1、Manufacturing Standards C Overhead Conveyors Scope Overhead conveyors are used for continuous or regular transport between production, assembly and storage areas and also for carrying parts through surface treatment / painting systems etc They are supported by rollers on a monorail track and carry l
2、oads in containers or on suspension arms. A powered chain is used for the drive mechanism. This Ford Manufacturing Standard is mandatory for the design, construction and installation of 458 and 678 overhead conveyors. It defines basic design parameters and construction rules to ensure that specifica
3、tion, manufacture, maintainability and health frequency regulated). 5.3 5.4 In case of overload the drive unit, and so the whole unit, will be turned off by mechanical limit switches. If it is possible, the slack chain behind the drive unit should be tensioned (best formation: drive unit positioned
4、on the top, tension station positioned low). If several drive unit stations belong to a conveyor, design and size have to be identical. In order to avoid misalignment or after-running deviations due to different loads, angular synchronism will be used to achieve synchronism of two or more conveyors.
5、 Each chain track to be synchronised will drive unit synchro generators. The comparative values originating from the synchro generators will be controlled and arising deviations then will be equalized. The selection of the ratio of the gear box will be based on comparable chain sections (for example
6、 load spaces). Tolerances and control accuracy depend on the specific demand. They will be specified in the enquiry. October 1994 Overhead Conveyor u-cxoo3 Page 3 I 20 - =lll0=ll,b0 lllJi805b 72b - Manufacturing Standards C 6. 6.1 Tensioning Stations Number and position of the tensioning stations an
7、d the position of the drive unit will be shown in the conveyor layout. 6.2 Width of the tension station will depend on the material to be conveyed. If it is possible, normal widths should be used. 6.3 Design and mode of operation of tensioning stations is shown on page 15. The size of tension spring
8、s of counterweights will depend on the chain tension strength. Counterweights must be easily exchangeable. Each weight must be visibly marked. 6.4 6.5 Exact adjustment will take place after commissioning under production conditions. Conveyor units with large and constant pitches (for example for car
9、 body transport) will have tensioning stations with a long futed frame, so it is possible to remove a complete pitch if the chain needs to be lengthened. The complete linear expansion of the tension frame is achieved by making it in short sections. 7. Horizontal Bends 4” and 6” see Page 16 8. Dirt a
10、nd finger guards see page 17 9. 10. Forward Run Stop for 4” and 6” conveyor see page 18 Backward Run Stop for 4” and 6” conveyor see page 19 October 1994 Overhead Conveyor u-cxoo3 Page 4 / 20 . 0 Manufacturing Standards C 11. 11.1 Safety Requirements Overhead conveyors have to follow the safety dema
11、nds covered in all applicable national legislation and safety standards. 11.2 The Electrical installation has to be in accordance with EN 60204 as well as the manufacturing standard Ll-EXOOl (electrical units, application SPS) and with the user specification for SPS. 11.3 Emergency stop buttons must
12、 be provided: - at loading and unloading stations - at long and blind conveying sections - on the working and service platforms at the drive units. Monorail conveyors at Ford UK will be supplied with an emergency stop release line. Emergency stop controls have to be arranged in a way, that they can
13、be approached easily. Also they have to be marked visibly. Their number and position are to be determined by the technical department. 11.4 Differences in level of more than 1500 mm have to be provided with forward- and backward run stops working automatically. Every 4000 mm a safety device as menti
14、oned above has to be installed. The first stop should be installed 500 mm before the lower end of the slope. No stops are permitted within the radius of the rail guide see page 18, 19. 11.5 If monorail conveyors are conducted through a ceiling break the openings have to be provided with side rails,
15、knee protections and baseboards. 11.6 Safety Slack Rope If work must be done underneath the suspension and the material to be trans- ported, or if these suspensions are conducted over passage ways safety slack ropes have to be installed. They should prevent the suspensions and their load from fallin
16、g down in case loss or breaking of the connection bolts or any suspension components. Free fall may be 100 mm maximum. It should be damped and decelerated to standstill. Moreover, if necessary, safety catches for load hooks and / or statical supports are to be provided to intercept the items. The pr
17、otecting elements must be able to hold twice the effective load. October I994 Overhead Conveyor u-cxoo3 Page 5 I 20 Marnufacturing Standards C 0 11.7 Slack Rope Crash Protection If work must be done at or beneath the suspensions / items and / or items need to be protected against collision, slack ro
18、pe crash protection has to be provided (in addition to the forward- and backward run stop) see page 18, 19. The connecting elements should be arranged in a way, that a height of 0 -2000 mm and a minimum space of 500 mm can be guaranteed in order to avoid crush accidents. Since the protection ropes h
19、ave to prevent the pull chains from shooting back or forward, an extension strength twice as strong as the suspension weight will be sufficient. In case of pull chain breaking the horizontal slack rope distance may not exceed the difference between 500 mm and the actual clear distance between the su
20、spensions / items in front / behind. The slack rope has to prevent a sudden impact and should slow down the swinging of the load. Safely switching off the conveyors drive unit must be possible in case of a drive unit chain break. 11.8 The overhead conveyor suspension has to be connected to the troll
21、ey in a way that prevents them getting loose. Screws with castellated nut and wtters or self-locking nuts are permitted as connecting elements. Connecting plugs with discs and wtters are not allowed. 11.9 11.10 11.11 The feed side of the plug-in-chain at the drive unit and deviating wheel have to be
22、 covered up, so that access to these sections is impossible. At accessible sections a safety space of 500 mm ( exception: 400 mm) must be provided between the conveyors suspension and rigid items up to height of 2000 mm. If the overhead conveyors are suspended movably or in another way that avoids a
23、ccidents a safety space of 100 mm is sufficient. Safety space matters have to be agreeing in accordance with the department of industrial health and safety standards. Sprinkler All sprinkler installations have to comply with Ford Fire Control Bulletin No. 8. October 1994 Overhead Conveyor u-cxoo3 Pa
24、ge 6 / 20 Manufacturing Standards c 12 Safety Underguarding 12.1 Safety underguarding must always be used, if the space between the lowest point of the conveyed material and the floor surface is 2150 mm or more. At ascent or descent sections the safety underguarding has to be led down to 2000 mm. At
25、 the lowest point a collecting cage will be installed. Safety underguarding installed lower than 2500 mm above floor surface must be protected with barrierguarding. If safety underguarding must be conducted over passage ways the minimum space between floor surface and lower edge of cage has to be 32
26、00 mm. If passage ways are also used by lorries, fire brigades or ambulances the space must be greater. Deviations regarding minimum space of 3200 mm must be approved by the material handlitsg- and safety department. A movable black and yellow painted sign will secure the lower cage end in passage c
27、rossing areas. Safety under-guarding generally is not designed to walk on. For some exceptional reasons it has to be possible for a single person to enter upon them: - to remove fallen parts - for maintenance-service (pushing the hangers by hand to the service area - for repair purposes. 12.2 Safety
28、 underguarding components Floor and side mats The floor mat 3000 mm x 1000 mm and the side mat 3000 mm x 500 mm consist of a frame made by regular tubes 35 mm x 2.5 mm with welded wire mash 50 mm x 50 mm x 5 mm welded onto it. Deviations have to be permitted. After welding the mats have to be galvan
29、ized. The floor mats are to be arranged in this way that the wire mash side is on top. The side mat surrounds the whole cage with the wire mash side outside see page 20. The hand rail is made of galvanized 1.5” tubes with galvanized clamps fixed at the cage suspension or at additional supports. All
30、tube-pushes have to be coupled by sleeves and welded. The edges must be equipped with pipe bends. All pipe ends have to be sealed with caps. Additional supports are necessary if no cage suspension is provided and the taking up of forces of 1000 N/m is not guaranteed. October 1994 Overhead Conveyor u
31、-cxoo3 Page 7 I 20 Manufacturing Standards C 12.3 12.4 12.5 12.6 Clamp elements The clamp elements are to be used to clamp the mats together or to the scaffold (no welding permitted). They have to be produced in different sizes in order to meet specific requirements and to ensure a form-fit connecti
32、onClamps have to be provided each metre at least. The clamp straps are made of rod steel bended to an U-shape. Ends have to have a screw thread. A flat steel 8 mm thick will be used for clamping. All parts are to be delivered galvanized. The screw connections have to be arranged in a downward or out
33、ward direction using self-locking nuts. No projections permitted. Support Scaffold No scaffold is necessary for safety cages of any length till a width of 3000 mm. A scaffold will be necessary if a large-surfaced cage is used. The safety cage must be able to carry a travelling load of 1500 N / squar
34、e metre. Mat sizes may not exceed a maximum span of 3000 mm. At least two opposite sides have to lie on the scaffold. The suspending construction is fixed at the steel construction by means of suspension. They are made of comer steel 50 mm x 5 mm and have to be equipped with an appropriate connectio
35、n. Intermediate suspensions have to be made of round steel. All suspensions have to be screwed to the carrier construction or the building supports by means of clamp connections. In order to absorb horizontal movements / forces sufficient diagonal tensional bars or fixing devices to factory hall sup
36、ports has to be provided. Safety Margins Safety margins in working and transport areas have to be planned in accordance with the accident prevention rules and safety regulations for monorail conveyors of the “Berufsgenossenschaften ZH l/72” if no additional regulations have to be applied. Service Ar
37、eas In order to cany out service and maintenance work, an area will be declared as service area at larger units. This area is to be made of normal standard mats with additional fine-meshed steel net 10 mm x 10 mm x 1 mm welded beneath. The walkway has to be on the same level as the adjacent safety c
38、age. The service area must be capable to carry a load of 2500 N / square metre. The suspension and carrier construction has to be reinforced accordingly. A clearance zone of the least 1000 mm between the service track and load of at conveying track or side mat has to be guaranteed in order to ensure
39、 safety. This may cause October 1994 Overhead Conveyor u-cxoo3 Page 8 / 20 0 0 Manufacturing Standards C 12.7 13. 14. an extending of the service area. Access to Safety Underguarding As agreed with the technical department access has to be provided at suitable sections (for example ladders, bridges
40、from platforms or walkways). They have to be equipped with self-locking baniers and signs. Performance according Ford Manufacturing Standard. Lubrication Lubrication has to be agreed with the technical department. Painting Painting has to be out according to Ford Standard U-VAOO2-3. Unless otherwise
41、 specified all parts of the unit will be painted first with a priming coat, followed by the finishing coat. Corrections will be carried out after assembly, if necessary. Parts surface, which are not longer accessible after assembly will be coated before installation. October 1994 Overhead Conveyor u
42、-cxoo3 Page 9 / 20 Manufacturing Standards Over head Conveyor Plug-in chain X-4 58 4 = Plug-in chain X-678 6 nominal 153.2 nominal 153.2 I Drop forged end hnad treated. without dscarburileicon of edges. free of cracks and burrs. no sharp edges. Chatn pitch Application I Max. wking pull Mln.uttimstra
43、ngth we,ght per m 4 genarel use 1 11.8 kN 2ll kN 4.600 kg 6 heavy duty 20.6 kN 375 kN a.800 kg October 1994 Overhead Conveyor u-cxoo3 Page lo/20 - l)llanufacturing Standards C v Bolts must not protude wtside profile Overhead Conveyor H-attachment Monorail Material 5152-3 EN 10025 50D/C/B/ EN DO29 Ma
44、terial Cl5 EN I0025 Smooth rolling surface, convex across width. blend off radii. EIS hardened to RC 58min. 0.8mm deep Rating 5000N lOOrev./min, lobyrint seal. for mar. temperatures +250* c L Genrsl Purpose fitted with grease nipple AM 6x1 DIN 714l2 or Ul2 ES 1486 Lubrication according to requiremen
45、ta of order with l-attachment Special Purpose without grease nipple (only if noted expressly in the order) Supplied: lubricated-for-life Special her head bolls. nuts ond lack rashers B-at tachmenl Attachm. 1 6s No. Spat. Part-No. H u-cxOo3 1 B u-cxoo3 2 I U-CM)03 3 H*l-ettachmsnt hbterial St37 or mi
46、ld steel B-attachment forged steel Material C22 EN 10083 Thread bolt . cottered nut. cotter pin Live Loads 0) for 4eonveyors without vcrlicol curves: C=360kg b) for rlconveycrs with vertical curves: Vertical-Radii R Trolley spacing A Max. Live Load G per rrolley for a chain pull F WOON 1 9000N 1 l2D
47、OON 2438mm 3048mm 365Bmm 4000mm 406.4mm 609.&m 406.4mm 609.6mm 8l2Amm 406.4mm 609.6mm 812.8mm 26% 2lflkg 2aokg 24Okg 2oOkg 29% 2SOkg 23Okg 210kg mkg 24Okg mkt. L?Okg 2w 21Okg 1SDkg 16Okg 60kg POOkg lMke 40kg 2-204. 16Okg 90kg 609.6mm 27Okg 220& Bti3mm 240kg 120kg large trolley-spacings are permissib
48、le Where vertml chain deflecrion does not exceed go. For 011 condition not shorn the live load 0 con be colculoted by use of the following equation: L October 1994 Overhead Conveyor Page 11 / 20 Manufacturing Standards . C Over head Conveyor Trolley 6 Manorail Material frOD/C/E EN 10029 5152-3 EN lo
49、w5 Cl chain - .- with I-nltachmsnt Bd ts must not pratude outside praflle kiatsrial Cl5 EN 10025 Smooth rolling surlsce. convex moss width. blend off radii. 8s hardened to Rc 56 min. 0.6 mm deep . Ball bearing Rating 10000 N at lOOrer./min. labyrinth seal. for mox. working temperatures +250C .Genersl purpose fitted with grssse nipple lJl2 8.51486 or AU 8x1 DIN 714P Lubricstton according to requirements af order Special hex hd bolts. nuts aad lock washers Special purpose without grease mppla (Only if noted expressly in the order) Supplitd: lubricotcd-for-life H-attachment
