How to Design a Conveyor System Using LFT Modular
Conveyor Components :
STEP 1) Determine Product Size: In this
conveyor system design example, we will be
conveying a product box that is 8.0” (203.2
mm) long and 6.0” (152.1mm) wide. Next
determine the product orientation on the
conveyor belt. Let’s assume that we will be
conveying the product box in the direction of
the long dimension.
8.0”
203.2mm
STEP 2) Select the Belt Width Req’d: In
this example the product box width dimension of 6.0” (152.1mm) will determine the
conveyor belt width. LFT belts come in stock
widths in 3.0” (76.2mm) increments. Based
on this width dimension, select the next
belt width size larger than your product
width to allow for guide rails and mounting
bracket spacing. For this product width
select a 9.0” (228.6mm) belt width.
6.0”
152.1mm
Determine Product Size
STEP 3) Layout the Conveyor Path: The
conveyor system that you will be designing
and assembling will transfer a product from
one point (A) to a second point (B) on your
plant floor. Determine your path, take measurements, and make a rough layout sketch.
Select the Belt Width Required
In this conveyor system layout example, the
conveyor starts at a box forming machine. It
continues past a box filling machine, sealerlabeler machine, and a box loader machine,
where the product boxes are pushed unto an
accumulator. The measured distances are
on the sketch.
STEP 4) Conveyor System Basics: Every
conveyor system will always have certain
basic sub-sections or modules to make it
function. There will always be a (Drive Module) on one end, and a (Idler Module) on
Layout the Conveyor Path
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the other end of the conveyor line.
Between these two modules there will
usually be a combination of (Straight
Section) and (Curved Section) modules
mounted together to form the overall
conveyor system. There are endless
possibilities of conveyor layout configurations using the LFT Modular Conveyor
Components.
STEP 5) Determine the Type of Material Construction Required for the Conveyor System: LFT offers (2) material
construction options depending on the
application:
● FDA-USDA Sanitary Construction
● General Industrial Construction
Idler Module
(Qty 1 Req’d)
LFT Series 900 Drive Module
The FDA-USDA sanitary construction
conveyors are fabricated from #304 stainless steel and FDA-USDA polymers on all
surfaces which contacts product.
Washdown motors and gear reducers
options are also available. Class 100
cleanroom construction is also available
upon request.
Curved Section Module
(Qty 3 Req’d)
The general industrial construction conveyors are fabricated from painted carbon
steel, aluminum, and various polymers.
Powder coated option is available upon
request.
In this example we will select a sanitary
construction with a washdown motor and
gear reducer.
LFT Series 300 Support Leg
Straight Section Module
(Qty 4 Req’d-Various Lengths)
STEP 6) Determine the LFT Conveyor
Module Types Needed to Configure the
Conveyor System Layout: In this
conveyor system design example, there
are a number of different conveyor section
types used. Based on the layout sketch,
the conveyor line can be divided into the
following sub-sections or modules:
● (1) Idler End Section
● (3) Curved Sections
● (2) Long Straight Sections
● (2) Short Straight Sections
● (1) Drive End Module
LFT Conveyor Accessories
Drive End Module
(Qty 1 Req’d)
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STEP 7) Determine the Bearing Type
Required : LFT offers (2) bearing type
options for both the drive and idler section
modules:
● External Mounted Bearings
● Internal Mounted Bearings
External mounted bearings are standard and
are used for end or butt product transfers.
Internal mounted bearings are used for side
product transfers on the idler and drive end
section modules.
Example of External Mounted Bearings
(Washdown Type)
In this example external mounted bearings
are used.
STEP 8) Determine the Number of Support Legs and the Conveyor Height
Required for the Conveyor System:
In determining the number of support leg
assemblies required for your conveyor system layout, each individual section or module
requires:
● Idler End Module (1 support)
● Straight Section Module (3 ft (915mm)
or 4ft (1219mm) (1 support)
● Straight Section Modules (6 ft (1830mm)
or 8 ft (2438mm ) (2 supports)
● Curved Sections (1 support)
● Drive End Module (1 support)
In determining your conveyor height, LFT Leg
Support Assemblies have a height range
option of 30” (762mm) to 45” (1143mm)
available in 1” (25.4mm) increments. Select
the height that best suits your application.
Support Leg Assembly (Single Strut)
STEP 9) Select the Belt Material for the
Conveyor System: LFT offers (2) standard
belt materials (POM- and PP), and (7) nonstandard belt materials (PE, GR, AS-POM,
FR, PVDF, PA6, and PA6.6). Each belt type is
linked with stainless steel pins (Type 304 or
316). (Refer to the LFT website Belt Products
page for a full description and options)
In this this example the POM belt material will
be selected with (304 SST) link pins. Both
POM and PP are FDA and USDA approved.
POM Sanitary Belt Material
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STEP 10) Calculating the Gear Reducer Speed Ratio, Motor Type, and Motor Horsepower for
your Conveyor System: LFT offers the following drive components as part of our Modular
Conveyor Product offering:
● AC/DC Gearmotor Assemblies
● AC/DC Motors (56C mtg)
● RA Gear Reducers (56C mtg)
● AC/DC Electronic Motor Drives
STEP 10.1) Determine the Product Transfer Rate Required for your Process
Application:
>Determine the maximum conveyor transfer rate for your process. The
transfer rate unit for calculation purposes is (products per minute or
products/minute)
(In this example: Transfer Rate = 60 products/minute)
STEP 10.2) Calculate the Conveyor Surface Linear Speed Required for your
Application:
>Known or calculated data so far:
-Transfer Rate = 60 products/minute
-Product Length = 8.0”
Calculate the Conveyor Surface Linear Speed that Will Transfer in (1
Minute): (in Feet/minute)
>Determine the desired (nominal gap distance) between products on the
conveyor: (In this example: Assume a (gap distance) of 2.0”)
>Determine the total conveyor length transferred in (1) minute:
-(Conveyor Length/minute = 60 x (8.0” + 2.0”) =
600 Inches/minute)
>Convert the transfer rate units to Feet/Minute:
-(Conveyor Transfer Rate (Feet/Minute) = (600 inch/min) ÷ (12) =
50 Feet /Minute
STEP 10.3) Calculate the Gear Reducer Output Speed (RPM) Required for your
Application:
>Known or calculated data so far:
-Transfer Rate = 60 products/minute
-Product Length = 8.0”
-Conveyor Transfer Rate = 50 feet/minute
>In this calculation the nominal pitch diameter of the belt sprockets are
required. The nominal pitch diameter (PD) of all LFT Modular Conveyors
equals (5.88” diameter).
>Calculate the gear reducer output RPMs:
Gear Reducer Output: (RPM’s)
= (Conveyor Length/Minute) ÷ (3.14 x PD)
= (600.0”/minute) ÷ (3.14 x 5.88”)
= (600.0”/minute) ÷ (18.46”)
= 32.50 RPMs
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-Conveyor Length/minute = 600.0” (15240mm) per minute
STEP 10.4) Calculate the Motor Horsepower (HP) Required for your Application:
>Known or calculated data so far:
-Transfer Rate = 60 products/minute
-Product Length = 8.0”
-Conveyor Transfer Rate = 50 feet/minute
-Gear Reducer Output Speed = 32.50 RPMs
>Determine the combined weight of the product on the entire conveyor
length and the total weight of the conveyor belt:
-Based on the measurements on the design sketch layout, the
overall length of conveyor = 55 feet
-Based on this length (55 ft) and the length of product with the gap
(8” product + 2” gap), the total number of products on the total
conveyor length = 55 ft ÷ (10”/12) = 66 products
-For this example the product weight is 1.50 lbs each. Based on
this the total product weight on the conveyor (66 x 1.50 = 99 lbs)
-Next, determine the total conveyor belt weight. In this example the
belt material is (POM with SST link pins). Based on available belt
data on the web page the belt weight density = (2.62 lbs/ft2)
>The overall conveyor area = (Belt Length) x 2 x (Belt Width/12)
= (55 ft long) x 2 x (9”/12)
= (82.5 ft2)
>The total belt weight = (Total Belt Area) x (Belt Wt Density)
= (82.5 ft2) x (2.62 lbs/ft2)
= (216.15 lbs)
>Determine the coefficient of friction of the belt. LFT conveyors
incorporate a multi-under rail slider bed fabricated from UHMW-PE.
-To be conservative, the average (Coefficient of Friction = 0.30)
>Calculate the Required Motor Horsepower for your Conveyor System Layout:
>Known or calculated data so far:
-Transfer Rate = 60 products/minute
-Product Length = 8.0”
-Conveyor Linear Transfer Rate = 50 feet/minute
-Gear Reducer Output Speed = 32.50 RPMs
-Total Product Weight = 99 lbs
-Total Conveyor Belt Weight = 216.5 lbs
-Belt/Slider Bed Coefficient of Friction (uF) = 0.30
>Finally, determine the gear reducer efficiency factor for the motor
horsepower Calculation:
-Assume the gear reducer efficiency factor = 0.80
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>Calculate the Conveyor Motor Horsepower (Hp):
(Product Weight + Belt Weight) x (Belt uF ) x (Belt Transfr. Rate in (fpm))
Motor (Hp) =
33,000 x (Gear Reducer Effec.) x (Safety Buffer Factor of 0.90)
(99 lbs + 216.5 lbs) x (0.30 ) x (50.0 (fpm))
Motor (Hp) =
33,000 x (0.80) x (0.90)
(4732.5)
Motor (Hp) =
(23,760)
Motor (Hp) =
0.1992 Hp (Use the next larger motor HP size. )
Motor (Hp) =
0.250 HP
STEP 11) Determine the Conveyor
Accessories Required:
LFT offers many conveyor accessories to
complete your conveyor design. A complete
listing can be found on the LFT Product web
page. These conveyor accessories include:
● Guide Rails
● Guide Rail Brackets
● Rail Support Rods
● Rail Splice Brackets
● Swivel Guide Rod Brackets
● Straight Guide Rod Brackets
● Pneumatic Stops
● Electric Stops
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Technical Support and Accounting:
Lord & Frey Technologies
27068 La Paz Rd. Suite #273
Aliso Viejo, CA 92656
Phone:
(803) 403-9288
Web:
(www.LordFreyTechnologies.com)
Sales:
([email protected])
Technical Support: ([email protected] )
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