1、 Manufacturing StandardsFord Motor Company199312 TROLLEY CONVEYORS CX2Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 1 of 141. SCOPE: This standard covers requirements for 3 inch (76 mm) TrolleyConveyors with X-348 Chain, 4 inch (102 mm) Trolley Conveyors wit
2、h X-458Chain and 6 inch (152 mm) Trolley Conveyors with X-458 or X-678 Chain.This includes overhead monorail, power and free, and inverted power andfree conveyors. The requisitioning activity shall be responsible forproviding the functional performance specifications, which include theequipment layo
3、ut, job conditions, and other operating requirements.2. REFERENCES:American Gear Manufacturer Association (AGMA)American National Standards Institute (ANSI)ASME B20.1 - Safety Standard for Conveyors and Related EquipmentB29.22M - Drop Forged Rivetless Chains, Sprocket Teeth DriveChain/Drive DogsAmer
4、ican Institute of Steel Construction (AISC)American Welding Society (AWS)Conveyor Equipment Manufacturers Association (CEMA)601 - Overhead Trolley Chain ConveyorsFord Corporate StandardsCGX1 - Trolley Conveyor Stock GuardsCGX7 - Conveyor Uphill and Downhill Safety DevicesEX1 - Electrical Standard fo
5、r Mass Production EquipmentHX1 - Hydraulic StandardKZ3X-1 - Machinery and Equipment GuardsLX1 - Lubrication Standards for Industrial EquipmentNX1 - Pneumatic StandardSX-1 - Noise ControlFord Motor Company - General Conditions of Design and Fabrication ofEquipment, Plant Engineering Office Form 3647,
6、 dated January, 1957.Ford Motor Company - General Conditions for Lump Sum EquipmentInstallation Controls, Plant Engineering Office Form 3646, dated March,1968.Occupational Safety and Health Administration Standards (OSHA) - Title29, Code of Federal Regulations - Part 1910 for Canadian Plants: NBC,O.
7、B.C. and Ministry of LabourSociety of Automotive Engineers (SAE)SAE J534 - Lubrication FittingsManufacturing StandardsFord Motor Company199312 TROLLEY CONVEYORS CX2Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 2 of 143. GENERAL: Conveyor system design must c
8、omply with the latest editionof the referenced standards. In those instances where Ford standardsexceed the referenced standards, Ford standards will apply. It is theresponsibility of the supplier to determine that all standards are met orrequest a waiver of requirements if necessary. Any waiver mus
9、t be approved by the requisitioning activity. For all equipment supplied, the contractor is required to satisfy the identification and written procedures labeling for the control of hazardous energy during servicing and maintenance of production machines and equipment with multiple energy sources, a
10、s specified in OSHA1910.147 and Subpart S (1910.300 - 1910.399).3.1 SYSTEM DESIGNSystem design shall be in accordance with CEMA standard no. 601.Layout drawings containing the following design criteria shall besubmitted for approval by the requisitioning activity prior todetailing. All pertinent dat
11、a that determine the jobs per hour(JPH) shall also be included in the layout drawings.- Panel Point Loading/Location- Floor Loading- Chain Pull/Chain Tension- Actual Wheel Loading3.2 CONSTRUCTION3.2.1 BOLTEDBolts shall be long enough to allow the use of a full nut inaccordance with AISC. Bolt holes
12、shall be drilled or punchedin all structural members. The burning of holes in structuralmembers is not allowed. Use of J-Bolt connections orconnections not using bolts through both members will not beallowed.3.2.2 WELDINGWelding shall comply with the recommended practices of A.W.S.Welding to buildin
13、g steel is not permitted.3.3 EQUIPMENT ACCESSIBILITYThe Contractor shall provide access to all equipment requiringperiodic inspection, adjustment, maintenance or service, including:Drives, take- ups, lube points, anti-back-ups anti-runaways,traction wheel turns, roller turns, stops, lubricators,anti
14、-runaway conveyors, etc.Accessibility shall be defined as SAFE access from a level floor,service platform, catwalk, or conveyor screen guard with a 5-0“wooden ladder.Manufacturing StandardsFord Motor Company199312 TROLLEY CONVEYORS CX2Engineering Standards & Printed copies are uncontrolled.Systems E
15、ngineering (ESSE) Page 3 of 14Service platforms, catwalks and conveyor screen guard are to beaccessible by fixed steel ladders located at building columns orother approved locations.Equipment shall be accessible for maintenance without the removalof adjacent equipment. Minimum clearance for personne
16、l shall be24“.3.4 AIR CYLINDERAir and oil cylinders shall be lubricated for life, cushioned atboth ends, and pinned clevis to prevent rotation. Each cylindershall be provided with a filter regulator (FR) unit.4. CONVEYOR CHAIN:4.1 STANDARD APPLICATION: The conveyor chain shall be X-348 three inch(76
17、 mm) pitch, X-458 four inch (102 mm) pitch or X-678 six inch(152 mm) pitch, drop forged steel SAE 1046, rivetless heat treatedchain as described and illustrated in ANSI B29.22M and CEMAStandard No. 601. A maximum working pull of 1,200 pounds (545 kg.)for X-348 chain, 2,000 pounds (909 kg.) for X-458
18、 chain and 3,500pounds (1591 kg.) for X-678 chain shall be used for designpurposes. If greater chain pull is necessary, consult therequisitioning activity.The chain components shall have the following surface hardness:X-348 and X-458 Chain X-678 ChainCenter Link 331 to 388 BHN 331 to 401 BHNSide Lin
19、k 311 to 388 BHN 311 to 388 BHNPin 363 to 415 BHN 341 to 415 BHN4.2 OPTIONAL APPLICATION: For severe applications, the requisitioningactivity may specify SAE 8642 forged steel alloy for the CenterLink and Pins, case hardened to Rockwell Rc 60 - 63 with a casedepth of .040 to .060 inch.5. DRIVES5.1 A
20、ll drives shall be rotary floating caterpillar type and shall beprovided with safety brakes and limit switch overload protectionset to operate at 500 pounds above the chain pull capacity of thedrive. Drives for high speed conveyors shall be provided withelectric “soft start“ control.5.2 Whenever pos
21、sible, drives shall be installed at the top of inclinesjust prior to take-ups. Drives are not to be installed at the startof inclines nor at the bottom of declines.Manufacturing StandardsFord Motor Company199312 TROLLEY CONVEYORS CX2Engineering Standards & Printed copies are uncontrolled.Systems Eng
22、ineering (ESSE) Page 4 of 145.3 Design of the system with multiple drives shall locate the drivesso that each units pull is approximately the same. If any onedrive is out of service, the remaining units shall be capable ofaccepting the additional chain pull requirement.5.4 Caterpillar chain loop sha
23、ll be of RC 160 roller chain with steelhardened rollers and bushings and equipped with forged hardeneddogs. Caterpillar chain assembly shall be reversible so thatopposite faces of dogs can be utilized.5.5 Caterpillar sub-base assembly shall consist of a roller nestassembly and an adjustable high all
24、oy backup bar. The back-up baralignment screw to have locking-in-place means for prevention ofbar movement after alignment of chain.6. MOTORS:6.1 Drives shall be equipped with an A.C. foot mounted “U“ frame motor,totally enclosed, ball bearing type, unless specified otherwise bythe requisitioning ac
25、tivity.7. REDUCERS7.1 Drive reducers shall be selected on the basis of output torquerequirements using a minimum of 2,200 pounds pull for X-348 chain,a minimum of 3,000 pounds pull for X-458 chain and a minimum of5,000 pounds pull for X-678 chain.8. TROLLEYS:8.1 The maximum spacing between centers f
26、or 3 inch, 4 inch and 6 inchtrolleys shall be 24 inches, unless otherwise specified.8.2 For standard condition with operating temperature of less than 200degree F, wheels shall be flangeless, single row - full complimentdesign, locked race swaged, smooth rims and symmetrically true withaxle. Wheels
27、shall be equipped with high carbon steel 200 Gradeball bearings, labyrinth seals and grease fittings. Wheels shall bepacked with Ford Motor Company standard M-1C164A grease unlessotherwise specified.For corrosive environments such as phosphate, E-coat, washers, etc.trolley seal shall include purgeab
28、le contact (wiper) seal made ofNITRILE for applications up to 200 deg. F., and VITON forapplications from 200 deg. F to 450 deg. F.For temperature in excess of 200 deg. F, open trolley may berequired. If closed trolleys are used, trolley seals shall be ofsuitable material for the maximum operating t
29、emperature. Trolleysmanufacturers design must satisfy the requirements of theManufacturing StandardsFord Motor Company199312 TROLLEY CONVEYORS CX2Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 5 of 14application and must be submitted to the requisitioning act
30、ivityfor review and approval prior to fabrication.8.3 Wheels shall be locked to an approved forged bracket, so formed asto protect the grease fitting and be adaptable for automaticlubrication. Bracket shall be locked to a clevis attachment with aminimum of two high strength (grade 5 minimum) bolts.8
31、.4 Minimum Load Rating of each trolley shall be:3 inch 4 inch 6 inch- - -Single Trolleys 200 lbs 400 lbs 1200 lbsLoad Bar - Two Trolleys 400 lbs 800 lbs 2400 lbs8.5 Trolleys shall be lubricated at assembly (except for conveyorssubject to excessive heat or chemical environment such as ovens,washers,
32、bonderite.)8.6 Typical trolley designs are shown in CEMA Standard No. 601.9. TRACKS:9.1 Tracks shall be constructed of rust free SAE 1035-1045 steelsymmetrically true and straight, rolled in accordance with AmericanAISC tolerances:3 inch trolley - 3 inch (76 mm) I-beam at 5.7 lbs (2.6 kg)4 inch trol
33、ley - 4 inch (102 mm) I-beam at 7.7 lbs (3.5 kg)6 inch trolley - 6 inch (152 mm) I-beam at 12.5 lbs (5.7 kg)9.2 Track splices shall be at floor supports or hangers where possible,with bottom flanges and web welded and ground smooth.Unsupported track splices shall have top flanges reinforced asin App
34、endix A & B.9.3 Slip joint design shall be used at all take-ups, building expansionjoints and other areas where specified due to heat conditions.9.4 All track joints (bolted or welded) must be smooth and continuousand shall be designed to have at least the same or greater capacityas any sections of
35、the track.9.5 Track Hangers shall be provided at spacings, which will limit trackdeflection to a maximum of 1/8“.9.6 All tracks shall be sufficiently braced to prevent sway or lateralmovement.Manufacturing StandardsFord Motor Company199312 TROLLEY CONVEYORS CX2Engineering Standards & Printed copies
36、are uncontrolled.Systems Engineering (ESSE) Page 6 of 1410. VERTICAL BENDS:10.1 THREE INCH (76 mm): For three inch I-beam, vertical bends shall be8 foot (2.4 m) radii to center of track. Radii less than 8 feet(2.4 m), to a minimum of 6 feet (1.8 m), may be used on approval ofthe requisitioning activ
37、ity.10.2 FOUR INCH (102 mm): For four inch I-beam, vertical bends shall be15 foot (4.6 m) radii to center of track. Radii less than 15 feet(4.6 m), to a minimum of 8 feet (2.4 m), may be used on approval ofthe requisitioning activity.10.3 SIX INCH (152 mm): For six inch I-beam, vertical bends shall
38、be20 foot (6.1 m) radii to center of track. Radii less than 20 feet(6.1 m), to a minimum of 12 feet (3.7 m), may be used on approvalof the requisitioning.10.4 SAFETY DEVICE: An uphill or downhill safety device must be inaccordance with CGX7.10.5 MINIMUM STRAIGHT TRACK: A minimum of one trolley spaci
39、ng ofstraight track shall be maintained between tangents of verticalbend and a horizontal turn.10.6 Typical vertical bend designs shown in CEMA Standard No. 601.11. HORIZONTAL TURNS:11.1 Traction wheels shall be equipped with grease sealed tapered rollerbearings and grease fittings designed to permi
40、t lubrication whilein operation11.2 Traction wheels in ovens shall be equipped with carbon bushedbearings.11.3 The pitch diameter of traction wheel turns shall be a minimum of 24inches (610 mm) for three inch trolleys and 36 inches (914 mm) forfour and six inch trolleys.11.4 Roller turns shall be 24
41、 inch (610 mm) minimum radii to center ofsteel track. Standard turns should be used where possible.11.5 Rollers of the roller turns shall be equipped with two high qualityball bearings assembled in a hardened steel casing and equippedwith grease fittings.11.6 Typical roller turn designs are shown in
42、 CEMA Standard No. 601.Manufacturing StandardsFord Motor Company199312 TROLLEY CONVEYORS CX2Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 7 of 1412. TAKE-UPS:12.1 All conveyors shall be equipped with take-ups. Take-ups must becapable of accepting the removal
43、 of one unit spacing of chain, plusan additional 1- 0“ of travel.12.2 Unless otherwise specified, conveyors under 200 feet (61 m) shallhave manual take-ups12.3 Unless otherwise specified, conveyors over 200 feet (61 m) long orsubject to elevated temperatures shall have automatic take-ups.13. EQUIPME
44、NT GUARDS:13.1 Machinery guards shall be provided on all moving parts of drives,i.e., sheaves, belts, sprockets, chains, couplings, traction wheelsand roller turns, in accordance with Manufacturing Standard KZ3X-1.Trolley guards shall be in accordance with Manufacturing StandardCGX1 and OSHA (Title
45、29, Code of Federal Regulations).13.2 Take-up counter-weights shall be completely guarded and providedwith a catch basket.13.3 All motor couplings, belt and chain drives shall be totallyenclosed with sheet metal guards, with inspection windows, whichcan be securely fastened and easily removed.14. LU
46、BRICATION:14.1 Bearings shall be equipped with fittings and packed with ESA M1C164Agrease during assembly.15. SUPPORTS:15.1 Superstructure and hangers shall be securely clamped to buildingtrusses at panel points for conveyors supported from buildingtrusses.See Appendix C & D for minimum permissible
47、support member.Drilling or welding to building steel is not permitted.15.2 When the conveyor is connected to a concrete ceiling withoutinserts, each hanger shall be bolted with a minimum of two (2)through-bolts. The through-bolts shall consist of bolt shankswelded to a steel plate. Design and instal
48、lation shall be approvedby the Resident Plant and Safety Engineer.Manufacturing StandardsFord Motor Company199312 TROLLEY CONVEYORS CX2Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 8 of 1416. SURFACE PROTECTION:16.1 All fabricated components shall be given o
49、ne coat of steel primerM6J139A or (equivalent) prior to delivery, except tracks installedin paint booths or ovens. Finish color to be specified by therequisitioning activity.Manufacturing StandardsFord Motor Company199312 TROLLEY CONVEYORS CX2Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 9 of 14APPENDIX ATypical 3 inch (
