Automation: Systems for Distribution and Buffering

2-position distributor rockers are used to alternately fill two containers with bulk material. They are particularly suitable for applications in which there is usually sufficient personnel to change containers regularly or the container filling time is relatively long. Depending on the task, such rockers can be attached directly to the outlet of e.g. a conveyor belt or a separating device. The advantage of these distribution rockers is the optimum utilisation of space.

• Rocker made of aluminium, steel, stainless steel or acoustic panelling
• Slide coating with polyamide, felt, etc., or covering with resistant polyurethane rubbers for noise reduction and slide reduction
• Mounting brackets for MTF conveyor belts and third-party devices
• MTF counter control for simultaneous control of belt and distribution see-saw for exact piece-count container filling

2-way distribution see-saw as stand-alone device is used especially where containers must be filled on alternate sides. This can be necessary for buffering needs or, for example, for the filling of boxes for storage to allow the pieces to cool better.

• Stable, height-adjustable base
• Easy-to-use MTF counter controller for control of the see-saw and feed peripherals (use with counter impulse or change containers after a preset time)
• See-saw drive also possible electrically
• Dimensions, design and materials depending on the task

MTF Technik offers comprehensive know-how and a strong design department in order to realise almost every customer wish.

• Control functionalities, interfaces, display and use elements depending on the present problem or customer requirement
• Container centering, container presence controls, sensors for fill measurements, etc. integratable without difficulty
• Base design suited to the task

With enclosed belts (e.g. in clean room applications), tube systems or switches are often installed for transition into following processes. Likewise, these systems are useful when, for example, pieces must be carried over a great height difference to an output site.
In the design as two-way transfer tubes, the unit can be used in combination with a counter controller for exact piece-count filling of containers.

• Tube systems from different materials (usually stainless steel)
• Pneumatic or electrical switches
• Tube bends for flexible tube guides

Many deposit stations with round turntable serve to buffer cartons or boxes on a round turntable. For best utilisation of space, multi-story deposit stations are recommended. The different levels are aligned offset to one another and the upper container uptakes are provided with pass-through pipes to guide pieces securely from the outlet into the lower level.

• Container pick-ups in different materials, dimensions and designs
• One- and multi-storey designs possible
• Optimised use of space
• Counter control for precise piece-count filling of the containers and also for control of further peripheral devices (especially feed belts)
• Easy to use standard control with connection to the production machine for piece counting

Especially for applications in the clean room, special configurations with respect to material or the basic design are often desired. MTF Technik specialises in meeting these wishes with qualitatively high-quality products and solutions.

• Tray of stainless steel for bag support
• Upper section with triangles of stainless steel
• Multiplex turntable with Resopal coating
• Control in special configuration with Bollrath Small-SPS and indicator lights
• Stable base in moveable design
• Drive over friction wheel below the turntable

The special nature of the pictured uptake system consists especially in the adjustable bag uptakes that adjust themselves optimally to different diameters.

• Triangular, spring-loaded bag uptakes for optimal adjustment to bags with differing diameters
• Height-adjustable upper section with telescoping triangle uptake
• Turntable made of stainless steel
• MTF standard counter control including controllable socket for a feed belt, mounted on the frame
• Stable base in moveable configuration and custom paint job
• Drive over friction wheel below the turntable

Especially in the plastics industry, bags are often filled. The pickup system Type 202 offers for these tasks a very space-saving and affordable solution. The dimensions and equipment are designed according to customer or task specifications.

• Control design according to customer request
• Turntable of multiplex material with Resopal coating as standard design
• Upper piece with six-fold bag uptake in triangle form
• Moveable base
• Socket for feed belt 400V/50Hz attached to the drive shaft
• Turntable diameter between 800mm and 2,000mm
• Turntable runs on stable ball bearing circle
• Bag uptake available in special configurations (e.g. with bag collectors, spring-loaded bag openers, etc.)

This version of the Pickup System Type 202 is equipped with round bag retainers with fixation rings.

• Frame light barrier mounted above a fixation ring for counting parts
• Pneumatically operated drawer for collecting sample parts for QA check
• Dust protection cover above the bag retainers
• Moveable underframe

Unmanned shifts or weekend use is possible in many production plants only with the appropriate buffer technology. Since the available space is often very limited, stacked belt systems with lifts offer an ideal use of space.

• Length and width of the buffering belts as well as lifting height of the lifts individually adaptable
• Control systems with Siemens S7 controls are specifically adapted for the customer
• Two lifts for complete circulation use possible
• Modular construction for quick start-up

For the buffering of individual pieces that are deposited on conveyor belts by an outtake handling, a simple stacked belt system is recommended as a cost-effective alternative to similar lift systems.

Depending on the desired degree of complexity, different control concepts and interfaces with production machines or to the handling can be realised.

• Three separate small controllers (digital cycle switching devices) for the conveyors
• Belt dump buttons for manual control of piece removal
• Sensors according to customer requirements
• Interface to the parent robot controller
• Connection to emergency stop circuits

Directly from the production machine into the packaging and into intermediate storage. This requirement can be met with individually planned material flow systems from MTF Technik. With the help of a count controller, the containers are filled with exact piece counts and thus stand ready for further processing or for direct shipping to customers.

• Four multi-story belt systems, each with a lift and four or five buffer levels for uptake of max. 96 cartons per system
• Connects over the fire protection walls
• Integrated rotary distributor for interchangeable filling of two containers that constantly stand parallel on the stacked belts
• Large buffer capacity (ca. 55m2) per lift system.

Buffer system with Siemens S7 control for piece counting. With a switched CEE-socket, the feed belt can be paused and stopped for a box exchange.

The control is connected to the production machine with an interface and thus ensures the exact piece count filling of the containers.

• Flexible buffer system - easy to reposition and universally usable at different production machines
• Dimensions of the buffer lines and the feed conveyor technology are individually designed depending on the problem at hand.
• Combination with roller conveyors or weighing systems possible
• Adjustable side guides on the buffer belts allow secure positioning of containers of different dimensions
• Sensors for oversight of the output (buffer full, no more empty containers, etc.) and indicator light for presentation of the operation status

Through the low-wear and -abrasion construction of the MTF conveyor belts, they are also especially well suited for use in clean areas or clean rooms. In these demanding environments, linear buffer systems can be installed when boxes are to be automatically filled directly at the machines.

• Enclosure of the entire conveyor line with polycarbonate
• Integration of ionisation fans in the machine output belt
• Adaptation of the belt geometry to the on-site available output slides and machine shafts
• Covering of the linear buffer with polycarbonate and pneumatic spring-supported valves
• Avoidance of bulk spaces in the containers by multiple pre-cycles in the filling position
• Attachment bar for the container lids
• Siemens S7 for control of the outputs and signal light for visual control of the system status

With many stamped or bent pieces (e.g., springs), the bulk cone formation in the containers to be filled presents a problem because the available volume can often be used only incompletely due to piece interlocking. Here linearly shiftable feed belts in combination with multiple pre-cycling container belts offer an ideal solution to reach the most even distribution possible of products in the container.

• Filling belt pneumatically positionable in the lateral axis over the buffer containers
• Frequently pausing container belt
• Roller conveyor with end stop at conveyor end
• Control with Siemens S7 controller

As with all MTF devices, the Multi-Linea also distinguishes itself through a high degree of flexibility. The basic principle of the circulating container or bag storage is always adapted to the concrete problem formulation.

• Stable container uptake with slip-retardant surface for 8 plastic boxes 400x300x320mm.
• Base in raised version, adapted to the concrete usage
• MTF counter control for exact piece-count filling of the container including the possibility of controlling additional peripheral devices
• Optional use in counter mode or timer mode available

The pictured system is used at a machine that sometimes produces right and left pieces at the same time. In this case one box is constantly filled with right and one box with left pieces. Optionally after output for a preset time or after reaching a target piece count, the system cycles two positions further.

If a new kind of piece is produced, a box is constantly filled and also simply cycled onward.

• Freely programmable Siemens SPS with customer-specific special functions (e.g. double forward cycling, realisation of interfaces, signal displays, etc.).
• 12 container uptakes for plastic boxes 600x400x320mm

Especially in clean room applications, there is often the need to enclose the systems as completely as possible. Enclosures of polycarbonate, aluminium or stainless steel can be realised without difficulty.

• Unit enclosed on all sides with foldable covers
• Customer-specific construction of the system, adapted to the dimensional conditions on site

Apart from the task specific design with regard to the number and size of the containers to be buffered, the basic construction can also be adapted according to the customer's wishes. These changes include height-adjustable bases or special dimensional requirements.

• Geometric adaptation on the basis of the available space ratios
• Height-adjustable base in moveable design with additional floor stops

The Multi-Linea can be used not only for cartons and boxes, but also for bags. In this case, task-specific bag brackets are used.

• Clean room configuration with stainless steel bag brackets and special fixtures with FDA compliant materials
• Special construction with pneumatically positionable QA test bags that are filled in the running process
• Special transfer area from the production machine, consisting of a stainless steel hood with swinging suspended Teflon impact plates for noise reduction
• Siemens S7 control with special programming, specially adapted to the customer's requirements
• Doubled emergency stop switch and contact for avoidance of jam danger

Used as a stand-alone device, the Multi-Rounder can be easily integrated into different places of use. In every place where pieces need to be counted and buffered into different containers, it presents a cost-effective solution for automated material handling.

• Infinitely adjustable height and pitch for adaptation to a wide range of requirements
• Stable base for secure positioning
• Minimal space required
• Number and position of output points simple to change
• User-friendly count control, with a choice between count or time modes

For applications with which the conveyor belt and distribution guide function as a unit, the rotary distributor is used as an attached device. The distributor is connected individually to the conveyor frame or base depending on the task. It can likewise be adapted to almost any other manufacturer's devices.

• Conveyor belt and rotary distributor can be run as a unit
• Speed and control of the belt run time through the count control of the distributor
• Simple addition to MTF belts - also after the fact
• Can also be connected to third-party belts
• Turning or swinging use adjustable through the controller
• Infinitely adjustable height and tilt of the slide
• Planetary gear motor with brake for exact positioning

Especially in the metal industry, more resistant materials must be used for the swing slide. Depending on the task slides made of steel or stainless steel are often used. For noise reduction, special acoustic panels can also be added.

• Material, surface and geometry of the slide can be altered according to special client requirements
• Infinite height and pitch adjustability of the slide
• Special attachments (e.g., pneumatic valves, etc.) to the slide are possible

In the version with moveable base and Siemens controller, the Multi-Rounder is exceptionally flexible in its use. The stable base made of solid steel material provides a low center of gravity and stable position.

• Pattern-rolled slide plate for prevention of material adhesions, e.g. due to stamp oils
• Cover over the slide to prevent pieces from jumping out
• 400V-socket for connecting other peripherals to the control cabinet
• Siemens S7 control with individual programming according to customer needs
• Moveable base with locking wheels

Multi-Rounder Type MR-S1 Special with outlet chute in stainless steel, (patterned design). The chute is covered in order to prevent parts from jumping out. The cute closes the outlet during the movement, when the parts feeding cannot be interrupted.

Especially with production or packaging machines with free overhanging machine exit shafts, the parallel buffers with extra-low built heights are suited for optimal use of the space available. The buffer solution can thus be integrated directly into the base of the machine.

Depending on the installed machine control, the functions of the buffer can be taken over by this control.

• A rodless pneumatic cylinder with five stop positions allows an individual feeding of the filling position depending on the box size
• Compact shifting unit with rodless pneumatic cylinder for minimal built height
• Sensors for overseeing of the filling positions and the transfer positions
• Control via the on-site machine controller
• Conveyor belts with drum motor drive for minimal protrusions

22 containers with a base of 400mm x 300mm can be filled and buffered on this unit. This represents a net container area of 2.64 m2, with a total area required by the system of around 3.8 m2. The space usage of the system is thus 70%. This ratio can be improved even more if the system can be made even longer.

In the concrete example, the system enables the entire night shift at the stamping plant of an automobile supplier to run unmanned.

• Small conveyor belt with pneumatic distribution head at the belt exit for distribution of the conveyor stream into two parallel mounted containers
• Complete container circulation by two front-end shifting devices
• Pneumatic separation stations before the shifting positions to prevent a jam of the containers
• Manifold pre-cycle in the filling position prevents shaking and optimizes the degree to which the containers are filled
• Siemens S7 controller for control of the system functions
• Stable construction, designed for a total load of 250 kg

Cartons are to be fed toward a picking robot and then buffered on a conveyor line. Depending on the product, different carton sizes must be securely transported and positioned.

• Adjustable side guides for adaptation to different carton sizes
• Pneumatic cylinders positionable linearly on the conveyor belt profile for carton collection and separation before the cross-shifting positions
• Sensors re-positionably mounted on the side guides to ensure short changeover times
• Compact construction with drive mounted underneath the belt body
• Control of the pneumatics and sensors with the on-site robot controller

This device provides for a u-shaped material flow. The operater can put on empty boxes at a central point and take off filled boxes.

Conveyor-roller-combination with pneumatic shifting unit in floor version as box changer positioned below low-rised discharge chutes.

This type of container changer is suitable for various KLT-box sizes. Here, the shifting process takes place on a roller conveyor. The pneumatic cylinder stops at different stop positions, i.e. 4 boxes can be put up parallelly and be filled successively (for example).

• MTF Multi-Tech conveyor type GL-LD Special with pneumatic cross slider and two roller conveyors
• A short roller conveyor as an extension of the belt conveyor is used to minimize abrasion due to the sliding process
• The filling takes place on the long roller conveyor which is situated parallel to the belt conveyor
• The first rolls on the long roller conveyor are blocked by a pneumatic cylinder until a complete row of boxes is filled. Afterwards the filled boxes are released an roll towards the outlet of the roller conveyor.
• Resistant polyester belts suitable for shifting use on the conveyors guarantee long life

In almost every area of industry, roller conveyors are used mainly in areas where boxes, cartons or work piece carriers must be transported by gravity.

• Useable width from 100 to 1,200 mm in 50-mm increments
• Frame made of steel or stainless steel
• Rollers made of PVC, galvanized steel, aluminium or stainless steel
• Roller diameter 50mm
• Roller distribution depending on the task 62.5 / 75 / 100 / 150 or 200 mm
• Model R-50/70 without side guides
• Model R-50/100 with 30-mm-high side guides
• Adjustable side guides optionally mountable
• End stop if required
• Height- and angle-adjustable base

Roller beds made of stainless steel are used e.g. in wet areas or cleanrooms. In the illustrated version with a 70mm high underframe, the rolls are at highest level. Therefore the conveyed good rolls to the end without lateral guiding.

• Useable width from 100 to 1,200mm in steps of 50mm
• Underframes made of steel or stainless steel
• Rollers in PVC, galvanised steel, aluminium or stainless steel
• Roller diameter of 50mm
• Roller dispartment of 62,5 / 75 / 100 / 150 oder 200mm, depending on the task
• Model R-50/70 without lateral guiding
• Model R-50/100 with lateral guiding of 30mm height
• Adjustable lateral guidings are optional
• With end stop if needed
• Underframes are adjustagble in height and inclination

Behind a bag packing machine, packaged food products are to be moved to a manual packing station. Since the workers at the packing stations also carry out logistical tasks, overproduced amounts must in the meantime be carefully buffered for a short time. The products should not fall against each other and should be tendered to the workers ergonomically for further processing.

The containers stand on a sliding plate directly above the floor. Therefore the box changer can be installed below e.g. very low machine discharge conveyors (e.g. with ARBURG injection moulding machines) or below discharge chutes of selection switches.

The linear buffer offers an especially space-saving and perfectly enclosed solution with containers that remain still and a moveable distribution belt.

• Linearly moveable and reversible belt above the container level
• Depending on the desired buffer capacity, pneumatic rod cylinders, rodless cylinders or electric linear actuators are installed for the positioning of the distribution belt
• Additional pneumatic valves can be mounted at the outlets on both sides of the distribution belt to ensure the count accuracy
• Clean-room-suitable slide bearing of the shifting elements
• Frame of closed aluminium profiles for ease of cleaning
• Complete enclosure of the system with polycarbonate sides and pneumatic spring-supported top
• Acknowledgement button as indicator light for every container
• Siemens S7 counter control
• Indication of the operating conditions with a signal light
• Container presence control via sensors

Plastic injection moulded pieces are transported directly upon leaving the machine via a sharply climbing enclosed conveyor belt onto a linearly shiftable distribution belt. The reversibly running belt uses two three-way switches mounted at either end. Thus a total of 12 bags are filled.

• Complete enclosure of the system and thus suited for sensitive production areas.
• Siemens S7 for control of the system output
• Interface to the production machine and a parent storage manager
• Clean-room-appropriate construction of the system for the transport and buffering of medical-technological articles
• Quick coupling between machine output conveyor and buffer station for disruption-free material transfer
• Mobile buffer system, can be installed at different production machines