For manufacturers who have worked only with fixed conveyors, the ability to expand, shrink or repair their conveyor systems and simply snap on sophisticated modules with automated functions might sound a bit complex. After all, the conventional fixed conveyor is exactly that -- "fixed" -- offering little or no flexibility. Fortunately, modularity and flexibility are concepts that exist in today's "truly modular" conveyor systems, which allows operators to simply snap modules in place, change speeds on-the-fly, and roll the conveyor to various locations in a plant. Capable of innumerable configurations, truly modular conveyor system can quickly adapt to all types of light- and medium-duty manufacturing requirements.

"The need to reconfigure, and inevitably replace, conveyor systems is an all-too-frequent occurrence with many manufacturing and assembly operations," says Bob Steele, president of Steele Plastic Equipment, Marysville, MI. Steele's firm specializes in servicing manufacturers in the plastics industry, and is a pioneer in the design and sales of modular conveyor systems.

"A major factor in configuring and reconfiguring a conveyor is the need to include additional functional components or accessories," says Steele. "This could include a section that makes a radius turn, or a device that counts parts, or running the belt through a water bath, or incorporating sensors for detecting unwanted foreign objects. In some cases, there is a need to make a conveyor more compact, or even run it overhead to get it out of the way. And the easiest, quickest and normally least expensive way to do that is through the flexibility of a modular conveyor system. Otherwise, you could end up spending a fortune on reconfiguring and fine-tuning your conveyor system -- over and over again. A truly modular conveyor system, with a wide range of accessories and attachments, can provide a long lifespan and a high ROI."

Recognizing the need to meet frequently changing production flows, Steele's modular conveyor solution for light- and medium-duty applications (handling objects of up to approximately 5 to 10 lbs.) is the DynaCon® System from Dynamic Conveyor Corporation, Muskegon, MI.

This conveyor system is constructed of high-impact plastic modules that are assembled in what might best be described as a "Lego" scheme of interlocking sectional units. These include belts, sides, legs, motors and accessories that make up modules. Self-tracking belts are available in 10 styles in 4-inch to 60-inch widths. Optional features include drive flights of 1-, 2- and 3-inch heights, flanges to extend side retaining walls, adjustable leg sets to control conveyor height, and leg sets with casters to facilitate wheeling the conveyors away from work cells or to other plant locations.

The selection of DynaCon components and accessories enables manufacturers to adapt to a variety of changing situations and challenging ones, such as detecting mishaps on the conveyor line, cushioning the impact of items that must drop on the belt and accommodating a tote stacking system. With standard modules measuring 18 inches in length, the system offers users maximum flexibility of configuration. Accessories include feed shields that prevent parts from deflecting off the conveyor; drop-zone reinforcement modules; electrical components; electronic eyes; metal detection equipment; as well as electrical controls for indexing, reversing, cutting conveyor power, and piece counting.

Here's a look at some of the most useful attachments and accessories that integrate with DynaCon conveyor systems:

Cooling Tunnel Module

The use of rigid Lexan-Polycarbonate covers that fit snugly on either top or bottom of a standard DynaCon conveyor module allow users to create a "Cooling Tunnel" that cools parts efficiently without a water bath. Cold air is piped into the tunnel from beneath the conveyor module through a hose attached to an in-house forced air cooling system (up to 18,000 BTU/hour). This type of cooling tunnel can drop the temperature of the products from 200°F to room temperature in a short period. These covers can also be used for cleanroom applications and a variety of sterile/medical applications. Lexan covers prevent contamination from coming in contact with the product on the conveyor and can be used in Class 10,000 Cleanrooms. Brushless conveyor motors have virtually no emissions and the conveyor belts need no lubrication and are contaminant-free.

Water Bath Tank

This accessory is a 14-gauge stainless steel tank with a built-in cooling element that integrates directly into the standard-size conveyor system. The Water Bath provides for water bath and washdown applications, and is used widely in the plastics industry to cool hot articles as they exit injection-molding machines onto a conveyor system. Rather than allowing these hot items to deform as they sit and cool, the Water Bath cools them very quickly and enables them to retain their molded shape. DynaCon conveyors, with the exception of the drive module, can be completely submerged in water, because they are made from plastic and aluminum with stainless steel fasteners. Also, Variable Speed DynaCon Drive Motors can be used to slow conveyor speed so that even extremely hot parts can be cooled in a standard bath module.

Drop Zone Reinforcement Module

The Drop Zone Reinforcement Module, when placed under the belt, increases support for a particular section of the conveyor belt by providing a special, drop-in surface module designed to absorb the shock of impact. PVC pipe manufacturers are often good candidates for using the Drop Zone Reinforcement Module. An eight-inch section of PVC can weigh up to ten pounds, and when dropped onto the conveyor from more than a few inches, can hit with great force. The Drop Zone Reinforcement Module cushions the impact, preventing damage to the conveyor belt.

Dynamic Conveyor Corp., 5980 Grand Haven Rd., Muskegon, MI 49441.