Vertical sorters are line sorters that distribute baggage or parcels from one conveyor line to two conveyor lines arranged one above the other or - turned around - and then merge them. For this purpose, the vertical sorting unit comprises a pivotable belt conveyor that is moved dynamically upwards or downwards. Typical applications include sorting out individual conveyor pieces, splitting a material flow from one line to two or merging two conveyor lines into one.
The challenge for the material handling systems is to carry out the pivoting movement dynamically and precisely. The speed of switching between the upper and lower transport paths ultimately determines the transport speed in the overall system. A high number of operating cycles, however, leads to an increased load on the drive, as the direction of rotation has to change quickly accordingly.
The RAMO5-W reversing starter from the Rapid Link 5 series makes it very easy to implement a suitable drive solution. The unit guarantees a short response time and thus enables the required fast changes of direction.
Configuration of RAMO5-W with drivesConnect parameterization software.
With configuration “SEN Config Select: P1-13 = 3” the sensor inputs are set so that the changeover switching of the rotation direction is controlled automatically and without delay by the RAMO5-W. The entire application can thus be configured directly in RAMO5, without additional programming effort in the programmable logic controller (PLC).
The internal direction of rotation in the RAMO5-W is switched via thyristors and relays, which guarantee a long durability of over 10 million switching cycles
In more complex conveyor systems, pieces of luggage or packages are not only moved along one level, but also have to be transported across higher and lower areas within the facility.
On conveyor lines with gradients, i.e. where the conveyed material is transported from a higher to a lower level, dynamic operation with short deceleration ramps can result in regenerative operation of the motor: The inertia of the material being conveyed drives the conveyor belt faster than the stop ramp time. In this case, the energy is fed back into the DC link of the variable frequency drive, so that the voltage in the DC link increases. For overload protection of the capacitors, the variable frequency drive switches off with a fault message and the motor is inactive. In extreme cases, this can lead to a standstill of the facility.
To avoid this undesirable condition, the RASP5 variable frequency drive is also available with an optional internal brake resistor. It converts the excess energy in the DC link into heat and releases it to the environment via the device heat sink. This is a simple and effective way to prevent a malfunction.
Configuration of RASP5 with drivesConnect parameterization software.
The necessary configuration for this is as follows: “Brake Chopper Mode P4-05 = 2 Automatic Activation in Run and Stop” If the RASP5 is used with an internal brake resistor, the installation effort and the additional footprint of an external brake resistor are eliminated.
In particular, “sorters” or “infeeders” require precise sealing of the conveyed material at the desired position. Only in this way a trouble-free operation of the conveyor system is possible.
In a conventional drive control system, the signals from the sensors that detect the position of the conveyed material are reported to a PLC and processed there. When a material has reached a stop position, the PLC sends a corresponding stop signal to the motor. However, such a configuration can lead to problems in dynamic applications: This is because the cycle time of the PLC is not constant, nor are the bus run times and the processing time in the master. In this way, the motor always stops at a slightly deviated position. At high cycle rates, parcels or pieces of baggage can get “stuck” in the facility as a result. This leads to interruptions in the process flow, especially in sorters or infeed systems, since the material has to be conveyed with pinpoint accuracy to another running conveyor.
For such an application, the Rapid Link 5 series engine control units offer a quick stop function: If it is enabled, the motor is stopped directly by the SEN I1 sensor. The sensor signals are processed directly in the engine control unit, without involving the PLC. As a result, the cycle times of the PLC and fieldbus are no longer relevant, and the motor always stops at the same position with a very low jitter. This means that the stop position is repeatable, and the infeed or sorting can be carried out as quickly as possible.
Configuration of RASP5 with drivesConnect parameterization software.
The configuration required for this is as follows: “SEN Config Select P1-13 = 2”. The entire quick stop function can be configured in Rapid Link 5. This eliminates additional programming effort in the PLC and very high clock rates can be achieved.
Conclusion
Whether baggage handling systems in airports or parcel distribution systems: Rapid Link 5 offers the right solution as a decentralized, electronic drive system for a wide range of material handling system requirements. With a design specifically tailored to logistics facilities, the drive solution enables greater efficiency in assembly and maintenance. The devices can be easily adapted to changing requirements and, in addition to a high degree of flexibility, offer a wide range of functionalities with which material handling system-specific applications can be quickly and easily implemented.
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