Transport components efficiently and space-savingly using gravity

Overhead conveyor systems allow for a particularly productive provision of materials that, due to their irregular shape, are ideally moved hanging along a conveyor track. Especially when it comes to transporting goods that take up too much space in standard small load carriers or are easily snagged, overhead conveyor systems are recommended. They are not only cost-effective and flexibly adaptable but above all one thing: space-saving.

Less Empty Packaging in the Return Process

Overhead conveyor systems usually consist of a structure with trolleys to which the transport goods are attached. These trolleys move along a profile to the pick-up point. In contrast to small load carriers (KLTs), which come in many different versions concerning length, width, and height, the trolleys are available in a defined, uniform size. They are significantly smaller than KLTs and therefore require considerably less space when stored. This is not only the case for storage but also becomes apparent in the return process on the production line, where the overhead conveyor system is superior to the KLTs in terms of space efficiency.

An example: In the "traditional" transport of glove compartment lids in the automotive industry, four pieces per KLT can be brought to the production line via two feed levels. Two return levels are used to transport the empty containers. While the filled KLT on the way to the production line occupies as much space as the empty one on the return journey, this is different with the suspended transport of glove compartment lids via a conveyor system. This system reduces the volume of empty packaging because the trolleys are significantly smaller and thus more space-saving compared to the KLTs. After the material is removed, they can be collected and returned in just a single KLT. Consequently, two of the total four levels no longer need to be reserved for returning the empty KLTs, but can also be used for material supply to the production line. "In this way, by replacing KLT transport with an overhead conveyor system, around one and a half times the amount of material can be provided at the production line. Depending on the component, this factor can be even higher," explains Michael Guntermann, Product Manager and Team Leader Application & Support at Item Industrietechnik GmbH.

Significant Space Gain on the Production Line and in the Warehouse

Headliners can also be ideally transported using the overhead conveyor system. Its use allows for more material to be fed simultaneously while making significantly better use of space both on the production line and in the warehouse.

Headliners come in many different versions, with sliding or panoramic roofs or completely closed. Additionally, they vary in colors and materials. All these different variants are stored flatly stacked. To avoid damaging the lower headliners, the number is limited, or they must be stored separately, resulting in many stacks with a high space requirement. "The pallets including the aisles can quickly occupy up to 20 square meters. That's an enormous amount - the space could be significantly reduced by using an overhead conveyor system," says Michael Guntermann. For a hanging transport of the headliners, two tracks could be attached side by side so that two carriages (one per track) could transport a headliner. This way, with the same amount of material, about half the space would be saved, which could then be used to store additional headliners. An additional advantage: pallets become unnecessary with the hanging system, which positively affects space requirement in the warehouse. At the same time, thanks to the suspension, the risk of damage from floor vehicles or forklifts to the headliners is significantly minimized. This is an important factor as headliners are delicate and can easily become deformed or soiled.

In addition to glove compartment flaps and headliners, overhead conveyor systems are also suitable for many other components such as cables, dashboard panels, floor mats, measuring instruments, or other parts from the automotive industry. The systems are also usable for products and components from other industries that can be efficiently prepared for further processing thanks to an overhead conveyor system.