Roller conveyor keeps cycling gear on track

ZyroFisher is one of the largest privately-owned distributors of parts, accessories and clothing to the UK and Irish cycling markets. An expert in multi-brand distribution, the company represents more than 50 world-class leading brands and supplies its own Altura products to specialist retailers – a significant challenge for the material flow. 

ZyroFisher invited Advance Automated Systems to review existing handling methods. The UK conveyor manufacturer proposed improvements that included an innovative handling system incorporating energy-efficient 24V DC technology and MultiControl, ultra-modern and mission-critical components from Interroll. 

Smart solutions

With high levels of manual handling dominating pick, pack and dispatch operations at ZyroFisher’s 100,000ft² Darlington facility, the company needed a solution that would make the movement of goods from the packing area to dispatch more efficient. 

Advance engineers submitted a proposal to provide a bespoke, zoned, SmartLine roller conveyor to transfer various sized cartons directly to the dispatch trailer. 

Built by Advance Automated Systems, SmartLine is a zero line pressure conveyor system incorporating energy-efficient 24V DC technology from Interroll. It combines a quiet running RollerDrive EC310 and MultiControl, which together simplify and reduce system commissioning time on site. 

Interroll MultiControl is a network card that can connect four zone sensors and four RollerDrive EC310 and directly integrate these at fieldbus level. PROFINET, EtherNet/IP and EtherCAT real-time communication can be realised with every MultiControl by making a simple setting.

The configuration of sensor or RollerDrive properties is done over PLC software, a web user interface or with the Interroll teach-in procedure. This also makes automatic addressing possible and provides information on the order of all connected MultiControl or conveyor zones in the conveyor. This guarantees a quick and easy start up on-site. The IP54 protection class meets the requirements that pertain to industrial plants. The Interroll MultiControl can be used in temperature ranges of between -30 and +40°C. 

Plug & play technology allows for quick and easy replacement, if necessary. In case of replacement, no addressing or configuring is necessary.

Automated solution 

Advance’s proposed automation solution is flexible, modular and efficient to run. With each individual conveyor module being independently driven, they only operate when there are containers present; once these have moved off, the conveyor modules no longer run, but continue to be ready for transporting product. If required, product can accumulate over the full length of the conveyor. 

So as not to restrict access through the warehouse, the conveyor system was equipped with lift access gates both single width (for pedestrian/fire escape access) and double width (for pallet access). All gates include gas springs making them easy and safe to lift. An extendable gravity roller for loading on the back of a box trailer completed the configuration. 

Advance Automated Systems smart modernisation project integrated perfectly with ZyroFisher operations, enabling the company to optimise its complex flow of goods and increase its through-put.