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How To Stop Products From Banging Into Each Other

Posted by Ryan Beerley | Monday, October 21, 2019

Product damage is a common issue with traditional accumulation techniques. With pallets making hard stops, typical methods leave room for improvement (to say the very least!). To prevent products from banging into each other, you need to find alternatives to traditional conveying and accumulation methods!  A strong alternative is Glide-Line’ s Zero Pressure solution. With ZP zoned zero contact conveyors, avoid product damage and ensure smooth handling.

 

Single-Drive Conveyors Can Cause Product Damage. Not with ZP!

Pallets bumping into each is a common issue with traditional accumulation conveyor designs. Allowing workpiece pallets to contact each other throughout a system can be an issue as subsequent pallets bang into stops and other pallets as a normal course of action. This damage to fragile or partially-assembled products can be a major hidden cost and seriously jeopardize productivity and quality. To prevent accumulation-related product damage, alternative means of conveyance should be considered.

That’s where the Glide-Line ZP comes into play. Our zoned conveyors eliminate backpressure by adding and maintaining space between pallets all of the time. This minimizes most of the issues that cause product damage. 

 

 

Glide-Line’s ZP solution conquers the issues caused by traditional accumulation conveyors. By arranging Glide-Line conveyors into separate zones with small, independent drives, a permanent gap is created between pallets/products. With ZP zoned conveyors, products do not touch each other - no contact, no product damage! 

For smooth handling, the ZP does not use “hard stops.” Single-drive conveyors typically use “pop ups” to quickly stop pallets when they enter a production area. While this method can certainly be effective, it gives way to product damage. Upstream pallets bang into the stopped pallet. However, with the ZP, this is not an issue. Conveyor traffic is better managed, with the use of sensors. When a zoned pallet passes the sensor, it automatically turns off. This allows the zoned conveyor to gradually decelerate. The sensor also triggers upstream pallets to stop, preventing them from banging into the stopped pallet. 

 

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ZP Logic Controls Make Product Damage Control Even Easier

Most users use their PLC controls for their conveyor systems. But the ZP comes with logic controls of its own, which can save a lot of hardware, code development in the PLC, as well as field wiring. Here are a few reasons why our built-in logic in our driver cards can save you money and ensure smooth handling:

  • ZP Logic controls are easy to install. The only requirements are a source power to the motors and connecting zone to zone via plug
  • There’s no programming required for indexing operations; all you need to do is wire (and sometimes configure via dip switch depending upon the application)
  • ZP Motors are a robust solution - there is literally only one moving part
  • Cost-Effective-ZP Logic eliminates the need for a control panel/centralized control system with dozens of VFDs, code, and of course results in much less field wiring
  • Local I/O on the driver cards allow additional manual control to bypass automatic logic

 

We Can Help You Build the Right Solution

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We can customize the ZP line to fit your specific project needs. No matter how large (or how delicate) the product conveyed, we can help you build the best production line conveyor systems. Not only can we build it well, we can build it quick! You can quickly configure a customized solution using our IMPACT! configuration software. Put it all together, Glide-Line is a strong choice for developing a viable alternative to upsizing.

Want to know more about how reducing back-pressure can lead to a cost-saving conveyor system? Check out our white paper, How To Manage Backpressure From Accumulation.. Or check out our complete guide, The Ultimate Guide To Creating A Flexible Automation Conveyor Application Solution.

Written by Ryan Beerley

Ryan Beerley is an Applications Engineer for Glide-Line. Thanks to his degree in Mechanical Engineering, a minor in Business, and relevant experience in the controls industry, Ryan has a strong arsenal of skills and knowledge to help with selling conveyor systems. He loves to embrace new challenges big and small, whether they’re related to project design or an opportunity to help the Glide-Line business unit move closer to being the top-tier conveyor supplier in the world. When Ryan isn’t at work quoting conveyors or solving project problems, he enjoys playing basketball and softball with friends, attending concerts with his twin brother, and learning to play new musical instruments.

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Glide-Line offers the most versatile multi-strand panel and pallet-handling solution available for the assembly automation industry.

We solve problems that other conveyor systems manufacturers won’t. We developed Glide-Line from the ground up with a few key, driving factors in mind. First, our conveyors had to be robust and reliable. Second, they would be simple – easy to maintain and service. Finally, we insisted on flexible configurability, creating an efficient, hassle-free customer experience. We’ve built the most versatile multi-strand panel and pallet-handling solution available for the assembly automation industry.

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