Designing effective conveyor systems for foundry processes calls for innovation and collaboration. In several cases, coordinating the users’ objectives with latest available components and capabilities can improve the results of conveyor design.
Designs that follow from customers’ feedback include the Smart Spring System and Stabilizer Mounts, in which Conveyor Dynamics Corp. uses a reinforced, Open-T structure to allow easy access to the fasteners. Whereas some manufacturers may use angles with small ports cut to gain access to the fasteners, foundry maintenance personnel emphasize how difficult it is to tighten the bolts on this outdated design. The extra steps needed to produce the Open-T structure achieve the desired performance results and keep the operators’ interests in mind.
With machining capabilities like 6-axis turning and 5-axis milling, using CAM programming and working from CAD and 3D modeling technology, Conveyor Dynamics designs, engineers, manufactures, and machines components that reduce system costs and significantly improve the results. SolidWorks design and 3D printing are used from prototype to production, to streamline component development. Many customers don’t know that CDC supplies their components to other vibratory equipment manufacturers.
Innovative designs — Spring designs have evolved over several years, and while some manufacturers incorporate long-established designs. Conveyor Dynamics works with different spring manufacturers to develop the best spring for each application. For example, CDC uses springs formed from a larger-diameter bar and with one less coil to achieve the same spring rate as some 40-year-old designs. The benefits include reduced stress concentration in the pigtail, longer stroke capabilities, and better spacing between coils, for easier access to the spring fasteners. Also, CDC uses contoured cast spring retainers to match the spring profile with serrated seats for better clamping. Such details contribute to better conveyor performance, with higher up-time.
Another advantage is CDC’s dynamically balanced and isolated designs, which improve on crank-arm, single-mass conveyor designs by eliminating the risk of vibration transmission — a disruptive and costly effect of some poorly designed vibratory conveyors. Often the best resolution is to remove the non-balanced equipment and replace it with a balanced and isolated design.
Even with several tons of steel embedded in the concrete foundation, vibration transmission can occur. Two critical factors to consider are the water table level and soil conditions, which can vary across a single site, meaning the effects of vibration transmission may be found in one area of the plant but not in another. Operating factors such as speed, amplitude, and weight also need to be considered. For example, a wide and long mold dump conveyor will have substantially higher dynamic reactions versus a short discharge conveyor, say from a shot blast machine.
Modern technology — The Dyna Sync Dynamic Drive System™ is the most advanced vibratory technology worldwide. The dynamically balanced synchronous drive system uses patented stabilizers and chrome manganese steel coil springs to optimize performance efficiency and longevity. The amplitude and speed (up to 1,200 RPM) are variable, so travel speed and product flow can be adjusted easily. Expensive zero-tolerance bearings, HTD belts, cogged sprockets, eccentric shafts and alignment problems all are eliminated.
Conveyor Dynamics is recognized for offering the best dynamically balanced and isolated designs, with installations now in 33 countries. Frequently, customers discover that a superior design costs less than a single-mass, eccentric shaft-driven design, especially when factoring in the installation time and foundation costs of non-balanced designs.