Tag: automation|conveyors|materials handling

Megadyne, a recognised leader in the world of power transmission solutions for logistics, has introduced what it describes as a new game changer – Megadyne Rollpower. This recent development is a high-performance elastic ribbed rubber belt that requires less maintenance than standard options and offers savings on energy consumption.

The logistics industry has been calling for an innovation, because today, more than ever, the warehouses and distribution centres are under the pressure of time. They are required to run longer and at higher speeds without sacrificing the precision and efficiency of performance.

The Megadyne Research and Development Centre has recognised these needs and proposed a matched solution Rollpower, which is designed with an extra-strong elastic polyamide cord tension members for greater flexibility and extended belt life. Rollpower eliminates the need for frequent replacements, and its antistatic qualities prevent the accumulation of dust and dissipated electrostatic charges. The wide working temperatures, from -40°C to 120°C, make it operable in a variety of working conditions.

Though Rollpower has been originally developed with logistics applications in mind (including receiving lines, order picking, sortation, transfers and diverters), it may also be a suitable match for the world of domestic appliances and fitness.

What Are the Benefits?

Rollpower means improved efficiency. It provides stable tension, together with smooth, reliable and quiet running. Because of the resistance to wear, aging and abrasion, the life of the belt is extended. This, in turn, translates into cost savings. The belt can reduce energy requirements by up to 5%.

The installation is fast and easy. Rollpower is able to run even 50 rollers together. There is no need to use idlers or tensioners. No slippage occurs because of the precision of rib design and accumulated sidewall friction.

This innovative solution requires also less maintenance. The process of replacement and installation is simple, and the line downtime is significantly reduced.

E-commerce is booming and so is warehouse automation. Flexible warehouse systems are also in demand in large grocery chain warehouses, and require environmentally friendly, sustainable and intelligent drive concepts. Drive specialist is highly familiar with the industry’s requirements and offers a variety of dynamic drive solutions which are suited for various applications and requirements in warehouse logistics.

Nord offers customised drive solutions for warehouse logistics for an optimum compromise between investment, operating and maintenance costs. With motor efficiency class IE4 and system efficiency class IES2, the drive units achieve excellent efficiencies – especially in the partial load and speed range. The latest generation IE5 permanent magnet synchronous motors achieve an even higher energy efficiency and significantly reduces the energy consumption. The constant torque over a wide speed range allows for a targeted version reduction. This minimises administrative expenses, and enables leaner manufacturing, logistics, storage and service processes.

NORDAC ON frequency inverter

The decentralised NORDAC ON frequency inverter has been developed for horizontal conveyor technology requirements in warehousing, and the NORDAC ON+ variant for interaction with the new IE5+ synchronous motor. It is characterised by an integrated Ethernet interface, its ease of maintenance through complete pluggability and an extremely compact design – providing an economical and intelligent plug-and-play solution for IIoT environments.

The compact, smart frequency inverter for decentralised use can be mounted directly on the geared motor. It covers lower power ranges of up to 2.2kW and has an energy-saving function in the partial load range. The integrated Ethernet interface reduces the effort for integration into modern automation systems: Whether for ProfiNet, EtherNet/IP or EtherCAT, the required protocol can be easily set via parameters.

Efficiency in conveyor technology

The NORDAC FLEX SK 205E series is also ideally suited for applications in warehouse logistics. The compact, decentralised and energy-efficient frequency inverter offers a wide power range of up to 22 kW and enables energy savings over the entire load range. The inverter can be used to control standard asynchronous motors, high-efficiency synchronous motors and brake motors. It can be installed close to the drive in the field or motor-mounted.

Power and data cable connections are available as plug-in versions. The decentralised system enables short motor and encoder cables as well as short supply cables to sensors. Encoder feedback can be included, for example, for position-controlled transport systems. The large overload capacity of the NORDAC FLEX SK 205E makes dynamic movements with short start and stop times or cyclic operation possible. The integrated POSICON control enables high precision in synchronous and positioning applications.

Overall, Nord convinces with a wide range of products in the field of warehousing, including both established basics and high-efficiency products. Users benefit from tailored and reliable drive solutions which ensure an optimum system availability. The Nord modular drive system thus enables an optimum compromise between investment, operating and maintenance costs.

 

 

The fewer interfaces, the higher the system efficiency – based on this maxim, NORD DRIVESYSTEMS has introduced a revolutionary geared motor in a hygienic wash-down design one year ago, where the especially energy-efficient IE5+ permanent magnet synchronous motor and a single-stage helical gear unit are installed in one single housing.

The completely new, compact design with full integration of motor and gear unit in one single housing is described by NORD as an extraordinary leap in the development of geared motors and has now been successfully patented. The long-term durability and reliability of the innovative solution in terms of design and materials has been successfully proven in months of testing during the development of the DuoDrive, and thus real pioneering work has been accomplished in the field of geared motors.

The integration has been decisively advanced to achieve an optimal utilisation of installation space. Along with the IE5+ motor on which it is based, the encoder, speed feedback and brake are all safely accommodated in the housing.

Excellent system efficiency

As a system, the very compact DuoDrive concept achieves a significantly higher energy efficiency than the already proven drive systems with IE5+ synchronous motor and bevel gear unit, says NORD. At up to 92%, DuoDrive currently offers the highest system efficiency on the market in this power class, and achieves very high efficiency in the partial load range. It is thus future-proof and a real cost reducer.

The constant motor torque over a wide speed range allows for consistent version reduction and reduction of operating costs. Market-compatible connection dimensions facilitate the replacement and the integration into existing plant designs.

The first available DuoDrive size covers gear unit speed ratios of i = 3.24 to i = 16.2 and is designed for output torque ranges of up to 80Nm and speeds of up to 1,000rpm. In addition to the high system efficiency, the smooth, unventilated and compact design, and the quiet running with minimum noise emissions are further important features of the new DuoDrive geared motor. Elimination of many wearing parts results in lower maintenance.

 

Wachendorff Automation, the encoder and measurement systems manufacturer, has launched a new variant of its well-proven industrial grade rotary encoders that feature a freely definable pulse count.

The new WDGP series, available in the UK from Variohm EuroSensor, offers any number of output pulses from 1 to 16,384 PPR as TTL or HTL quadrature A and B channels, plus a freely configurable zero pulse (N). Utilising IP67 protection class stainless-steel housings in a choice of 36mm and 58mm diameters with industry-standard mounting options, these high accuracy incremental encoders are based on a patented magnetic sensor technology that offers durability and extremely high resistance to shock, vibration and undesirable shaft loading.

With its freely definable pulse count, Wachendorff’s new WDGP series encoder offers users a convenient alternative against standard output options that may lead to more complex control electronics or software calculation. Application flexibility is also aided with an input power requirement from 4.75-32V DC, which is reverse polarity and short circuit protected. The maximum pulse frequency is 600kHz for the HTL version whilst the TTL option offers 1MHz. The HTL variant also offers inverted output signals.

The 36mm diameter model is available with a choice of servo flange, round flange, and screw flange mountings – a special servo flange version includes IP67 + IP69K protection rating for use in high pressure washdown/steam cleaning applications. A version with an elevated radial and axial shaft loading to 300N is also offered. The 58mm diameter model is currently available with servo flange or clamping flange options. Both sizes offer a choice of shaft diameters; a custom design service can be made available for OEM applications.

The new WDGP encoder is based on the same robust and durable mechanical design used across Wachendorff’s wide range of rotary encoders. Generous axial and radial shaft loading and a wide operating temperature range of -40 °C to +85 °C combine for durability, high reliability, and long life for the most extreme rotary position feedback tasks in heavy engineering, off road vehicles, agricultural machinery and more.

Variohm EuroSensor is a longstanding UK distribution partner for Wachendorff, providing complete sales and service across the German manufacturer’s comprehensive range of rotary encoders, position measurement and counting systems.

Interroll has received a large order for delivery to a South Korean e-commerce company. It comprises the delivery of Interroll’s Modular Conveyor Platform (MCP), which is designed for highly efficient and flexible material-flow processes. The contract amounts to a lower double-digit million Swiss franc figure.

The new order comes after Interroll received other large orders from the same customer in 2018 and 2019 as well as a previous first and smaller order in 2017.

Based on the customer’s specifications, Interroll will deliver a complete conveyor platform that includes Interroll MCP modules, high-performance diverters, belt conveyors and transfers as well as roller conveyors and belt curve spiral lifts. The solution covers a total length of 4.8km of conveyor technology at one of the customer’s distribution centres in South Korea. The project is scheduled to be completed by the end of June 2022.

“The installation will support the further continuous growth of this successful customer,” says Dr. Ben Xia, Interroll Executive Vice President and Head of Operations Asia. “We are proud to continue contributing to the productivity of their distribution centres with our proven material-handling solutions.”

Interroll and Toyota Material Handling have installed a powerful and efficient conveyor system for Imnasa in Campllong near Girona, Spain. Core components of the new material-handling solution are the Modular Conveyor Platform (MCP), the RollerDrive EC 5000 and the MultiControl from Interroll.

The state-of-the-art system, which spans around 360m, automates the flow of goods between two buildings, increases productivity, and improves customer service as well as the working environment of the personnel deployed.

The automated conveyor system for Imnasa was fully designed and installed by Toyota Material Handling. Imnasa manufactures and distributes nautical equipment from numerous brand manufacturers to businesses and private customers. With a range of over 30,000 different products, it is one of the leading players in its sector in Europe.

The starting point for the new solution was the construction of a new building complex of 9,000 sq m expanding the capacity of Imnasa’s distribution centre. To seamlessly integrate the different work processes within the already existing and new buildings, the two sites were connected by a 360m-long conveyor system in a tunnel. Using a zero-pressure-accumulation material-handling solution, the diverse goods are thereby automatically routed between the picking area in the existing building via the respective packing stations to the shipment area in the new building.

“The new solution has not only enabled us to significantly increase the capacity and productivity of our distribution centre. We have also succeeded in further increasing customer satisfaction through faster and more reliable deliveries. In addition, the new solution now offers our employees significantly improved work ergonomics,” explains Pol Revuelta, Project Manager at Imnasa.

A total of around 250 EC 5000 RollerDrive and 120 MultiControl from Interroll are used for the energy-saving transport of boxes and totes via driven roller and belt conveyors.

Beiersdorf AG is relying on the expertise of STILL for the design and implementation of the production and warehouse supply of its state-of-the-art production centre for cosmetic products in Seehausen near Leipzig.

This is the first major joint project for the two long-standing Hamburg-based companies. In a six-month selection process, the STILL automation experts impressed the jury with their extensive experience in internal logistics and in-depth expertise in the automation of logistics processes. STILL also brought KION’s sister company Dematic on board. As part of this project, Dematic is supplying a conveyor system for pallets that links all subsystems together.

“I think that in addition to our technical concept, we were able to impress above all with our solution-oriented approach and the constructive teamwork with the customer and his planning partner,” says Florian Kratzer, International Key Account Manager Automated Solutions.

This is also confirmed by Beiersdorf’s logistics team: “Right from the start, the communication was open, appreciative and very results-oriented. The team repeatedly presented us with alternative approaches and made competent suggestions during the planning process. This eye-to-eye exchange and the excellent consulting services were key factors in our decision to choose STILL as a partner. We are very much looking forward to working with them in the future.”

The new facility near Leipzig is one of Beiersdorf’s largest investment projects in Europe. In order to make the plant sustainably fit for the future, the production supply processes are to be integrated according to the latest standards of efficient warehouse organisation. Here, automation in particular is of decisive importance.

For where driverless transport systems interact perfectly with each other, with manually operated equipment and intelligent warehouse elements to ensure a flawless flow of materials, productivity can be increased, processes optimised, costs reduced and capacities increased.

“Projects of this dimension are not commonplace in Germany. They offer specialists like us an outstanding opportunity to contribute their entire spectrum of know-how,” explains Florian Kratzer. “We are all the more pleased to be a partner in this innovative project at a structurally important location like Leipzig.”

Specifically, it is about goods receiving, quality control, internal transport and storage of incoming materials. The next step is to make them available and transport them on to production. For this purpose, STILL has designed an integrated system in close cooperation with Beiersdorf.

For goods receipt and dispatch, manual STILL electric forklift trucks and warehouse technology equipment are used. Conveyor technology from the group’s sister company Dematic provides the link between the goods-in area and the narrow-aisle warehouse, where six fully automated STILL MX-X iGo systems very narrow-aisle trucks are in operation.

In addition, the conveyor system ensures onward transport from the narrow-aisle warehouse to production, where six STILL EXV iGo systems high lift stackers take over the goods. These provide fully automated transport to Beiersdorf’s production facilities.

“The special challenges of the project arise from its volume and the resulting complexity,” explains Florian Kratzer. “We have heavy loads in different dimensions, high racks and long distances that have to be covered quickly and safely.” Thus, around 140m of conveyor technology are installed and about 25 manual and automated vehicles are used. A large number of different load carriers weighing up to 1,250kg each had to be taken into account and a storage height of up to 12.7m in the fully automated VNA narrow-aisle warehouse had to be made possible.