Stillage Conveyor System

Stillage Conveyor System

One of our newer clients Valeo – a multinational independent group focused on the design, manufacture and sale of automotive spare parts – approached us to see if we could provide a complete turnkey solution which were outlined in documents they supplied.

We collaborated with Valeo to define the technical requirements and supply a stillage conveyor system in its entirety, as well as manufacturing a control system complete within the PLC Panel and also the complete cost including site installation and commissioning.

The key details discussed were that DBI would be able to…

• Automate the system apart from unloading empty skid
• Allow for vision system implementation
• Have a minimum of 3 x full & empty Skid capacity

Once it was concluded we would be able to fulfil all of Valeos ideals, we produced full GA drawings of the system along with a full written specification made available for approval / modification prior to any manufacturing. This was to ensure that everything was manufactured to Valeos exact requirements.

The details of the stillage conveyor we supplied included the …

• Heavy Duty Powered Roller Conveyor with 80mm Diameter Driven Rollers
• ¾” Simplex chains running on UHMWP wear strips and supporting mild steel painted channels.
• Single Direction Drive

We provided Festo Solenoid vales for the Pneumatic System, which were controlled through the PLC Output cards, and Metalwork Pneumatic Cylinders were transferred on all transfers and stops. An Integrated Filter & Regulator along with all the necessary pipework and tap off points was supplied with the system, and DBI agreed to assist Valeo with the selection of a suitable compressor system.

The main Control Cabinet was required to be located near the Load and Unload end. All controllable elements of each Line would be monitored and controlled by the Siemens S7 PLC. The manual functions were provided via a HMI mounted within the Cabinet door of the cabinet. All control circuits had a standard voltage of 24v dc and all inputs and outputs had an LED functional indication and the machine was wired PNP.

DBI Control supplied the… Enclosures

• IP55 Minimum (Panel only)
• IP54 with Rittal Cooling Fans
• RAL 7035
• Rittal Floor Standing Panel, 2 Door
• 1800mm (h) x 1000mm (w) x 500mm (d) 
• Plinth 200mm  
• LED Lighting kit door operated

Siemens LV equipment

• 230v AC Panel Cooling Fans & Filters
• A complete Motor Control package

PLC & HMI equipment

• Siemens S7-1200CPU
• Input modules (10% Spare capacity)
• Output modules (10% Spare capacity)
• 1x Touch panel KTP700 HMI

Emergency Stops (mounted at regular intervals along the length of the powered system) and Sensors and monitors (positions were stated on the layout drawing). The stillage dimensions were …

• Size 1900mm long x 1000mm wide
• Product Direction –Both Wide & Short Edge leading
• Skid–1700mm wide x 800mm long x 57mm high
• Weight Empty –75 Kgs/ stillage
• Weight Full –150kgs / stillage

DBI Control decided that all new conveyors will be supplied with 10m/min speed, and the stillage system will be designed to operate within the specified cycle time of 70 seconds.

Due to the camera position and transition points the capacity is

• 3 (4) xFEM’s (including load position)
• 4 (5) x Empty Stillage (including unload position)
• 1 x Loading FEM position

The system was engineered to allow the loading and unloading using a Fork Lift Truck. Valeo supplied…

• 1 x 400Vac TP & N Rated at 63Amp
• 1 x Compressed Air Supply (7Bar)

All parts of the machine were protected against corrosion. Non-ferrous manufactured items were left in their natural state (aluminium, brass, stainless steel, etc.) and steel components were given a powder coat finish to RAL 7035.

DBI Control endeavoured to design the system so that, wherever possible, all controls and operator interfaces were ergonomically positioned so as not to cause stress or strain to the operator. The Perimeter Guarding included personal access gates with a maximum height of 2 metres, and 3 SICK Lights Guards were included to protect the Fork Lift Truck loading aperture, unloading aperture and the FEM Loading position.

DBI Control delivered the equipment to Valeo’s Swindon Site, and allowed an inspection of the completed equipment and tested all functionality. The installed system was inspected in comparison to the system designs and finally DBI Control showed the completed system demonstration the ability to cycle at the specified rate and efficiency with no major stoppage.

DBI Control supplied a copy of a comprehensive documentation pack with the machine which included

• System GA
• Control Schematics in PDF and hardcopy formats
• Spares lists
• Proprietary equipment manuals
• Operator manual

DBI Control also supplied the relevant CE Marking and certificate with the equipment, in line with current health and safety legislation, and Operator / Technician training was given during the commissioning stage.

We also accommodated any requests on technical training throughout the build period, to encourage “ownership” of the system by Valeo’s technical team prior to handover.