Notice the different track types for each conveyor. free overhead conveyors Figure 3: Free or “trolley” overhead conveyor (left) versus a powered overhead conveyor (right). Also, open track models are typically only found in straight runs, while enclosed tracks are more suited towards applications that require bends in the conveyor path. Enclosed track overhead conveyors will prevent excess damage, but open track conveyors can hold more weight per carrier, so the choice is ultimately dependent on the characteristics of the conveyed items. Conversely, open track conveyors are easier to install, taking a more typical I-beam form and opting for trollies instead of a chain, and are generally simpler. Enclosed tracks are less susceptible to environmental decay, especially in applications such as painting where overspray can damage the chain over time. An overhead conveyor track can be completely enclosed, or an open monorail (see Figure 2). The first major distinction between overhead conveyors is their type of track. Note that the bottom two tracks are enclosed and the top four are open track designs. open track overhead conveyor Figure 2: Overhead conveyor track cross-sections. Know that any given overhead conveyor exhibits some mix of these traits, so you can understand the huge variety in buyer options. This list is not exhaustive but should cover the primary types of overhead conveyors that are usually seen in plants and should help the reader choose what works best, if interested. As a result, this section will explore the broad categories of overhead conveyor features that differentiate one system from the next. There are no set “types” of overhead conveyors, as they are often built to address specific needs. If properly used, they are an incredibly efficient, safe, and reliable means of conveyance that maximizes space and minimizes hassle. Also, the conveyor chain will naturally lengthen as time goes on, which requires either chain replacement, repair, or compensation in the form of a take up. Overhead conveyors are usually installed in hard-to-reach places (the ceiling/above other equipment) and can be prone to wear with continuous long-term use. The only major disadvantages of such a conveyor system are its increased price over traditional on-floor conveyors, as well as their constant need for maintenance and monitoring. They are especially useful for painting parts and are commonly seen in the automotive industry but note that these conveyors are used in most assembly lines. Given the right carrier, overhead conveyors can move virtually any kind of material and are only held back by their mechanical properties and drive limitations. The overhead conveyor is functionally flexible in its uses – as a result, its list of potential applications is innumerable. They are a fantastic choice for parts that are unable to be conveyed via other means and come in both accumulating and non-accumulating varieties (more on this in the following section). They are energy efficient and use smaller amounts of power than most other conveyor types, if powered at all. Overhead conveyors are easily implemented into most plants, as their modular design is meant to work around the complicated twists and turns of on-floor machines. Both the track and the carriers are simple enough to be designed into any desired shape, making them incredibly versatile in form and application. Members known as carriers are connected to the chain/trollies and are responsible for handling the material, and either manual force or a motor pulls the conveyed items. They maximize conveyance by utilizing unused overhead space, and do so via a revolving, endless loop of chain within a rigid track, or a straight run of trollies. Overhead conveyors are unique from other conveyor types in that they operate above – or over – the head of both workers and other equipment. Notice the unique carrier and track shapes. What are overhead conveyors? Figure 1: Boxes being conveyed via an overhead conveyor. This conveyor, its types, designs, and uses will be detailed so that the interested buyer can determine which overhead conveyor will work for them. The focus of this article will be on the overhead conveyor, which has been built to specifically address unused factory space. There are many ways that conveyor technology transports product to see the wide variety of methods, read our article on understanding conveyor systems. Material handling equipment such as elevators and conveyors makes this task easy, as these machines move product around faster and cheaper, and more compactly than with using traditional manual labor. Factories save time and money by using their space as efficiently as possible.
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