combined with demanding requirements

The conveyance of light loads is commonly

combined with demanding requirements

in terms of functionality and frequency which

can only be met with the seamless integration

of each and every component of the system.

Mecalux offers a conveyor system which is

scalable to the needs of its users and

adjustable for growth.

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Roller conveyorsBelt conveyorsMixed roller and belt transferSwitch and exit/entrance

conveyorConveyor transfer carriageLifts stationsP&D stationsSpecial systems

Technical characteristics

Driving system of conveyorOperation system� Drive roller� Chain� Toothed belts� Belt conveyor� Drive shaft and chainType of driveConveying elements� Rollers� Belts� Elastomeric beltsMorfologi of conveyor

systems

Goods to be handle

Handled unitWorking conditions

INDEX 76 84

90

74 Conveyor Systems for Boxes

A continuous conveyor system for boxesoffers numerous benefits including:

� Reliability. The components which form the conveyors are systems with a proven track record and a very high level of reliability.

� Low maintenance. The compactdesign of all the conveyors enablesmaintenance work to be easilycarried out.

� Low operational cost. The efficacyoffered by these systems in the working environment has a verypositive effect on the return oninvestment of the whole of theinstallation.

� Scalability. There are many differentpossible configurations of thecomponents involved. Any of thecomponents of the installation can be reused orexpanded.

� Durability. the robust system isdesigned to withstand daily work at a high performance level.

� Ergonomics. The system features allthe ergonomic guidelines, facilitatinginteractions of the machine with theoperator. It also simplifies themaintenance work in the installation.

Transport unitsThe box transport systems developedby Mecalux accept several types ofunits and transport bases:

Materials

� Cardboard� Plastic

In addition to adapting to different sizeboxes according to the application

� Boxes with standardizedmeasurements (Euroboxes). Mecaluxfeatures a wide range of plasticcontainer types (see correspondingcatalogue).

� Different sized-cardboard boxesusing universal width which canadapt to a wide variety of weightsand sizes. These load units do notimply any changes in the transportsystem.

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TYPE OF CONVEYORS�

The size of the load units and their transport

base, together with itsdimensions, are the chieffactors used to determinethe best conveyor system.Functionality, speed and

incline are also factorswhich help to determine

the optimal type of systemfor each application.

12 376 5 9

1

2

3

4

5

6

Zero-pressure buffer roller

conveyor (LRA)

Curved buffer roller conveyor

(LRAC)

Continuous roller conveyor

(LRC)

Free roller conveyor (LRL)

Continual belt conveyor

(LBC)

Roller conveyor with delay

lifting (LEE-1L)

12


8

Buffer roller conveyor (LRA)Enables the transfer of boxes in astraight line without them touching and is able to carry out stackingfunctions.

Its robust design is highly reliable for allwork environments. The environmentalconditions described on the technicaldata chart are those allowed bystandard models, but these can beextended with the installation of theright guards.

TECHNICAL DATA / Roller conveyors (LRA)

Transport units allowed Cardboard and plastic boxes and trays

Max. weight of the load unit 100 kg

Min. length of conveyor 525 mm

Max. length of conveyor 3,150 mm

Max. exterior width of conveyor 947 mm

Max. useful width for boxes 800 mm

Min. length of box (longitudinal direction) 250 mm

Max. length of box (longitudinal direction) 800 mm

Standard transport speed 25/45/60m/ min

Standard conveyor heights 570/750 mm

Maximum slope 0º

Working conditions Room temperature from 0 ºC to 40 ºC

10

4

11

Double conveyor with delay

lifting (LEE-2L)

Roller and belt transfer (LTM)

Switch and exit/entrance

conveyor

Conveyor transfer carriage

Lifts stations

P&D stations

7

8

9

10

11

12

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Curved bufferroller conveyor (LRAC)It is very useful of have these curvedtransport units when having to drawnon-straight flow lines or overcome anytype of architectural or structuralobstacles.

TECHNICAL DATA / Roller conveyors (LRAC)


Curve angle 40º/90º/180º

Buffer areas 45º/90º/180º 1/1/3






Standard transport speed 25/45/60 m/min


Maximum slope 0º


TECHNICAL DATA / Roller conveyors (LRC)


Maximum weight per liner meter 100 kg/m

Min. length of conveyor 2.000 mm

Max. length of conveyor 30.000 mm





Standard transport speed 25/45/60 m/min


Maximum slope 6º


Continuous roller conveyor (LRC)Used to move boxes in a straight linewhen it is necessary to have a constantload flow and the loads canaccumulate by contact. It also is asystem well suited to transportingloads over long sections or even withslight inclinations.

The continuous roller transporter, asopposed to the buffer conveyor (LRA),functions with a single motor thatprovides enough traction to maintaina continuous flow of loads that isoptimal for covering long distances ata high flow rate.

It allows boxes to be moved alongdirectional changes at various angles,with standard curve configurations of 45º,90º and 180º. These conveyors can becombined together.


TYPE OF CONVEYORS >>

TECHNICAL DATA / Roller conveyors (LRL)



Min. length of conveyor 1,000 mm

Max. length of conveyor 12,000 mm






Maximum slope Variable


Roller conveyor with delay lifting(LEE-1L and LEE-2L)Specially-designed conveyors for pickingand delivering loads at incoming andoutgoing stations at automatedwarehouses using stacker cranes.

These conveyors are available in twofamilies, mono-load and bi-load, perfectlyadapting to the picking systems of thestandard Mecalux stacker cranes.

This system combines a roller conveyorand a hoisting group that can access thecrane’s LHD through the bottom of theload.

Transport units allowed Cardboard and plastic boxes and trays Cardboard and plastic boxes and trays

Maximum weight per liner meter 50/100 kg/m 2 x 50 kg/m - 2 x 100 kg/m

Conveyor length 700/900 mm 1.064/1.264 mm

Conveyor width 565/765 mm 690/890 mm

Min. length of box (longitudinal direction) 250 mm 250 mm

Max. length of box (longitudinal direction) 800 mm 800 mm

Standard transport speed 25 m/min 25 m/min

Standard conveyor heights 750 mm 750 mm

Height increment for lifting run 90 mm 60 mm

Working conditions Room temperature from 0 ºC to 40 ºC Room temperature from 0 ºC to 40 ºC

TECHNICAL DATA / Roller conveyor with lift-out

LEE-1 (single) LEE-2 (double)

Free roller conveyor (LRL)This is a system of rollers without amotor, suited to channel sectionsaccumulating through gravity,expediting areas or work posts.

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Continual belt conveyor (LBC)Useful for moving boxes in a straight linewhen a constant flow of boxes is required,maintaining them at a constant distanceor position from one another. It likewise is apt for sections with slopes of lessthan 24º.

This system is also well suited for arequired transport speed higher than 60 m/min or when the adherencebetween the load surface and rollers isinsufficient.

TECHNICAL DATA / Straight transfers between roller and LBC belt

Line 1 Line 2 Line 3straight and inclined straight straight and inclined

Transport units Cardboard and plastic boxes and trays

Maximum weight per liner meter 50 kg/m

Min. length of conveyor 675 mm 4,500 mm 4,500 mm

Max. length of conveyor 4,500 mm 20,000 mm 30,000 mm


Max. useful width for box 600 mm


Speed 60/120 m/min

Maximum slope 12º 0º 24º


TECHNICAL DATA / Straight transfers between roller and LTM belt




Conveyor length 685/885 mm

Maximum load width of the rollers 600 mm



Standard conveyor heights 570/750 mmStandard transport speed/ 25/900 m/min Transfer flow at 90º 45/1,300 c/h

Maximum slope 0º


Mixed roller and belt transfer (LTM)Offers high-performance solutions tointersection problems and adapts to themost complex facility design.

This system can change directions by 90ºand combines a fixed roller conveyorand lifting belt conveyor arrangedorthogonally, as well as having a built-inswinging buffer to ensure the boxesbeing transferred stay perfectly in line.

According to the length the beltconveyor has to cover in one direction,there is a choice of using a symmetricalsystem (requires a greater transportdistance) or an asymmetrical one(requires a shorter distance).

It can be used to move boxes and makechanges in the transport direction atvarious angles with standard curveconfigurations of 45º, 90º and 180º,which may be combined together.



Switch and exit/entranceconveyorsInstallations where a largequantity of handled units aremoved through the whole system,require building switch conveyorsto secondary lines or inductionconveyors to high speed lines.These devices are most useful insuch situations as they enablechanges of direction at highspeeds.

TECHNICAL DATA / Switch and exit/entrance conveyors

Mechanical characteristics of the conveyorsConveying elements Roller with metal encasing Elastomeric ribbon

or coated in plastic

Gravity conveyor 3% 3%

Height (own structure) Min. 300 mm - Max. 800 mm Min. 300 mm - Max. 800 mm

Driving mechanismSpeed Max. 1.2 m/s Max. 2 m/s

Operating system Drive roller (loop to loop) Transmission to theor flat belt drive ribbon itself

Type of drive Asynchronous engine Asynchronous engine

Working conditionsTemperature –30 ºC to +40 ºC 0 ºC to +40 ºC

Handled unitLength Min. 400 mm - Max. 800 mm Max. 1,500 mm

Width Min. 400 mm - Max. 600 mm Min. 400 mm - Max. 800 mm

Height Min. 100 mm - Max. 700 mm Min. 100 mm - Max. 700 mm

Weight Max. 100 kg Max. 100 kg

ROLLERS BELTSOnly transport Only transport

at 30º at 45º at 90º at 30º

+_ +_

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Shuttle carsThis non-continuous system for deliveringhandled units to different receptionstations can form an important part of anoperational environment which needsmultiple resources. Another benefit is aquick return on investment withouthaving to forsake orderly and profitableoperations.

These devices provide a great deal offlexibility in reception and dispatch work.

Lifts stationsLifts stations are useful in cases wherethere are limitations in terms of thedesign of the floor or the transit areas.Lifts can also make these areas moreprofitable. In such cases a range of liftsis available which are capable ofdistributing the handled units todifferent levels, continuously or non-continuously, without affectingoperations in the installation.

These devices enable the loads to berecirculated around new levels inheight.

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P&D stationsThese are positions in which theoperators interact with the automatedsystem. The goods inside theautomated warehouse are handledfrom here.

Their ergonomic design guaranteesquality in load handling and a safeworking environment.

Safety is ensured by the differentequipment in the stations, minimizinglabour hazards for the operator who isworking in the P&D stations.

Special systemsWithin the range of products offered byMecalux, systems are available whichprovide solutions for special situationsand projects with major levels ofoperational capacity.

These devices include:

� Box sorters� Stackers� Vertical warehouses� Carrousels� Plastic box folders

Mecalux integrates these products intocomplex logistics systems for boxes,according to the requirements of eachinstallation.


Designed and developed by Mecalux, the systems for moving light loads are particularly suitable for

responding to the demands of the market, offering aquality product with low maintenance needs.

They are built with standard electrical and mechanical components, which guarantee the

reliability and supply of spare parts.

TECHNICALCHARACTERISTICS

�

Driving system of the conveyor SpeedDepending on the characteristics of thehandled unit, different speeds are studiedfor the drive movement. The speed is directly related to theoperational capacity of the origin anddestination points.

Operation powerThe factors which determine theoperation power of the elements thatmake up a conveyor system are the weightof the handled unit along with thedifferent features included in theinstallation. Mecalux offers a wide rangeof options for driving mecanism whichprovide solutions for all the jobs needed toensure that the installation workscorrectly.

Drive rollerThe roller has a motor fitted internally andis mechanically connected by means ofelastomeric belts to a group of rollerswhich turn in time with the motorisedroller.

Transmission systemThe operation devices are chosenaccording to the nature of the loadunit and the operation method of theconveyor system. The systems can be:

� Drive roller� Metal drive chain� Toothed belts� Conveyor belt � Drive shaft and chain

Driving rollersTop-quality driven roller accepts awide range of speeds and loads.

Drive roller.

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Type of driveA number of different types of driveare commonly used in light conveyorsystems. Asynchronous engines are agood option for standardization andhave a proven track record with drive.

The climatic and working conditionsalso determine the selection of themost suitable form of drive.

Conveyor belt The load units move along as theelastomeric belt turns. The boxes arecarried along by the conveyor beltwithout any friction between the box andthe conveyor system.

Drive shaft and chainThe turning movement is transmitted to apair of chains through the operating ofthe motor and a shaft with two cogs,which are connected to the conveyorchain.

Driving metal chains The movement of the rollers is activatedby a metal chain-pinion system built ontoone side of the conveyor chassis.

Toothed beltsHigh-resistant long-lasting toothed beltsare implemented on mixed transfers withcrosswise movements or rollers for theboxes. These are composed of highlyadherent materials on the face coming incontact with the load, while the interiorface has great flexibility.


Conveying elementsDepending on the nature of the box to betransported and the role of the functionalunit, different conveying elements can beused for the same conveyor system.

The most common components include:

Roller with metal casingAs a standard conveying element, themetal casing of the roller cylinder gives itthe adherence needed to move handledunits in most situations.

Roller coated in anti-slipmaterialThis system is used when adherencebetween the load unit and the roller isrequired, thus preventing the load unitfrom slipping.

Poly-V Belts (poly-vinyl) Poly-vinyl belts are an alternative to O-ringbelts when having to carry loads heavierthan 50 kg, as this type offers bettertraction over the rollers.

O-ringsThey are designed to transmit themovement between rollers. Their usefacilitates conveying along long sectionsof rollers without the need for chains, thusavoiding the need for lubrication andfrequent maintenance.

Mecalux's continuous conveyor systemsare designed by selecting the most

suitable components for each application.This principle is one of the design priorities in order to achieve the desired quality level.

Roller with metal casing.

TECHNICAL CHARACTERISTICS>>

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Elastomeric beltsUniversal system used for handled unitswith uneven bases or which areincompatible with any other conveyorsystem.

High-adherence elastomeric belt When the transport unit is used toovercome slopes or at high speeds and thetransportability must be guaranteed, abelt with a bumpy or adherent material isused.

Elastomeric belt for easy slidingIn order to make changes in direction withcertain types of elements, the handledunit must slide on its base, and so asurface which facilitates this task isrequired. The solution is a belt made froma highly-resistant material which allowseasy sliding.

Morphology of conveyorsystemsGravity conveyor The gravity conveyor is the incline alongwhich the load is transported.

HeightAll conveyors have their own supportstructure which allows them to be height-adjustable and ergonomically indicated tomake operator interaction comfortableand to overcome changes in the transportlevels between floors.

LengthMaximum distances can be coveredwith a single conveyor using the samedriving mechanism unit.

WidthThe width is directly related to the size ofthe handled unit.

There exists the possibility of buildingdifferent heights according to needs.


TECHNICAL CHARACTERISTICS>>

The distances within an installation canbe covered by means of differentdevices included within the family ofproducts discussed here.

Mecalux offers a standard solution forconveyor which covers all thepossibilities arising in typical workingenvironments.

The use of driving mechanism andpresence-detection systems by meansof mechanical or optical detectiondevices enables the boxes to be movedunder controlled conditions to thedesired positions.

All the parts which make up theseconveyors are seamlessly integratedwith the rest of elements of theinstallation for the conveyance of lightloads within the warehouse.In manycases, they are also built with intelligentsystems fitted inside them.

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A

B


Handled unitPlastic containers (boxes) are often usedas handled units. To a lesser extent, metalcontainers are also used. In certaincircumstances, the goods are conveyed bytrays (metal or plastic) which replace thetypical container. If the goods arepackaged, either definitively ortemporarily, in a sufficiently strongcardboard box, this can be used as thehandled unit.

The handled unit must meet a series ofcharacteristics which permits it to behandled in automated workingenvironments. Among thesecharacteristics, the following should benoted:

HANDLED UNIT �

� The contact surface of the base with theconveyor must be flat and stable withsufficient thickness to guarantee amaximum deformation due todeflection of 6 mm.

� The area for the barcode has to be atleast 80 mm above the base of thehandled unit.

� The function of the photocells must beguaranteed. The light beam must notgo through the box. The use oftransparent containers or containerswith thin mesh can cause detectionproblems.

� If stacked units are being transported,ensure that they keep the same shapeand form when accelerating,decelerating and changing direction.

In automated conveyorsystems, the container orhandled unit plays a vital role in guaranteeing the proper functioning and performance of theinstallation.

* In the whole perimeter

Smooth bottom With reinforcementB

15.75 mm* 15.75 mm*G

FC AP1 P2

3 m

m

20 m

m

TECHNICAL DATA / Mecalux Euroboxes

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Working conditionsTemperatureThis is the range of temperaturesbetween which the standard materialhandling systems can be operated. Theconveyor components of Mecalux aredesigned to work between -30 ºC and+40 ºC.

HumidityThe relative humidity in the workingenvironment can lead to the need foradditional systems of mechanical andelectrical protection in the installation.For instance, the transfer of handledunits may require lower handlingspeeds, in addition to other speciallyprotected devices.

� If possible, the units should not haveholes in the base nor in the first 50 mmof the sides in order to minimisedamage to the belts from leakage.

� The plastic deformation of the base inthe rack must be no more than 5 mmand the elastic deformation no morethan 10 mm.

� External maximum tolerance +/- 2 mm.

� The foldable boxes should preferentiallybe built with single hinges as they aresturdier and more stable.

Measurements in mm

reinforced

The general table for each systemindicates the sizes and weight of the loadunit transported.

With the aim of improving the reliability ofthe conveyor systems for boxes andreducing the problem of certain containertypes, Mecalux has developed its ownrange of plastic boxes. The boxes havebeen designed in accordance with theEurobox regulations and comply with themechanical requirements for theirintensive use in the conveyor and Mecaluxstorage systems.The models available areshown in the table below.

Model Height Width Length G F P1 P2

CME 640 x 420 420 600 400 568.5 368.5 417 –

640 x 320 320 600 400 568.5 368.5 317 –

640 x 240 240 600 400 568.5 368.5 237 –

640 x 170 170 600 400 568.5 368.5 167 –

640 x 120 120 600 400 568.5 368.5 117 –

CME 640 x 420 420 600 400 568.5 368.5 – 400

640 x 320 320 600 400 568.5 368.5 – 300

640 x 240 240 600 400 568.5 368.5 – 220

640 x 170 170 600 400 568.5 368.5 – 150

640 x 120 120 600 400 568.5 368.5 – 100

MECALUX SLOVENSKO, s.r.oBratislava - tel: 00421 220 545 117

Boženy Nemcovej 8811 04 Bratislava

fax: 00421 220 545 118

For more information visit our website: www.mecalux.skor contact email: [email protected]

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Documents

combined with demanding requirements