1、 Manufacturing StandardsFord Motor Company199312 ENCLOSED TRACK CONVEYORS CX11Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 1 of 111. SCOPE: This standard applies to the design and installation of EnclosedTrack Monorail and Power and Free conveyors. The requ
2、isitioning activityshall be responsible for providing the functional performancespecifications which include the equipment layout, job conditions, andother operating requirements.2. REFERENCES:American Gear Manufacturer Association (AGMA)American National Standards Institute (ANSI)B20.1 - Safety Sta
3、ndard for Conveyors and Related EquipmentB29.22M - Drop Forged Rivetless Chains, Sprocket Teeth DriveChain/Drive DogsAWS D1.1 - American Welding SocietyAmerican Institute of Steel Construction (AISC)Canadian Institute of Steel Construction (CISC) - for Canadian PlantsonlyCanadian Standard Associatio
4、n (CSA) - for Canadian Plants onlyConveyor Equipment Manufacturers Association (CEMA)601 - Overhead Trolley Chain ConveyorsFord Corporate StandardsCGX1 - Trolley Conveyor Stock GuardsCGX7 - Conveyor Uphill and Downhill Safety DevicesCX2 - Trolley ConveyorsEX1 - Electrical Standard for Mass Productio
5、n EquipmentHX1 - Hydraulic StandardLX1 - Lubrication Standards for Industrial EquipmentNX1 - Pneumatic StandardSX-1 - Noise ControlFord Motor Company - General Condition of Design and Fabrication ofEquipment, Plant Engineering Office Form 3647, dated Jan. 1957Ford Motor Company - General Conditions
6、for Lump Sum EquipmentInstallations Controls, Plant Engineering Office Form 3646, dated March1968Occupational Safety and Health Administration Standards (OSHA) - Title29, Code of Federal Regulations - Part 1910 for Canadian Plants: - NBC,O.B.C. and Ministry of LabourManufacturing StandardsFord Motor
7、 Company199312 ENCLOSED TRACK CONVEYORS CX11Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 2 of 113. GENERAL: Conveyor system design must comply with the latest edition ofthe referenced standards. In those instances where Ford standards exceedthe referenced s
8、tandards, Ford standards will apply. It is theresponsibility of the supplier to determine that all standards are metor request a waiver of requirements if necessary. Any waiver must beapproved by the requisitioning activity.3.1 SYSTEM DESIGNSee Manufacturing Standard CX2 - Trolley Conveyors.3.2 CONS
9、TRUCTION3.2.1 BOLTEDSee Manufacturing Standard CX2 - Trolley Conveyors.3.2.2 WELDINGSee Manufacturing Standard CX2 - Trolley Conveyors.3.3 EQUIPMENT ACCESSIBILITYSee Manufacturing Standard CX2 - Trolley Conveyors.3.4 AIR CYLINDERSee Manufacturing Standard CX2 - Trolley Conveyors.4. CONVEYOR CHAIN:4.
10、1 STANDARD APPLICATION: The conveyor chain shall be Universal link 4in (102 mm) nominal pitch, 4 1/16“ (103 mm) actual, drop forgedsteel SAE 1046, heat treated chain. A maximum working pull of 600pounds (273 kg) for Universal link chain shall be used for designpurposes. If greater chain pull is nece
11、ssary, consult therequisitioning activity.The chain components shall have the following surface hardness:Universal Link Chain Side Link 311 to 388 BHN Pin 363 to 415 BHN4.2 The ultimate strength of the chain when assembled must be a minimumof 10,000 lbs.4.3 The chain wheels must be full compliment b
12、all bearing stylemachined steel with machined ball bearing races. Nylon tired wheelswill be permitted provided they have a steel inner race.Manufacturing StandardsFord Motor Company199312 ENCLOSED TRACK CONVEYORS CX11Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE)
13、Page 3 of 114.4 The chain pusher/puller dog attachment can shall be a (1) or (2)piece steel forging. If a particular manufacturer has no othermeans of reducing the noise caused by the accumulating of theadjacent carriers, a plastic or nylon composite pusher may be used.4.5 Pusher dog must withstand
14、a 1200 pound jamming load.4.6 Stamped chain wheels will not be permitted.4.7 The maximum load per hanger shall be 75 pounds at 1- 4“ minimumcenters. With load bar, the maximum load per hanger shall be 150pounds at 1-4“ minimum centers.5. CONVEYOR TRACKAll track joints (bolted or welded) must be smoo
15、th and continuous andshall be designed to have at least the same or greater capacity as anysections of the track.Track hangers shall be provided at spacings which will limit trackdeflection to a maximum of 1/8“. Conveyor contractor to supply therecommended spacing to Plant Engineer.All track shall b
16、e sufficiently braced to prevent sway or lateralmovement.Tracks shall be installed true and level wherever possible, except onaccumulated runs where track shall be sloped downward approximately 1/4“per 100 linear feet in the direction of travel.Power and Free track sections shall be shop jig assembl
17、ed and welded.Yokes shall be spaced at a maximum of 3-4“ for straight horizontal tracksections and at a maximum of 2-0“ for the entire length of verticalcurves and horizontal turns.All tracks being installed in a corrosive environment, such as aphosphate machine, E-Coat enclosures, etc. shall be of
18、AISI 314 stainlesssteel or equivalent.5.1 TRACK DROPEngagement bite of the chain pusher dog to the free trolley is to beachieved by varying the distance between power and free tracks. Thethree required bites are as follows:Manufacturing StandardsFord Motor Company199312 ENCLOSED TRACK CONVEYORS CX11
19、Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 4 of 11- Normal track drop, normal dog bite, shall be used on level carrierruns and accumulation areas.- Positive track drop, positive dog bite, shall be used on levelruns when used for production and process are
20、as. This pusher/freetrolley engagement shall eliminate accidental de-dogging duringproduction, but allow for manual disengagement.- Closed track drop, tight dog bite, shall be used on all verticalcurves. This pusher/free trolley engagement shall not allowde-dogging.5.2 DECLINE TRACKOn decline track,
21、 the transition to closed bite shall start at aminimum of 1-0“ prior to the top curve tangent. The transition fromclosed bite to normal bite at the bottom of a decline shall occur ata minimum of one full carrier assembly length from the bottomtangent line.All declines shall be preceded by a 4-0“ lon
22、g inclined section offree track located so that at least one load bearing trolley is onthe inclined section before the power rail is depressed on thetowing trolley. The minimum slope for this incline is 3/4“ per foot.5.3 INCLINE TRACKOn the incline track, the transition to closed bite shall start at
23、 aminimum of 1-0“ prior to the bottom curve tangent. The transitionfrom closed bite at the top of the incline shall occur at a minimumof one full carrier assembly length.5.4 INSPECTION GATESAt least one (1) hinged inspection gate shall be provided perconveyor loop and one (1) inspection gate per 400
24、-0“ of free trackto facilitate addition or removal of trolleys. Locations will bedetermined at the time of layout approvals. Access catwalk, platformand ladder for servicing gates shall be provided.5.5 EXPANSION JOINTSExpansion joints shall be designed so that the wheels maintaincontinuous contact w
25、ith the bottom flange of the track. Expansionjoint designs with a open gap in the bottom track flange shall notbe allowed. Cuts in each side of the track shall be staggered.Manufacturing StandardsFord Motor Company199312 ENCLOSED TRACK CONVEYORS CX11Engineering Standards & Printed copies are uncontr
26、olled.Systems Engineering (ESSE) Page 5 of 115.6 VERTICAL CURVESAll power and free vertical curve assemblies are to be of tight biteconstruction.The minimum radius for vertical curves shall be 2-0“ for poweronly, and 3-0“ for power and free. The wear surfaces shall behardened for all 2-0“ and 3-0“ r
27、adii.The power and free vertical curves shall be designed to have anangle of inclination no greater than 30 degrees. Power only ormonorail enclosed track shall be designed for a maximum angle of 90degrees. The minimum dimension between the tangent line of avertical curve and the tangent line of a ho
28、rizontal curve shall be1-4“ for power only, and the center-to-center distance between thecarrier free trolleys.5.7 HORIZONTAL TURNSThe minimum radius turn for power and free shall be equal to .85times the maximum center distance between free trolleys on acarriers assembly but never less than 2-0“.Po
29、wer only track shall only use traction wheel when a 180 degree3-0“ pitch diameter turn is required. All other horizontal turnsshall be 2-0“ radius.Supports for turns shall withstand 150 percent of chain pull withoutlateral movement.All 2-0“ radius turns shall have hardened wear surfaces. Turns withl
30、arger radii should be evaluated by the manufacturer based on thedesign requirements to ensure that no significant wear will resultwithout flame hardening the wear surface.6. FREE TRACK TROLLEYSFree trolley assemblies shall be made of high tensile malleable iron orhigh tensile single plate, machined
31、wheels, and side guide rollers.Materials for other components shall meet the requirements system designparameters. If the trolley body is an assembly, it must be assembledusing high tensile strength bolts and Nylock nuts, or slotted nut with acotter pin.Manufacturing StandardsFord Motor Company19931
32、2 ENCLOSED TRACK CONVEYORS CX11Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 6 of 116.1 Free trolley wheels shall be hardened steel. They shall beflangeless and machined to suit the contour of 3“ free track flangeor the enclosed track flange. Bearings shall
33、be high carbon chromesteel grade 200, single row, full ball complement with deep grooveand locked races.Free trolley wheels can be either swaged or bolted to the trolleybody. Bolted wheels must utilize studded wheels, slotted nut andcotter pin, or centerlock jam nuts with locktite.Free trolley guide
34、 wheels can be either a roller or full complementtype bearing.7. VERTICAL CURVE SAFETY DEVICESSee Manufacturing Standard CGX7 - Conveyor Uphill and Downhill SafetyDevices.8. DECLINE SAFETY CONVEYORDecline safety conveyor shall be provided on power & free conveyordeclines with a 6-0“ or greater chang
35、e in elevation and whereproduction personnel are located near the bottom of the vertical curvesuch that the potential for injury exists in the event of a run-awaycondition. The decline safety conveyor shall prevent any overspeedrun-away motion of the carriers due to chain breakage or disengagementfr
36、om the chain.The safety conveyor shall be equipped with an air release/spring set“failsafe“ caliper disc brake. Brakes shall be held upon by means of aplant air supply which is interlocked to set the brake when the conveyoris not running.Chain and track size of the safety conveyor shall be the same
37、as themain conveyor as a minimum.Braking devices shall be capable of holding a load at a minimum of 200percent of power and free drive rating or the load inertia force,whichever is greater.An electrical device and controls shall be provided for the inching downof carriers after the fault has been co
38、rrected.Manufacturing StandardsFord Motor Company199312 ENCLOSED TRACK CONVEYORS CX11Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 7 of 119. GUARDS9.1 FALLING PARTS GUARDFalling parts guard shall be provided under the conveyor system inaccordance with Manufa
39、cturing Standard CGX1 - Trolley ConveyorStock Guard.9.2 MACHINERY GUARDSMachinery guards shall be provided on all moving parts of drives,i.e. sheaves, belts, sprockets, chains, couplings, as described inManufacturing Standard KZ3X-1.9.3 FINGER AND PINCH GUARDSFinger and Pinch guards shall be provide
40、d on all rails, rollerturns and vertical curves wherever the bottom of the rail is below7-0“ measured from the plant floor or work platform.9.4 AWARENESS GUARDSPersonnel Awareness guard shall be provided to restrict access topotentially hazardous area. Design and location shall be approvedby the saf
41、ety engineer. Example: At bottom of vertical curves.9.5 BARRIER GUARDSHigh lifts, side mask mast fork lifts, drop lifters, etc. shall beguarded on (4) sides, restricting access to the equipment from thefloor level to bottom chord of truss. Access for the product shallbe limited to the silhouette of
42、the product plus nominal clearance,providing for protection from access by personnel when the productis being raised or lowered.10. DRIP PANSSee Manufacturing Standard CGX111. DRIVES11.1 GENERALAll enclosed track drives shall be rotary floating caterpillar typeand shall be provided with safety brake
43、s and limit switch overloadprotection set to operate at 750 lbs. Normal chain pull limitsshould be 600 lbs.Manufacturing StandardsFord Motor Company199312 ENCLOSED TRACK CONVEYORS CX11Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 8 of 11Whenever possible, dr
44、ives are to be installed on the power onlytrack runs at the top of inclines just prior to take-ups. Drivesare not to be installed at the start of inclines nor at the bottomof declines.Design of the system with multiple drives, shall locate the drivesso that each units pull is approximately the same.
45、 If any onedrive is out of service, the remaining units shall be capable ofaccepting the additional chain pull requirements.All drives will have an outrigger type frame that allows for theuse of integral brake “U“ frame motors.All caterpillar chain shall have a fixed forged heat-treatedcaterpillar d
46、og. Caterpillar chain assembly shall be reversible sothat opposite faces of dogs can be utilized.11.2 REDUCERSDrive reducers shall be selected on the basis of output torquerequirements using 1,000 pounds chain pull for the design load.11.3 MOTORSSee Manufacturing Standard CX2 - Trolley Conveyors.12.
47、 TAKE-UPSAll take-up assemblies shall be located on the power only return trackand immediately after a drive at a point of minimum chain tension.Alternate locations must be approved by the requisitioning activity.Take-up units shall consist of a 180 degree horizontal turn, 2-0“radius attached to a m
48、ovable inner frame, a fixed outer frame with wheeltracks and wheel retainers, and alignment guides to support and alignthe inner frame.The minimum take-up travel shall be 8 inches. The effective travel ofthe take-up shall be sufficient to remove one complete job spacing plusa minimum of 6 inches add
49、itional travel for disassembly and reassemblyof the conveyor chain.Air and Air/hydraulic take-up units shall be equipped with three (3)limit switches, actuators, and indicating lights which shall signify thefollowing:Manufacturing StandardsFord Motor Company199312 ENCLOSED TRACK CONVEYORS CX11Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 9 of 11- Take-up fully retracted (shut drive off and illuminate warning light -Take-up fu
