components are made with structural steel channel, steel platens, heavy duty rollers, heavy gage guards with guide wheels and stainless steel wear strips and heavy duty adjustable feet. The control system consists of powerful and flexible PLC's that utilize distributed processing as well as digital I/O modules and communication modules. Touchscreen HMI's, heavy duty DC power supplies, managed Ethernet switches, variable frequency drives utilizing DeviceNet communication, programmable laser safety scanners, photoeyes and proximity sensors were also used. Additionally, the customer supplied PC's, monitors and keyboards that were integrated into the system.
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 load station The Load Station consists of a fabricated steel base frame with chain driven powered steel rollers. A brake motor, controlled by a variable frequency drive, controls the powered chain driven rollers. The steel rollers have a molded polyurethane coating to protect the load. Stainless steel set-down guides are attached to each side of the conveyor to assist the operators when loading. A steel drip pan is bolted to the conveyor frame under the rollers to catch any dripping fluids from the load. An Operator control station is provided for automatic and manual control. Proximity sensors control the positioning and the advancement of load as well as determine the load size.
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180 deg rollover The Block Rollover consists of a fabricated steel drum inside a steel base structure frame. The rollover drum is cut-out on each end to match the load profile. The rollover rotates 180 degrees using chains powered by an electric brake motor controlled by a variable frequency drive. The rollover drum has a top and bottom level of reversing chain driven roller conveyors powered by electric brake motors. The powered rollers have a polyurethane coating to eliminate slipping of the load. To guide the load as it transfers in and out of the rollover, gravity steel wheels are installed on each inner side of the rollover drum. Photo eyes control the advancement of the load as well as monitoring the ends of the Rollover for obstructions. A Safety Fence surrounds the Block Rollover to protect operators and personnel.
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 turntable The Robot Cell Turntable consists of a fabricated steel base frame and a fabricated steel conveyor deck. The conveyor deck has an internally geared bearing and pinion gear that allow it to rotate up to 180 degrees. Two motors are attached to the conveyor frame. One brake motor, controlled by a variable frequency drive, is used to control the turntable rotation. Another brake motor controls the powered chain driven rollers on the conveyor deck. A Pneumatic cylinder with flow controls is installed to control the turntable lock. A steel drip pan is bolted to the conveyor frame under the rollers to catch any dripping fluids from the load. Proximity sensors control the positioning of the turntable and Photo eyes control the advancement of each block on the conveyor. Photo eyes also monitor the ends of the turntable conveyor deck for obstructions. A hard wired interface cable provides the interlock signals necessary for other operations. An Operator control station is provided for automatic and manual control. A Safety Fence surrounds the Robot Cell Turntable to protect operators and personnel.
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 gate The Gate consists of fabricated steel frame with a gravity urethane coated roller. An electric cylinder controls the gate motion. An electric brake motor controlled by a variable frequency drive, powers the electric cylinder. The Gate pivots on a steel pivot pin. A steel drip pan is bolted to the lift gate frame under the roller to catch any dripping fluids from the load. An Operator control station is provided on each side of the Gate for automatic and manual control. Proximity sensors monitor the position of the Gate. A Safety Scanner monitors the hazardous area before allowing Gate motion.
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 straight run conveyor The Straight Run Conveyor consists of separate fabricated steel base frames bolted together to form separate stations. Each conveyor station includes chain driven powered steel rollers with molded a polyurethane coating. A brake motor, controlled by a variable frequency drive, controls the powered chain driven rollers. A steel drip pan is bolted to the conveyor frame under the rollers to catch any dripping fluids from the load. Photo-eyes control the positioning and the advancement of the load as well as determine the load size. A safety fence surrounds a portion of the conveyor that interacts with the automated machinery to protect operators and personnel.
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 main control panel The control logic and components are provided through the main control panel. A Beacon stack is mounted to the top of the enclosure to alert the operators of system faults and system mode status. An operator interface HMI terminal and programming shelf is mounted to the front of the enclosure. An Ethernet programming port and computer power outlet is also mounted to side of the control panel.
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  operator control station The Operator Control Stations are positioned near the conveyors for easy access and include pushbuttons for manual and automatic mode operation and an emergency stop pushbutton. A beacon tower is also located on top of the Operator stations to alert operators of various conditions.
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