At CATS, we specialize in the design, programming, and installation of conveyor control systems that keep production moving efficiently and are reliable. We can integrate PLC automation, variable speed drives, and smart sensor technology to deliver smooth, synchronized material handling across your entire operation. Whether you’re running a simple packaging line or a complex multi-zone distribution system, we tailor every control solution to your specific process requirements – maximizing uptime, throughput, and energy efficiency.
From concept and control design to onsite commissioning and support, CATS provides the complete conveyor control package for easier maintenance and reliability.
Conveyor systems are essential in manufacturing for automating the movement of materials, parts, and products along production lines, improving efficiency, reducing labour costs, and ensuring consistent workflow. They come in various types, each suited to specific tasks based on factors like load weight, material type, speed requirements, and environmental conditions. In general manufacturing, conveyors handle everything from bulk materials in food processing to precision parts in electronics assembly.
Common Types of Conveyor Systems in Manufacturing
Here are some of the most widely used conveyor types across manufacturing industries:
- Belt Conveyors: These use a continuous loop of material (often rubber or fabric) driven by pulleys to transport items. They’re versatile for horizontal or inclined movement and ideal for lightweight to medium loads, such as packages or loose materials. They are common in assembly lines due to their smooth, continuous operation.
- Roller Conveyors: Consisting of rollers mounted on a frame, these can be gravity-fed (non-powered) or powered. They’re excellent for moving boxes, pallets, or heavy items over flat surfaces using motors for controlled speed.
- Chain Conveyors: These employ chains to pull or carry loads, often with attachments like slats or buckets. They’re robust for heavy-duty applications, such as transporting pallets or large components, and can handle harsh environments like high temperatures.
- Overhead Conveyors: Suspended from the factory roof, these systems use trolleys or chains to move items above the floor, saving space and allowing for complex routing. They’re useful for painting, drying, or assembly processes where floor space is limited.
- Screw (Auger) Conveyors: Featuring a rotating helical screw inside a tube, these are designed for bulk materials like powders, grains, or slurries.
- Pallet Conveyors: Specialized for moving pallets, these often combine roller or chain elements to handle heavy, standardized loads in warehousing or assembly setups.
These systems are customized with sensors, diverters, or integration with robotics for smart manufacturing.
Conveyor Systems in Car Manufacturing
In automotive manufacturing, conveyors are critical for high-volume production lines.
They provide an assembly line where vehicles move progressively through stations for welding, painting, and final assembly. The focus is on durability, precision, and synchronization with robots and workers.
Key types include:
- Overhead Conveyors: Widely used for suspending car bodies during painting, welding, or storage to free up floor space and allow for dipping in paint baths or drying ovens. They can handle the weight of full vehicle chassis and provide flexible routing through the plant.
- Chain Conveyors: Essential for moving heavy components like engines or chassis along the floor. In car factories, they’re often used in power-and-free systems, where carriers can stop at stations without halting the entire line, facilitating tasks like assembly or inspection.
- Belt Conveyors: Employed for smaller parts like tires, seats, or electronics on sub-assembly lines. They’re also used in final trim and finish areas for smooth, continuous flow.
- Roller Conveyors: Common for transporting pallets of parts or sub-assemblies between warehouses and production areas. In car plants, powered roller systems help in accumulation zones where vehicles or parts queue up.
- Pallet and Slat Conveyors: These handle heavy loads like full engines or body panels on pallets, often integrated into automated storage and retrieval systems (AS/RS).
- Automated Guided Vehicles (AGVs) and Transporters: These mobile systems act like flexible conveyors in modern car factories, autonomously moving vehicles or parts between stations, especially in electric vehicle plants for battery installation.
Safety devices like emergency stops, area scanners, light curtains and other sensors are used with conveyors to protect workers.
Contact us using the form on this page to see how we can provide a conveyor control solution that meets your requirements.
