Ceiling conveyor system for system linking
Task: Integrated production, assembly and packaging systems
In a large cleanroom (ISO Class 8), various pharmaceutical plastic parts are manufactured, assembled, and packaged at numerous different locations. The production hall measures approximately 140 x 35 meters. The machines are distributed throughout the hall.
The parts are to be transported in batch-separated and independent manner and fed to various assembly machines and packaging machines.
The entire conveyor belt system is to be suspended from the ceiling as much as possible.
Existing obstructions such as machinery, utility columns, skylights, ventilation outlets, building edges, conveyor belts, etc., must be taken into account during the planning process.
MTF Technik will assume complete responsibility for project planning, assembly, control system construction and commissioning.
The implementation took place in several stages starting in 2006 and lasted 6 years.
The assembly can mostly only take place within very narrow time windows (either on Sundays or during two so-called rest weeks per year).
The conveyor belts must be divided into sections with a maximum length of 4 meters to be transported to the production area via elevators. The assembly of these sections must largely be carried out on-site.
Solution: Large controlled overhead conveyor system with distributors and switches
The conveyor system consists of approximately 150 conveyor belts with a total conveying distance of approximately 700 meters, from the machine discharge conveyor to small hopper conveyors, large Z-conveyor belts with 75° bends, diverter valves, and pipe systems. The illustration shows only a small section of the entire system. The conveyor sections marked in red, yellow, and green indicate a project phase that will be implemented in one step.
Approximately 250 MTF devices (conveyor belts, separating attachments, separating drums, material buffers, etc.) are used throughout the hall: Decentralized control system with several Siemens S7 controllers (one control cabinet per product) and control of the drives via bus systems
Decentralized operating devices and touch panels for system operation, including multiple 7-segment displays and signal lights for monitoring system status.
Special control system with interface to a higher-level operational data acquisition system
Interfaces to existing production machines (material requirements, release messages, etc.)
Remote maintenance modules in the control system allow for quick and easy program changes.
Material overflows at the respective line ends with weighing systems for level control or quantity determination of the overflow containers
Reversing belts and pipe diverters for distributing the flow of material to different delivery points
Reversing belts and pipe diverters for distributing the flow of material to different delivery points
Multi-tech conveyor belts with individual lengths up to approximately 45m and widths between 200 and 400mm, depending on the product. The sections are 4m long and can be assembled on-site using bolted connections. The belts, when split, feature detachable endless splices.
Sophisticated sensors on the conveyor belts for permanent monitoring of the system conditions (jam monitoring, etc.)
Complete documentation of the system, including the assignment of conveyor belts to individual production machines.
Maintenance agreement with the customer regarding regular maintenance and servicing (in preparation)
