36 n LINEAR MOTION May 2025 www.drivesncontrols.com Linear transfer system ends conveyor failures An automotive parts manufacturer was experiencing around 15 stoppages every day on a conveyor line due to failures of components such as position sensors and electromechanical stoppers. Although the problem was usually xed in a few minutes – often with a simple reset command – the total time being lost per shift was a ecting productivity. The company’s production team embarked on a project to increase output by preventing the conveyor stoppages, and to nd a more reliable alternative that was capable of operating continuously for extended periods. After analysing the market, the team discovered a linear transfer system that was highly regarded by other manufacturers facing similar challenges. The LCMR200 system – from Yamaha Motor Robotics FA section – is based on electronically controlled and programmable linear motors, designed to o er high reliability. After arranging a demonstration of the technology, the company was impressed with the design that reduces the number of driving devices and sensors, while ensuring accurate and precise control. The modular system for automated production lines transfers workpieces quickly and eciently between the di erent processes needed to assemble and package products – especially small parts such as the automotive components in this application. The modules are equally suitable for manual production lines, or for partially or fully automated production lines. The speed, acceleration/deceleration, stop positions and direction are all programmable, allowing fast set-ups, as well as exibility to adapt as manufacturing demands change. With the help of a system integrator, the manufacturer replaced its failure-prone conveyor system with the new technology, which has eliminated the frequent stoppages that proved so disruptive in the past. Working with the same line rate and process cycle times as before, the new line is producing an extra 5,400 items per month – a 10.3% increase in output, through increased uptime. The new system’s maximum speed of 2.5m/s allows faster transfer times than the previous conveyors. Its length can be scaled by increasing or decreasing the number of modules. Each module has an individual identity, allowing up to 64 to be connected and controlled simultaneously. The total height of each module and slider is 109mm, and they are 175mm wide. Each slider can carry up to 30kg and they are rigid enough to allows production processes to be performed on the module. This avoids the need to remove and return workpieces to the sliders, allowing short cycle times as well as reducing engineering and tooling costs. Special modules are available for circulation and traversing, allowing integrators to build compact production lines that support branching or overtaking to change the sequence of processes, if required. This can be useful if individual workpieces need to be diverted for special processes such as personalising or applying customer-speci ed options. Tatsuro Katakura, FA section sales manager at Yamaha Motor Robotics Europe, says that close cooperation between the system integrator, customer and supplier in this application resulted in a fast system that “totally ful lled the requirement for uninterrupted production, increased output, and greater productivity”. He expects the customer to adopt similar systems for other production processes in the future. n When an automotive parts manufacturer was experiencing frequent failures on a conveyor line, it looked for an alternative. It opted for a linear transfer system which has resulted in a 10% increase in output, as well as eliminating the shutdowns. The original conveyor line had many failure-prone components which resulted in frequent stoppages The linear transport system has eliminated many of the causes of conveyor failures, such as cylinders and sensors
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