Having reliable operating systems in place is essential for efficient material flow in today’s fulfillment operations.
One key component of any well-functioning material handling system is the ability to transfer product from one conveyor line to another in a smooth flowing and uninterrupted way.
The method of transferring product between conveyors is a crucial consideration. Filling in the gaps can make the difference between success and failure in automation.
Let’s review four different methods of executing such transitions, each designed to optimize transfers for specific applications.
90 Degree Pop-Up Transfer
When your product needs to move through a 90-degree turn, the pop-up transfer conveyor is frequently used. A section of the conveyor is recessed until given the signal, at which point it pops-up with powered rollers spinning in a perpendicular direction to the flow of the main conveyor. In the “up” position, the rollers contact the bottom of the package and smoothly take it out of the main flow into a new, orthogonal channel.
End-to-End Transfer or Inline Transfer
Perhaps the most common transfer is from the end of one conveyor to the beginning of another.
An End-to-End Transfer refers to the process of moving materials from the end of one conveyor to the beginning of another. This type of transfer is common in systems where conveyors are aligned in a linear sequence but do not physically touch. A small gap is typically present between the two conveyors.
An Inline Transfer occurs when materials move directly between two conveyors that are physically connected or in close proximity, ensuring continuous and uninterrupted flow.
Side-to-Side Transfers
When an End-to-End Transfer is not possible, two conveyor systems can be placed next to each other – side by side. Guides are used to shift product between the two parallel conveyor systems. This will only function if there are no housings at the edge of each conveyor that would prevent lateral movement.
Nosebar Tail Transfer
Sometimes called a knife-edge transfer, a nosebar tail can be added to the end of a conveyor system, mostly to accommodate smaller objects. The nosebar tail uses a smaller radius roller than the rest of the conveyor. The effect is to make the edge of the conveyor “sharper”, allowing for a closer positioning of the system to which the product is being transferred.
Gravity or Passive Roller Transfer
A passive roller transfer can be highly cost-effective when the product size, shape, and rigidity allows it to be used. As the name implies, the rollers are not powered – they simply spin freely in accord with the item with which they come in contact. Gravity transfer roller modules come in different widths and feature a lift-out design that makes it easy to remove the roller unit for cleaning.
Driven or Powered Transfer
Driven or powered transfer units contrast with the passive rollers described above. Sometimes the transfer unit rollers will cause the product to travel 10% faster than the main conveyor to ensure a smooth transition.
The Micro-Span Transfer module from Spantech features a knife-edge profile at either end, enabling it to transfer even small products between conveyors. For tinier products, a transfer plate can be added to minimize the distance between the edge of the transfer module and the end of the conveyor unit.
Conveyor Gap Plates
Conveyor gap plates are a specialized component designed to bridge gaps between conveyor sections, ensuring a seamless transfer of materials while enhancing safety and operational efficiency. These plates are typically installed in areas where conveyor systems transition from one segment to another, such as at transfer points, diverters, or junctions.
Types of conveyor gap plates:
Transfer Plates: A flat, thin plate extending the edge of a transfer module. The plate prevents small objects from falling through the gap between the end of the conveyor and the edge of the transfer system. A transfer plate can be used as an inexpensive transfer method instead of rollers if the product being moved has a small degree of friction with a flat surface.
Segmented Transfer Plates: These plates are made up of individual segments that lock together. They can be used for belt-to-belt, belt-to-chute, and belt-to-roller gaps.
Roller Conveyor Transfer Plates: These plates float between two rollers to prevent small packages from falling through the gap.
Assisted Transfers
In some situations, an assisted transfer device is needed. A few examples of such devices include pushers, robots, and diversion gates. These types of solution are customized and will depend upon the operational needs of the system. Consultation by a systems integrator like AEC is crucial for success.
Take the Next Step
For improved speed, efficiency, safety and ergonomics for your material handling systems, contact an AEC conveyor specialist today to discuss overcoming operational challenges.
