Tray Manual 3.8

For internal use only
Airport Logistics
TRAY Conveyor System

User Manual
Description and Configuration Rules
Siemens Industry - Mobility

September 15, 2010 V. 3.8 Industry, IL LS
www.siemens.com/airports
© by Siemens AG 2010
This is a copyrighted documentation of Siemens AG. It may not be altered, amended or

reproduced without the prior written approval of Siemens AG and may not be used in any other
manner that is contrary to their legal interests.
All trademarks and registered trademarks are the property of the individual owners. The use of
registered names, trade names, description of goods etc. in this manual, even if not specially
identified, does not imply that such names may be regarded as free in the sense of legislation
pertaining to registered trademarks and protection of trademarks and may therefore be used by
anyone.
Responsible for the contents:
Devices J. Bruett Phone +49 (0) 911 145 7602

Configuration rules A. Fiedler Phone +49 (0) 911 145-7724
Text editing H. Steinke Phone +49 (0) 911 145 6933
Postal address Siemens AG

Sector Industry, Airport Logistics
Colmberger Straße 2
90451 Nuremberg
Germany
The right to make modification to design and equipment is reserved.
Industry, IL LS September 15, 2010 V. 3.8

TRAY System User Manual History of Changes
Conveyor System Concept Description and Configuration Rules
History of Changes
Version Date Change/Comment

2.0 15.08.2002 Complete revision of layout and contents
2.1 25.11.2002 minor corrections and amendments
2.2 21.01.2003 Redesign of the loading station, avoid inclined
conveyors after loading stations
2.3 27.01.2003 installation without welding, energy consumption
2.4 13.02.2003 Info on paint (Introduction), new configuration rule
for loading station
2.5 05.05.2003 Increased throughput of merge switches, new
photos, side guards
2.6 09.09.2003 Changes to configuration rules of the accumulator,
new device compact tilter
2.7 05.05.2004 Update to Siemens L&A, new introduction, further
technical changes
2.8 30.03.2005 Various changes to almost all sections
3.0 21.03.2006 Various changes, configuration rules new
3.1 19.06.2006 Changes to loading station, metering and tilter
3.2 27.07.2006 Extended configuration rules for knees and turns
3.3 07.11.2006 New configuration rule for traverses with slave drive
3.4 08.02.2008 Inclusion of Cross Belt Tray
3.5 28.11.2008 Standardized height differences for inclined
conveyors
3.6 03.03.2009 CrossBeltTray sections updated, large tilter taken
out
3.7 20.10.2009 Terminology adapted
3.8 15.09.2010 Belt descriptions updated
This version supersedes all previous versions of the manual.
The TRAY user manual is available in a German and an English version.
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TRAY System User Manual Contents
Contents
1 Introduction and overview .............................................................1

1.1 The main components and their application .....................................3
1.2 The main reference sites so far.......................................................14
2 Cross Belt Tray .............................................................................20

2.1 Fire resistance of the trays..............................................................21
2.2 Tray identification ............................................................................21
2.3 Drive concept and station................................................................22
3 Static loading / unloading station................................................25

3.1 Functional specification of equipment .............................................25
3.2 Technical data.................................................................................26
3.3 Drive ratings ....................................................................................26
4 Dynamic loading / unloading station ..........................................27

4.2 Technical data.................................................................................28
4.3 Drive ratings ....................................................................................28
5 Tray ................................................................................................29
5.1 Project-specific tray dimensions......................................................31
5.2 Special case of service tray ............................................................32
5.3 Material properties of the trays........................................................32
5.4 Tray identification ............................................................................33
6 Loading station .............................................................................35

6.2 Technical data.................................................................................37
6.3 Drive ratings ....................................................................................38
7 Straight conveyor..........................................................................39
7.2 Technical data.................................................................................40
7.3 Drive ratings ....................................................................................44
8 Metering conveyor (discontinuous) ............................................46

8.2 Technical data.................................................................................47
8.3 Drive ratings ....................................................................................50
9 Accumulation conveyor ...............................................................51

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9.2 Technical data.................................................................................52

9.3 Drive ratings ....................................................................................52
10 Wheel conveyor ............................................................................53

10.2 Technical data.................................................................................54
11 Adapter and normal traverse .......................................................55

12 Slave drive for wheel conveyors and turn ..................................57

12.2 Technical data.................................................................................58
12.3 Drive ratings ....................................................................................58
13 Inclined conveyor .........................................................................59

13.1.1 19o inclined conveyor ......................................................................60
13.1.2 8° inclined conveyor ........................................................................63
13.2 Technical data.................................................................................64
13.3 Drive ratings ....................................................................................67
14 Turn ................................................................................................68
14.1.1 Standard turns R = 2550 mm Vmax = 2.5 m/s...............................69
14.1.2 Standard turns R = 2000 mm Vmax = 1.5 m/s...............................70
14.2 Technical data.................................................................................71
14.3 Drive ratings ....................................................................................73
15 Switches ........................................................................................74
15.1.1 Standard switches...........................................................................75
15.1.2 Special switches..............................................................................76
15.2 Technical data.................................................................................77
15.3 Drive ratings ....................................................................................78
16 Compact tilter ................................................................................79

16.2 Technical data.................................................................................81
16.3 Drive ratings ....................................................................................82
17 Roller checking station.................................................................83
18 Steel support system....................................................................85

18.1 Clearance dimensions.....................................................................85
18.2 Attaching the conveyors..................................................................86
18.3 Supports..........................................................................................87
18.4 Hangers ..........................................................................................89
18.5 Steel platforms ................................................................................91
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18.6 Service walkways............................................................................93
19 Systems .........................................................................................96
19.1 Introduction to Systems...................................................................96
19.2 Basic system design assumptions ..................................................99
19.3 Throughputs ....................................................................................99
19.4 Energy consumption of a tray conveyor system ...........................101
19.5 Considerations for the system control system ..............................101
19.5.1 PLC limits ......................................................................................101
19.5.2 Number of initiators .......................................................................101
20 Sub-systems................................................................................103
20.1 Introduction to sub-systems ..........................................................103
20.2 Tray loading ..................................................................................105
20.3 Tray tilting .....................................................................................106
20.4 Transfer.........................................................................................108
20.5 Tray storage ..................................................................................111
20.5.1 Conveyor lengths in the dynamic storage location........................111
20.5.2 Overview of storage types.............................................................112
20.5.3 Implementation examples of static and dynamic stores................115
20.5.4 Storage capacities ........................................................................118
20.6 Sorting...........................................................................................119
20.7 Manual operations.........................................................................120
21 Function Groups .........................................................................122

21.1 Introduction to function groups......................................................122
21.2 Loading stations: FGT_Load_A ....................................................123
21.3 Compact Tilter: FGT_Tilt_C ..........................................................127
21.4 Diverting ........................................................................................128
21.4.1 Standard Divert: FGT_Divert_S ....................................................128
21.4.2 Total Priority Divert: FGT_Divert_TP ............................................135
21.5 Merging .........................................................................................137
21.5.1 Standard Merge with ratio: FGT_Merge_R ...................................137
21.5.2 Total Priority Merge: FGT_Merge_TP...........................................148
21.6 Tray accumulation: FGT_Accu_A .................................................153
21.7 Highspeed track: FGT_HighSpeed ...............................................156
21.8 Buffer: FGT_Buffer........................................................................158
21.9 Gap optimization: FGT_Gap_Opti.................................................162
21.10 Fire Doors: FGT_FireDoors ..........................................................165
22 Devices ........................................................................................169
22.1 Straight conveyors ........................................................................169
22.1.1 Calculation of lengths....................................................................169
22.1.2 Minimal vertical displacement .......................................................170
22.1.3 Knee conveyors ............................................................................170
22.2 Metering conveyors (discontinuous) .............................................172
22.3 Slave drive for wheel conveyors and turns ...................................172
22.4 Traverses with slave drive.............................................................173
22.5 Inclined conveyors ........................................................................174
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22.6 Turns .............................................................................................175

22.6.1 Turns with slave drive ...................................................................175
22.6.2 Turn combinations.........................................................................176
22.6.3 Segmentation of 180° turns ..........................................................176
22.6.4 Speed transitions at turns .............................................................177
22.6.5 Installation rule ..............................................................................177
22.7 Switches........................................................................................178
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TRAY System User Manual Illustrations
Illustrations
Figure 1 Loading of the cross belt tray ............................................................3

Figure 2 Static loading station .........................................................................4
Figure 3 Dynamic loading station ....................................................................4
Figure 4 Flat bottom shaped standard tray .....................................................5
Figure 5 Load station from belt to tray conveyors ...........................................6
Figure 6 Photo of a straight conveyor .............................................................6
Figure 7 Photo of a metering conveyor ...........................................................7
Figure 8 ID tag and reader to identify trays in motion .....................................7
Figure 9 In-/Declined conveyor to manage height differentials .......................8
Figure 10 Photo of a turn ..................................................................................8
Figure 11 Standard merge for tray conveyor system ........................................9
Figure 12 Accumulation conveyor .....................................................................9
Figure 13 Compact tilters to unload bags to belt conveyors ...........................10
Figure 14 Toothed belt and guide roller ..........................................................10
Figure 15 Side cover of longitudinal beam ......................................................11
Figure 16 Layout design with CONCEPTIX Engineering tool .........................13
Figure 17 Typical baggage tray at Frankfurt International Airport ...................14
Figure 18 V-shaped trays at Dubai International Airport ................................14
Figure 19 Tray for nonconveyable packages ..................................................15
Figure 20 Tray sample for Paris Charles de Gaulle Airport.............................15
Figure 21 Tray sample for Madrid Barajas Airport ..........................................16
Figure 22 Tray conveyor line at Malpensa Airport...........................................17
Figure 23 Special trays for OOG bags on the same track...............................17
Figure 24 Tray conveyor line at Beijing T3......................................................18
Figure 25 Tray conveyor systems designed to meet customer requirements.19
Figure 26 Photo of the Siemens Cross Belt Tray ............................................20
Figure 27 Tray identification by code carriers .................................................21
Figure 28 Drive station ....................................................................................23
Figure 29 Cross Belt Tray drive concept .........................................................24
Figure 30 Static loading station .......................................................................26
Figure 31 Tray front view drawing (Example: Paris) .......................................29
Figure 32 Tray side view drawing (Example: Paris) ........................................30
Figure 33 Tray plan view drawing (Example: Paris)........................................30
Figure 34 Drawing of top view of trays in turns ...............................................31
Figure 35 Drawing of service tray (Example Paris) .........................................32
Figure 36 Drawing of tray identification ...........................................................33
Figure 37 Photo of tray identification...............................................................34
Figure 38 Drawing of the tray loading station..................................................36
Figure 39 Drive station, intermediate bed section and tension station............40
Figure 40 Main dimensions of carrier belt .......................................................41
Figure 41 Photo of straight conveyor belt type................................................42
Figure 42 Drawing of straight conveyor individual elements ...........................43
Figure 43 Drawing of a metering conveyor with standard drive ......................46
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Figure 44 Main dimensions of tooth belt .........................................................48

Figure 45 Photo of metering conveyor belt type..............................................49
Figure 46 Photo of accumulation conveyor .....................................................52
Figure 47 Drawing of wheel conveyor .............................................................53
Figure 48 Photo of wheel conveyor belt types ................................................54
Figure 49 Drawing of adapter traverse............................................................55
Figure 50 Photo of adapter traverse................................................................56
Figure 51 Photo of normal traverse.................................................................56
Figure 52 Layout of slave drive after a turn.....................................................57
Figure 53 Layout of slave drive between turn segments.................................58
Figure 54 Drawing of a lower bow with special toothed belt ...........................60
Figure 55 Photo of special toothed belt in of inclined conveyor lower bow .....61
Figure 56 Drawing of an upper bow with high-grip toothed belt ......................61
Figure 57 Photo of metering toothed belt in inclined conveyor with high grip .61
Figure 58 Drawing of upper bow/metering conveyor/lower bow .....................62
Figure 59 Photo of an inclined conveyor .........................................................63
Figure 60 Drawing of a complete inclined conveyor........................................63
Figure 61 Main dimensions of timing belt........................................................64
Figure 62 Photo of belt type for lower bow......................................................66
Figure 63 Drawing of turn 45 deg....................................................................69
Figure 64 Photo of turn ...................................................................................69
Figure 65 Photo of turn belt type .....................................................................72
Figure 66 Drawing of a switch .........................................................................75
Figure 67 Photo of a switch.............................................................................76
Figure 68 Photo of switch belt type .................................................................78
Figure 69 Schematic of Compact Tilter with tray.............................................80
Figure 70 Photo of Compact Tilter ..................................................................80
Figure 71 Photo of Compact Tilter with chutes at both sides ..........................81
Figure 72 Functional principle of roller checking station .................................83
Figure 73 Photo of roller checking station .......................................................84
Figure 74 Drawing showing clearances ..........................................................85
Figure 75 Drawing of cross-beam with buffers................................................86
Figure 76 Ground support ...............................................................................87
Figure 77 Single support bed section..............................................................88
Figure 78 Double support frame......................................................................89
Figure 79 Standard hangers ...........................................................................89
Figure 80 Top-hung platform...........................................................................90
Figure 81 Top-hung platform system from the building ceiling........................91
Figure 82 Standard wide-surface platform ......................................................92
Figure 83 Standard platform of light-weight construction ................................93
Figure 84 Service walkway, example Madrid ..................................................93
Figure 85 Crossover........................................................................................94
Figure 86 Ladder, stairs ..................................................................................95
Figure 87 Railings ...........................................................................................95
Figure 88 Example of the design process for a tray store...............................98
Figure 89 Sub-systems for tray loading.........................................................105
Figure 90 Sub-systems for tray tilting............................................................106
Figure 91 Position of tilters in bypass lane....................................................107
Figure 92 Sub-systems for tray transfer ........................................................108
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Figure 93 Drawing of sorting area and tunnel sections .................................108

Figure 94 Layout of tunnel-conveyor ring link ...............................................110
Figure 95 Sub-systems for empty tray storage .............................................111
Figure 96 Sub-systems for early bag storage (tray) ......................................111
Figure 97 Layout of a static store with parallel accumulation sections..........116
Figure 98 Layout Longitudinal static store with switches ..............................116
Figure 99 Layout of a dynamic store .............................................................117
Figure 100 Layout of a dynamic store with distribution circuit.........................117
Figure 101 Sub-systems providing tray sorting ...............................................119
Figure 102 Sub-systems for manual operations..............................................120
Figure 103 FGT_Load_A – Design 1 ..............................................................125
Figure 104 FGT_Load_A – IT response time..................................................126
Figure 105 FGT_Tilt_C – Design 1 .................................................................128
Figure 106 FGT_Divert_S – Design 1 .............................................................130
Figure 107 FGT_Divert_S – Design 2 .............................................................131
Figure 108 FGT_Divert_S – Problem in the control strategy at a divert..........132
Figure 109 FGT_Divert_S – Routing strategy .................................................133
Figure 110 FGT_Divert_S – Look-ahead control of a divert............................134
Figure 111 FGT_Divert_S – Position of PS for divert routine..........................134
Figure 112 FGT_Divert_TP – Application .......................................................135
Figure 113 FGT_Divert_TP – Design 1...........................................................136
Figure 114 FGT_Divert_TP – Design 2...........................................................136
Figure 115 FGT_Merge_R – different ratios ...................................................138
Figure 116 FGT_Mege_R – Design 1 (max. ratio 3:3) ....................................140
Figure 117 FGT_Merge_R – Design 2 (max. ratio 3:3)...................................141
Figure 118 FGT_Merge_R – Design 3 (max. ratio 3:3)...................................142
Figure 119 FGT_Merge_R – Design 4 ............................................................143
Figure 122 Merge – Crossing for redundancy.................................................146
Figure 123 FGT_Merge_R – PLC control .......................................................147
Figure 124 FGT_Merge_TP – Design 1 ..........................................................149
Figure 130 FGT_Merge_TP – Minimum window.............................................152
Figure 131 FGT_Merge_TP – Zone of prenotification.....................................153
Figure 132 FGT_Accu_A – Design 1 ..............................................................154
Figure 133 FGT_Accu_A – Design 2 ..............................................................155
Figure 134 Drawing of accumulation conveyor ...............................................156
Figure 135 FGT_HighSpeed ...........................................................................157
Figure 136 FGT_Buffer - application ...............................................................159
Figure 137 Incorrect interconnection Highspeed <> Distribution ....................160
Figure 138 FGT_Buffer - Example 1 ...............................................................161
Figure 139 FGT_GapOpti – Design 1 .............................................................162
Figure 140 Functional scheme of Gap Optimizer............................................164
Figure 141 Layout of situation at the fire protection gate ................................165
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Figure 142 Drawing of the transition at the fire door .......................................166

Figure 143 Photos of top view of the transition at the fire door .......................166
Figure 144 Photo of side view of the transition at the fire door .......................167
Figure 145 Schematic drawing of vertical knee downward .............................170
Figure 146 Schematic drawing of vertical knee upward..................................171
Figure 147 Drawing of horizontal knee............................................................171
Figure 148 Wrong application of slave drive with traverse..............................173
Figure 149 Schematic support arrangement of two-tier ascending section ....174
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TRAY System User Manual Tables
Tables
Table 1 Relationships between speed, tray spacing and throughput.........100

Table 2 Sub-System  Function Group Application Matrix ...............104
Table 3 Function Group  Components Application Matrix ..............123
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TRAY System User Manual 1 Introduction and overview
1 Introduction and overview
Automatic conveyor systems are used at airports to transport incoming and

outgoing passenger baggage. The equipment developed for this purpose
transports items of baggage either loose on conveyor belts or in specially
designed bins.
The well known Siemens tray conveyor system has entered into a new
generation by enhancing it with an extended Cross Belt Tray technology.
This document describes the CrossBeltTray and the tray conveyor system
manufactured by Siemens AG. In addition to flight baggage, it is suitable for
transporting and sorting other similar goods. Tray conveyor systems of this type
are particularly suitable for transporting goods across longer distances.
The bags are loaded individually into trays, which are then transported along
toothed belt conveyors to tilters. The baggage is unloaded at these destination
points either by tilting the tray (for passive trays) or by a movement on the same
level (for cross belt trays).
These standardized trays can be transported more quickly and safely through
the baggage system than baggage on regular conveyor belts. Each tray has a
unique code which is used to control the flow of baggage from the loading station
onwards. Each bag therefore needs only to be identified and assigned a tray
code once before loading. From this point on, the tray code is read automatically
before each divert point in the material flow, in order to control the route of the
tray to the unloading point.
The tray conveyor system with passive trays has already been applied for
baggage handling systems for several years. Based on this experience Siemens
engineers have enhanced the system for high speed applications, which are
typically needed to link the growing number of satellite terminals at modern
airports with the main terminals.
The Cross Belt Tray conveyor system has been developed based on the
standard tray conveyor system, which is already in use with several baggage
handling systems since many years. The well proven conveyors like straight and
metering conveyors, turns, inclined conveyors or switches remain unchanged.
With the Cross Belt tray conveyor system the bags are transported at the same
level even during loading and unloading of the tray. With this new feature top
load loading stations and tilters to unload the trays, which transport bags
vertically as well, are not necessary any more. Instead of a vertical movement
forced by gravity the cross belt on the tray carries out an active and controlled
movement to the adjacent belt conveyor (and vice versa).
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According to throughput needed the load or unload station can be
static i.e. while the tray stops on the conveyor, or
dynamic i.e. without stopping the tray’s movement along the conveyor.
The Cross Belt Tray can transport a bag loaded sidewise onto a belt conveyor at
the same level. For this purpose the tray is equipped with an integrated cross
belt. The movement of the synclinal cross belt will not be forced by an integrated
electric drive, but simply by using friction fit to a stationary drive, which is part of
the conveyor. Thus there is no need for an electrical transmission to a motor
on a moving tray (with all its known problems).
Due to the loading or unloading of the tray at the same level especially compact
layouts are possible. The space required in vertical (bag remains at the same
level) or horizontal (no need for chutes and tilters) direction is minimized.
The CrossBeltTray conveyor system is 100 % compatible to the well proven

Siemens tray technology. Existing systems can easily be extended. A mixed
operation with standard trays is possible.
Conveyor advantages of high speed system

● Application of a single system for normal and high speed baggage
transportation avoids change over between different conveyor types and
reduces variety of parts.
● Top speed 12 m/s (43 km/h) or 2400 fpm (27 mph).
● Up to 3000 bags/hour throughput at each line.
● Fast baggage transportation contributes to a short connecting time.
● Frequency controlled electrical motors with belt drives instead of gear
boxes.
● Transportation of Trays on curve-shaped tracks with maximum speed.
● Operational experience with dedicated testing system.
● First application of this system at Madrid airport (18 km of high speed track).
Within chapters 2 to 18 this User Manual describes the conveyors applied for our
baggage handling systems and from chapter 19 onwards the configuration rules
for their application. These rules combine the exact knowledge of the products
used with the experience gained in earlier projects.
This means that the application of the rules is mandatory. If it is absolutely

necessary to make project-specific deviations or to use different conveyors in
individual cases, BL Solutions will have to be consulted.
Tray Manual 3_8.doc

1.1 The main components and their application

The main components of the tray conveyor system are as follows:
Cross Belt Tray

One item of baggage is transported in each concave tray.
Figure 1 Loading of the cross belt tray
Tray advantages
● Carrier tray fulfills the fire prevention standard DIN-EN 20 340 for Tray
components
● Solid construction
● Specially shaped Tray for safe baggage transportation
● Precision guidance due to guide rollers and z-shaped rails
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Static loading / unloading station

A static loading / unloading station connects to a rectangular belt conveyor.
Figure 2 Static loading station
Dynamic loading / unloading station

To achieve increased throughput the belt conveyor is placed at an angle of 450
to the tray conveyor.
Figure 3 Dynamic loading station
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Tray
One item of baggage is transported in each concave tray.
Figure 4 Flat bottom shaped standard tray
Tray advantages
● Carrier tray fulfills the fire prevention standard DIN-EN 20 340 for Tray
components
● Solid construction
● Supported on rollers
● Specially shaped Tray for safe baggage transportation
● Precision guidance due to guide rollers and z-shaped rails
● Noise reducing inner layer
● Tilting while in motion
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Loading station
The bags are automatically loaded into the Trays from above. Guards at both
sides of the loading conveyor ensure that items with complicated shapes are
loaded with no overhang.
Figure 5 Load station from belt to tray conveyors
Straight conveyors
They transport empty or full trays through the baggage system. The conveyor
line consists of one or more straight conveyors, these being available in
horizontal and arched vertical form. These main conveyor sections connect
switches, turns and other elements of the TRAY conveyor system.
Figure 6 Photo of a straight conveyor
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Metering conveyors (discontinuous conveyors)

Metering conveyors are straight conveyors with high pulse frequency (start-stop
cycles) and short acceleration and braking paths.
Figure 7 Photo of a metering conveyor
RFID-Technology
Stationary read/ write devices are used to store or read data on the Trays.
Figure 8 ID tag and reader to identify trays in motion
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Inclined conveyors
Inclined conveyors are used to overcome differences in height. We distinguish
between uphill and downhill inclined conveyors. 8o or 19o inclined conveyors are
used, depending on the difference in height.
Figure 9 In-/Declined conveyor to manage height differentials
Turns
Standard turns are available for different angles and speeds. Normal turns have
driven wheels at the outer radius. For start and stop (metering) functions turns
are driven both on the out- and inside.
Figure 10 Photo of a turn
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Switches
Switches divert the conveyed goods from one line to another or merge two lines
into one.
Figure 11 Standard merge for tray conveyor system
Accumulation conveyors
Accumulation conveyors consist of a straight conveyor with integrated brake
strips which can be raised.
Figure 12 Accumulation conveyor
Each pair of the brake strips lifts one Tray and is driven by a motor.
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Compact tilters
Tilters incline the tray to one side and unload the baggage onto a chute. Tilters
function in a similar manner to tilt tray sorter, but without the sorter’s fixed tray.
Figure 13 Compact tilters to unload bags to belt conveyors
Toothed belts
The trays are moved by driven belts with a flat upper side and a toothed
structure on the driven side. This provides the following advantages:
● Low elongation (short tensioning stations)

● Formfit avoids slippage of belt and burn out of drive pulley.
● Low noise transport due to soft v-profile.
● Long lifetime
● Cost effective
Figure 14 Toothed belt and guide roller
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Side covers
To protect staff working in that area, the longitudinal steel beams supporting the
belt are covered along the outer side. In addition these covers reduce the noise
emission.
Figure 15 Side cover of longitudinal beam
Typical design features

● Low resistance bearings in all rollers
● Plastic roller sockets to reduce noise emission
● Wear optimized materials for belts and rollers
● Special low friction fabric on belt back for smooth baggage transportation
Further supplementary components include undriven wheel conveyors, wheel

switches and wheel turns.
The section of the overall baggage system comprising the TRAY conveyor
system can be assembled from the basic standardized components described
above. Customized systems are also possible. The conveyor tracks can be
arranged adjacent to each other or in several stacked levels.
These basic elements are pre-assembled at the factory and delivered as one
unit. Long conveyors such as straight conveyors or inclined conveyors are
shipped as separate modules. Supports are mounted on-site. Wherever possible
drives, switches, photo eyes and other controlling components are assembled,
wired and pre-tested in the factory.
During installation on site welding is not necessary. Connections are made with
screws.
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Theoretical machine throughput

This is the maximum throughput of the isolated machine with optimum loading
and unloading, i.e. without any hold-up. The only limiting factor is the machine
itself, but not its environment in the installed system.
Achievable process throughput

The theoretical machine performance is usually not achieved in a system. Gaps
between trays or a pile-up of trays after the corresponding conveyor can interrupt
the continuous transport flow and reduce the throughput to the achievable
process throughput. Within a chain of sequential conveyors, the conveyor with
the lowest machine performance will determine the throughput of the entire
chain. This means that all other conveyors in the chain will not be able to
achieve their full machine output.
Environmental conditions
The tray conveyor system is designed for common environmental conditions
(ambient temperature in the shade +5oC to +40oC). Subtropical temperatures
and humidity can, for example, cause fogging of the PECs. The limits for
humidity are 5 to 95% non condensing.
In extreme environmental conditions (extreme temperatures, aggressive air, high

dust content etc.), consultation with BL Solutions will be required.
Paint
Painted parts are provided with an antistatic powder coating that resists impact
and scratching (mix of epoxy resin and polyester, coating thickness of 50 – 200
µ). The coating thickness can vary according to requirements.
The standard color is RAL 7035 (light gray). All other RAL colors are also
available. The normal gloss level is 50%.
Layout planning and engineering tool CONCEPTIX

The configuration program CONCEPTIX (CAD add-on) helps the planning
engineers to create customized layout design based on the described standard
elements.
The basic elements of the belt conveyor system are designated with a unique
name in CONCEPTIX. So-called attributes are then used to define and describe
the different versions of this basic element.
● Simple menus in CAD-system show all elements.

● Elements are selected and then combined at their center lines.
Tray Manual 3_8.doc

● The tool generates a complete dataset for each conveyor. Datasets are the
basis for total Bills of Material.
● Interface to calculation & simulation applications.
● Detailed 3D support planning helps to identify potential interferences from
existing building structures (columns, ducts, electrical systems).
● 3D views of each area provide helpful impression to the site crew.
● Cross-section drawings can be created easily.
● Tight integration of simulation and IT control system allow effective testing,
leading to significantly shorter on-site system integration and trial phases.
Figure 16 Layout design with CONCEPTIX Engineering tool
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1.2 The main reference sites so far

Frankfurt/Germany
The tray conveyor system at Frankfurt Airport, with more than 60 km of
conveyors the largest in continental Europe, is now running for over 35 years
ensuring high uptime rates. Quick transfer times are achieved by high speed
connections between the terminal buildings.
Figure 17 Typical baggage tray at Frankfurt International Airport
The Tray size corresponds to standard bag dimensions.
Efficient tracking is ensured by the unique Tray code which is linked to the bag
data.
Dubai
In March 1999 Dubai Airport received the first segment of the new Siemens tray
conveyor system. The Tray size was adjusted to accommodate a high volume of
oversize baggage in the Middle East.
Figure 18 V-shaped trays at Dubai International Airport
The system provides automatic loading and unloading of Trays.
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Since the Trays are dynamically unloaded by tilting devices, an additional sorter
is not required.
Louisville/U.S.A.
An oversize tray conveyor system for goods up to 2.5 meter or 8 feet length was
required for nonconveyables at this facility. Siemens adapted the high speed tray
conveyor system to meet the requirement. Oversized and standard Trays can be
incorporated in the same system for both airport installations or package
distribution centers.
Figure 19 Tray for nonconveyable packages
Paris CDG/France
Extension plans to develop Paris CDG as a Hub required a solution for linking
several satellites to one central terminal. Siemens has installed a tray conveyor
system for transfer bags to connect terminals E and F to the baggage system
already installed.
Figure 20 Tray sample for Paris Charles de Gaulle Airport
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The system provides secure and reliable handling of all types of baggage and
the minimum transport time between the terminals.
Madrid Barajas/Spain
With a total length of more than 80 km, the new combined Tray-Belt-System at
Madrid Barajas Airport is one of the largest single baggage handling projects for
Siemens.
Although the satellite building is more than 2 km away from the main terminal, a
transport time below 8 minutes had to be achieved. This was possible by the use
of the new High Speed Tray conveyors, running at a speed of 10 m/s or 1820
fpm.
Figure 21 Tray sample for Madrid Barajas Airport
Due to the size and complexity of this baggage system, AENA decided to place
the contract with Siemens as a strong and well known partner.
Milano Malpensa Intercontinental Airport

Since its opening in 1998 this new airport has enjoyed rapidly growing traffic.
With the existing belt based baggage system close to the throughput limits, the
airport decided to install a tray based extension.
The new tray conveyor system with a length of about 3 km and a system
throughput of 4000 trays/hour provides a back-up to the existing baggage
system and the flexibility needed for further extensions already planned.
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Figure 22 Tray conveyor line at Malpensa Airport
Incheon International Airport (ICN)

Located just outside Seoul, this new airport was only opened in 2001 and has
already undergone a major extension with a new concourse. This concourse –
the fist of planned four - is connected by an 8-line high-speed tray conveyor
system via a tunnel. The tray conveyor system at a total length of 39 km and top
speed of 10 m/s supports a Minimum Connection Time (MCT) of just 45 minutes.
The tray conveyor system transports standard bags and out of gauge (OOG)
baggage on the same track, whereby larger trays are used to convey OOG bags.
Figure 23 Special trays for OOG bags on the same track
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Beijing Capital International Airport, Terminal 3

The new terminal 3 for 40 million more passenger p.a. adds 68 km of conveyors
to this growing airport, most of it a tray based baggage system. The high speed
lines within the connecting tunnel run at 10 m /s and reduce the minimum
transfer time to just 35 mins.
Siemens as a main contractor supplied this large BHS in less than 3 years.
Figure 24 Tray conveyor line at Beijing T3
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The following table shows some typical parameters for the projects described.
Figure 25 Tray conveyor systems designed to meet customer requirements

Frankfurt/Main Dubai Oversize tray Paris CDG Airport Madrid Barajas
Airport International conveyor system France Airport
Germany Airport USA Spain
U.A.E.
Tray
Tray Size
and Weight
LxWxH 980 x 760 x 223 1680 x 1225 x 350 2600 x 1250 x 340 1350 x 1120 x 300 1680 x 1225 x 300
(mm)
LxWxH 3.2 x 2.5 x 0.7 5.2 x 4.1 x 0.7 8.5 x 4.1 x 1.1 4.4 x 3.7 x 0.9 5.5 x 4.1 x 1
(feet)
Weight 28 kg/62 lb 40 kg/88 lb 64 kg/141 lb 48 kg/106 lb 60 kg/32 lb
Bag/Package
LxWxH 850 x 650 x 450 1300 x 1000 x 900 2500 x 1000 x 1000 900 x 700 x 500 1400 x 900 x 800
(mm)
LxWxH 2.8 x 2.1 x 1.8 4.3 x 3.3 x 3 8.2 x 3.3 x 3.3 3 x 2.3 x 1.6 4.6 x 3 x 2.6
(feet)
Weight 50 kg/110 lb 70 kg/154 lb 80 kg/176 lb 60 kg/132 lb 55 kg/121 lb
Speed
(m/s) 0,6 – 5 1–5 1,5–5 1– 5 1–10
(fpm) 120 –1000 180 –1000 200 –1000 180 –1000 180 – 2000
Throughput
System 18000 bags/h 12000 bags/h 4400 items/h 12000 bags/h 18500 bags/h
per line 4500 bags/h 3000 bags/h 2000 items/h 3000 bags/h 3000 bags/h
Loading/
Unloading
Automatic Dynamic/ Manual Dynamic/ automatic Dynamic/ automatic
automatic
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TRAY System User Manual 2 Cross Belt Tray
2 Cross Belt Tray
The tray generally comprises five principal components (Figure 26).
A metal sheet frame (1) guarantees the robustness and stability during the
rough baggage transportation process. On it an integrated high grip concave
cross belt (2) is mounted for a maximum of friction with a minimum of slipping.
The subshell of the tray includes a passive belt drive (3) for activating the cross
belt. The exact guidance during rides in the BHS is ensured by lower guide
rollers and additional guide pins (4). Each piece of baggage can be traced
exactly because trays are equipped with a code carrier which identifies the tray
and thus the bag (see Figure 27).
Figure 26 Photo of the Siemens Cross Belt Tray
2
4
1
The load capacity is made up of the tray weight plus the flight baggage. An
empty tray weighs approximately 75 kg.
External dimensions (depending of bag size): approximately 1350 x 1300 x 360

mm (L x W x H).
The pieces of baggage are placed in the concave trays at automatic loading or
manual handling stations. Later horizontal unloading takes place at unloading
stations, where the cross belt transports the bag sidewards onto the adjacent
belt conveyor.
On the conveyors, the trays are guided from both the front and rear by means of
the horizontal roller arranged at the bottom. For guidance within the open
sections of switches, each tray is provided with two pilot pins at the rear. The
Tray Manual 3_8.doc

front roller has a pilot pin that is elongated in the downside direction and used to
guide the tray at the divert switches.
One piece of baggage is transported in each concave tray.
2.1 Fire resistance of the trays

Each basic component of the Cross Belt Tray is made of fire resistant material.
For example the cross belt and the plastic cover are fire resistant to EN
20340/ISO 340.
2.2 Tray identification

The trays are identified by electronic code carriers, which are affixed to the trays.
Stationary read/write scanners are used to store or read information on the code
carriers.
Figure 27 Tray identification by code carriers
The plant control system uses the unique tray code to control the material flow at
junction points (e.g. tilters and diverters) and to trace the baggage in the
baggage handling system.
Technical data for tray codes

The code carriers affixed to the trays (data carriers from Balluff or Siemens Moby
are currently used) store the following information:
Tray Manual 3_8.doc

● The permanent tray number (four digits, binary, numeric)

● Variable data
■ Global ID (9–11 bytes, unique bag code, not identical to the IATA code)
■ Transport destination in the system
■ Status information (e.g. tray full or empty)
Only 16 bytes of the available memory capacity of the data carrier (255 bytes)
are used.
The scanning distance is 20 to 30 mm.
The data exchange with the moving tray is possible up to:
● 7 m/s for read access

● 3 m/s for write access
The tray sequence is non-critical, i.e. the encoding rate is adequate.
The stationary read/write code scanner is connected via interface modules to the
PROFIBUS network and hence to the PLC level.
2.3 Drive concept and station

The drive station for loading and unloading purposes is directly fixed to the
relevant conveyor. Basically it consists of an electric motor (1) of low output
power for driving the belt and a simple mechanical lift system (2) to provide the
contact to the tray in case of loading/unloading process.
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Figure 28 Drive station
The system is designed to allow static and dynamic loading and unloading with
only one and the same drive station. The cross belt can be moved in both
directions, which allows for maximum flexibility during loading or unloading
operations.
As already mentioned the tray has not been equipped with drives that would be
sensitive to interference. The loading function is carried out from drive stations
firmly attached to the conveyors. Once a tray has to be loaded or unloaded at a
certain position the turning belt of the drive station is lifted slightly. A wedge
mounted on rollers is pushed by a magnet to lift the belt by only a few
millimeters. The acceptor belt at the bottom side of the tray provides a friction fit.
The power of the drive is transmitted onto rollers inside the Cross Belt Tray.
Those rollers effect the movement of the cross belt which on the other hand
loads or unloads the piece of baggage. If a specific tray needs to pass the
loading station without loading or unloading a bag, then the drive station belt
remains in its position and provides a smooth crossing of the conveyor.
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Figure 29 Cross Belt Tray drive concept
Acceptor belt
Rollers
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TRAY System User Manual 3 Static loading / unloading station
3 Static loading / unloading station
Designation in the Bill of Quantities

LOAD CB Static loading conveyor
in the following configurations:
● Motor right / left
Illustration of the static loading / unloading station in the layout
3.1 Functional specification of equipment

The static loading / unloading station comprises of a belt conveyor placed
orthogonally to the tray conveyor line and a tray metering with the additional
drive unit needed to power the cross belt on the tray.
Once the try has stopped at the correct position both belts (stationary and at the
tray) form a friction fitting. The stationary drive can then move the cross belt
directly. Depending on the drive direction the cross belt will be moved either to
the right or left. This will then cause loading or unloading of the tray.
Before being loaded, the baggage is identified by means of the IATA label. After
loading, a unique baggage code, referred to as the tray code, is determined
internally by the system and written onto the code carrier. From this point on, the
tray code is used to control the flow of trays through the baggage handling
system.
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TRAY System User Manual 3 Static loading / unloading station
The following figure shows a static loading process by use of the Siemens Cross
Belt Conveyor System.
Figure 30 Static loading station
3.2 Technical data

Product specifications
Length of tray conveyor (metering) min. 2000 mm
Performance data
Loading / unloading rate 600 - 1200 bags/hr
The achievable process output (amongst others) depends on:
● the length of the bags

● the continuous supply of bags and empty trays
● the PLC cycle time
3.3 Drive ratings

Metering 1.5 KW with brake
Loading / unloading drive 0.75 KW
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TRAY System User Manual 4 Dynamic loading / unloading station
4 Dynamic loading / unloading station

LOAD CB DYN dynamic loading conveyor
Illustration of the static loading / unloading station in the layout

The dynamic loading / unloading station comprises of a belt conveyor placed at a
450 angle to the tray conveyor line and a straight tray conveyor with the
additional drive unit needed to power the cross belt on the tray.
While the tray passes the adjacent belt conveyor, both belts (stationary and at
the tray) form a friction fitting.
The sideward movement of the cross belt depends on the speed difference
between tray and stationary belt.
The stationary drive can then move the cross belt directly. Depending on the
drive direction the cross belt will be moved either to the right or left. This will then
cause loading or unloading of the tray.
● The bag position remains unchanged, if tray and stationary toothed belt
move at the same speed.
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TRAY System User Manual 4 Dynamic loading / unloading station
● The cross belt moves to the right, if the stationary toothed belt is slower than
the tray.
● The cross belt moves to the left, if the stationary toothed belt is faster than
the tray.
This allows loading or unloading the tray or simply passing the station. Loading
and unloading is possible at both sides.
system.
4.2 Technical data

Length of tray conveyor (metering) min. 4000 mm
Performance data
Loading / unloading rate 1200 - 1800 bags/hr

4.3 Drive ratings

Metering 1.5 KW with brake
Loading / unloading drive 0.75 KW with brake
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TRAY System User Manual 5 Tray
5 Tray
The trays generally comprise five principal components:
● An extruded plastic carrier tray

● An intermediate body manufactured in foam plastic
● A deep-drawn sheet metal underbody
● Lower guide rollers and guide pins
● A code carrier
There is no single standard type of tray. The trays must be customized according
to the baggage dimensions and weights to be transported by each particular
conveyor system.
The load capacity is made up of the tray weight plus the flight baggage. An
empty tray weighs approximately 50 kg (Paris) or 60 kg (Madrid).
Figure 31 Tray front view drawing (Example: Paris)
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Figure 32 Tray side view drawing (Example: Paris)
Direction of travel → → →
Figure 33 Tray plan view drawing (Example: Paris)
External dimensions: 1350 mm x 1120 mm
The items of baggage are placed in the concave trays at automatic loading
stations or manual handling stations. Unloading takes place at tilter stations,
where the baggage slides off to one side, as in the case of tilt tray sorters.
On the conveyors, the trays are guided from both the front and rear by means of
the horizontal roller arranged at the bottom. For guidance within the open
sections of switches, each tray is provided with two pilot pins at the rear. The
front roller has a pilot pin that is elongated in the downside direction and used to
guide the tray at the divert switches.
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:NOTE: In turns, it must be observed that the minimum distance between the
trays on the straight track is approx. 400 mm (Example Paris with tray length
1350 mm)
Figure 34 Drawing of top view of trays in turns
5.1 Project-specific tray dimensions

Total length Bottom tray Top tray Tray Space for
across length width height load
buffers
Dubai 1680 mm 1490 mm 1225 mm 350 mm 1500 mm
Paris 1350 mm 1260 mm 1120 mm 300 mm 1200 mm
Korea 2560 mm 1000 mm 382 mm
OOG
Madrid 1680 mm 1590 mm 1225 mm 300 mm 1500mm
Beijing 1680 mm 1590 mm 1225 mm 350 mm 1500mm
Note:
References contained in this manual Dubai, Paris, Madrid, UPS, Korea or Beijing
mean the orders of DXB Dubai TD57, BHS Charles de Gaulle ADP Paris, NAT
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Barajas in Madrid, UPS Express Parcel Distribution System in Louisville, BHS

Incheon II and BHS Beijing T3.
In new projects, the following approximative formula applies:

Bag length (~900 mm)
Interior length of tray = Bag length +300 (~1200 mm)
Exterior length of tray = Bag length + 470 (~1370 mm)
5.2 Special case of service tray

In the project Paris, a tray variant for the transport of spare parts is used. The
usable height of the tray is 240 mm, the interior bottom is flat, the side walls are
removable. The cover placed on top of the tray ensures that the tray can safely
pass through the empty tray lines of the system (vertical passage clearance 350
mm).
The tray is equipped with a battery-powered signal lamp and horn. The service
mechanic will recognize this tray and stop the line when its reaches its
destination.
Figure 35 Drawing of service tray (Example Paris)
5.3 Material properties of the trays

Fire resistance
● The carrier tray, made of deep-drawn PP/S plastic, is fire-resistant to EN
20340/ISO 340.
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● The intermediate body, consisting of foamed EPP plastic, can be supplied

fire-resistant to EN 20340/ISO 340 as an option (additional cost).
● The underbody, made of 2.5 mm deep-drawn sheet metal, is fire-resistant.
Suitability for baggage screening while loaded in trays

The trays currently available are not suitable for X-ray screening of baggage in
the trays.
The enclosed steel-bottomed tray, made of 2.5mm-thick deep-drawn sheet metal

with material reinforcement at the edges, absorbs part of the X-ray radiation.
Some of the fire-resistant additives in the plastic materials compound this effect.
:NOTE: This topic is under continuous review. Please consult BL Solutions, if X-

ray screening is required to be carried out in the trays in your project.
5.4 Tray identification

The trays are identified by electronic code carriers which are affixed to the trays.
Stationary read/write scanners are used to store or read information on the code
carriers.
The plant control system uses the unique tray code to control the material flow at
junction points (e.g. tilters and merges or diverters) and to trace the baggage in
the baggage handling system.
Figure 36 Drawing of tray identification
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Figure 37 Photo of tray identification
Technical data for tray codes

The code carriers affixed to the trays (data carriers from Balluff or Siemens Moby
are currently used) store the following information:
● The permanent tray number (four digits, binary, numeric)

● Variable data
■ Global ID (9–11 bytes, unique bag code, not identical to the IATA code)
■ Transport destination in the system
■ Status information (e.g. tray full or empty)
Only 16 bytes of the available memory capacity of the data carrier (255 bytes)
are used.
The scanning distance is 20 to 30 mm.
The data exchange with the moving tray is possible up to:
● 7 m/s for read access

● 3 m/s for write access
The tray sequence is non-critical, i.e. the encoding rate is adequate.
The stationary read/write code scanner is connected via interface modules to the
PROFIBUS network and hence to the PLC level.
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TRAY System User Manual 6 Loading station
6 Loading station

LOADING CONVEYOR Loading conveyor
STRAIGHT Induct conveyor
each in the following configurations:
Illustration of the loading station in the layout

The loading station comprises an upper conveyor belt, along which the baggage
is transported for loading, and a lower tray conveyor for transporting the empty
trays to the loading point. Both conveyor lines are synchronized such that each
tray receives one item of baggage.
system.
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Figure 38 Drawing of the tray loading station

← Loading conveyor ← Induct conveyor ←
The loading conveyor is mounted lower than the induct conveyor, in order to
prevent baggage jams between the two conveyors (“cascade”).
The tray codes are read and written at three points:
1. The empty tray code is read before loading and the code of the next item of
baggage is assigned to this tray internally in the control system.
2. The code of the full tray is read after loading. The control now determines
the transport destination.
Tray Manual 3_8.doc

3. Complete encoding of the data carrier with the baggage code, transport
destination, etc. now takes place after the loading station. The physical
separation of steps 2 and 3 means that the encoding procedure is
decoupled from the computer response time.
6.2 Technical data

Dimensions of Paris example:
Length of upper convex conveyor 1000mm
Length of lower conveyor 4800mm
Width 1190mm
Clear width of belt conveyors 1050mm
Total height including side parts 1430mm
Height up to top edge of belt 980mm

(if top edge of belt of metering conveyors at 400 mm)
Performance data
Loading rate at 2m/s (with FC)
● with tray length 1350 mm 1800 bags/hr


Limits
Loading rate at 2m/s (with FC)

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6.3 Drive ratings

Conveyor belts 2 x 1.1 kW
Metering conveyors 3 x 1.5 kW
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TRAY System User Manual 7 Straight conveyor
7 Straight conveyor

STRAIGHT
● Drive Station right / left

● Slave drive to next conveyor yes/no
● Number of accumulator locations 0 through 8
(see Accumulation conveyors, section 9)
Illustration of the straight conveyor in the layout

Straight conveyors are the main conveyor lines for transport of empty or full trays
through the baggage handling system. The conveyor line consists of one or
more straight conveyors connecting switches, turns and other elements of the
TRAY conveyor system.
These conveyors comprise a drive station with a slip-on geared motor, one or
more intermediate beds and a tensioning station.
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Figure 39 Drive station, intermediate bed section and tension station
7.2 Technical data

● The length of the straight conveyor ranges from 3,000 to 30,000 mm.
Shorter conveyors are termed metering conveyors. Any length can be
implemented by installing standard intermediate beds, intermediate adapter
sections or adapter traverses (described in section 11).
● The track width of the belt is 800 mm.
● Weights
■ Drive station 300 70 kg (incl. drive)
Drive station 800 92 kg (incl. drive)
■ Intermediate sections 48 kg/m
■ Tensioning station 62 kg
Belt equipment of these conveyors

■ Woven fabric coated belt with low friction coefficient
■ Toothed belt type 50ATK10/K13 V PAR with V wedge profile
■ PU V WEDGE K13 MBF30A
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Figure 40 Main dimensions of carrier belt
Description: Timing belt:

50 ATK-10 K13 V PAR Pitch: AT10
Width [mm]: 50
Thickness [mm]: 4,5
Polyamide on
PAR: Cord members [pieces]: 35
backside
Cord material: Steel cord, ∅ 0,9 mm
Color: White
Hardness: 92 Shore A
Timing belt material: PU
Tolerances: Width: ± 0,5 mm
Height: ± 0,2 mm
Pulley
± 0,5
diameter 189,10 Length:
mm/m
[mm]:
Weight 0,38 kg/m
V-guide K13 MBF30A
max. perm. tensile load [N]: 3750
PU with wear
Material:
protection “F”
Color: Transparent
± 0,5 mm in width and
Tolerance:
height
Tray Manual 3_8.doc

Standards and material of timing belts:

1. The raw material used for our timing belts fulfils the requirements of the UL-
94 standards, classification V-2 without flame-protection additives. The
material is free from halogens.
2. The oxygen percentage, at which a combustion is just maintained, amounts
to 22% according to ISO 4589.
3. The specification of the motor vehicle safety standards FMVSS 302 are
fulfilled.
4. The requirements of the DIN 57422 T. 813 with respect to fire gas corrosion
are fulfilled.
5. The spontaneous ignition temperature pursuant to ASTM D 1929 – 77
amounts to approx. 500° C.
Figure 41 Photo of straight conveyor belt type
● The standard drive type is a slip-on geared motor with disk brake. Other
designs are possible, depending on the application.
Performance data
● Standard speed: 2.5 m/s (1.3–1.5–2.5–5 m/s) (e.g. Paris plant)
Limits
● Maximum lengths of the straight conveyors up to
■ 1.5 m/s Max. length 22 m
■ 2.5 m/s Max. length 15 m
Tray Manual 3_8.doc

■ Empty tray Max. length 22 m at 2.5m/s

■ 5 m/s Max. length 30 m (frequency controlled)
● Push operation is the term used to describe a system where the drive is
mounted on the back section of the conveyor. This is only possible with
short conveyors up to 3 m in length, i.e. with meterings.
Example for the arrangement of individual elements

The following “Assembly list.xls” is generated based on the bill of quantities
derived from the layout program CONCEPTIX:
Pos tot. Qty. Designation

STRAIGHT L TRAY L=12400
125 1 Tension Station 700

1001 1 Variable Intermediate L=1400
121 1 Intermediate bed section L=1600
124 3 Intermediate bed section L=2800
1315 1 Drive Station 300 Drv/Fkt-Side=L L=0
180 1 Safety-Box L&R incl. Screws
M 28 Lower Roller for Intermediate
M 6 Set of Screws for Intermediate
M 1 Screws for Conv.-Connection
1371 1 Drive Drv/Fkt-Side=L 2,2kW 97,Umin W
1044 2 Tooth-Belt, low friction L=24650
129 1 Initiator Dislocation
131 5 Supports
1004 2 Guide-Rail L=5600
1005 2 Guide-Rail L=1600
The installation begins with the shortest sections at the tensioning station and
continues towards the drive with increasing intermediate bed section lengths.
Figure 42 Drawing of straight conveyor individual elements
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7.3 Drive ratings

The drive ratings for a straight TRAY conveyor depend on
● Conveyor length
● Workload from loaded trays (weights shown include the tray)
● Conveyor speed
● Pulse rates needed
The drive sizing is determined by the pulse rates and not by the continuous
operation.
The table below shows the relationships for an environmental temperature up to

400C. For environmental temperatures up to 500C the pulse ratings need to be
decreased by 10%.
The pulse ratings relate to continuous operation with the conveyor switched on
60% of the time. The pulse rates are always referred to 1 hr. .
Pulse ratings not shown are small (<50/hr) and are not practical.
Tray Manual 3_8.doc

Conveyor speed 1.0 m/s 1.5 m/s 2 m/s 2.5 m/s 5 m/s
Theoretical drive speed 100 150 200 250 500

(rpm)
Max. Max. Max. Max. Max.
permitted permitted permitted permitted permitted
pulse rates pulse rates pulse rates pulse rates pulse rates
@ 1.0 m/s @ 1.5 m/s @ 2 m/s @ 2.5 m/s @ 5 m/s
Up to 3 m / 90 kg
Drive rating 1.1 kW 2475 1326 775 485 75
Drive rating 1.5 kW* 3315 1955 1220 800 172
3 to 10 m / 330 kg
Drive rating 1.1 kW 910 400 200 116
Drive rating 1.5 kW* 1360 643 353 213
Drive rating 2.2 kW 1442 706 400 250
10 to 16 m / 550 kg
Drive rating 1.1 kW 530 210 94
Drive rating 1.5 kW* 863 380 190 106
Drive rating 2.2 kW 940 430 230 140
Drive rating 3.0 kW 1125 530 300 190
16 to 22 m / 1300 kg
Drive rating 1.5 kW* 350 120
Drive rating 2.2 kW 409 162 75
Drive rating 3.0 kW 520 224 115 65
*) High performance drive 1LA9..
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TRAY System User Manual 8 Metering conveyor (discontinuous)
8 Metering conveyor (discontinuous)

METERING in the following configurations:

● Slave drive to next conveyor yes / no
● Tilter metering yes / no
Illustration of the metering conveyor in the layout

Metering (or discontinuous) conveyors are straight conveyors with high pulse
frequency and short acceleration and braking distances. They always feature a
carrier belt with high friction vis-à-vis the tray. The length of the standard
metering depends on the tray length.
Figure 43 Drawing of a metering conveyor with standard drive
In special applications the drive may be inserted between the intermediate beds.
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Shortened metering conveyors

Shortened metering conveyors are shorter than standard metering conveyors.
These conveyors do not constitute a tray location of their own. A tray location
must have a length of Tray length + 250 mm. A tray location may be created in
combination with an undriven turn. It must be observed that the friction against
the tray is reduced in turns (see information in Turns section).
:NOTE: Conveyors which are shorter than those described are supplied as
wheel conveyors.
8.2 Technical data

● Length of the standard metering
■ For tray length 1350 mm 1600 mm
■ For tray length 1680 mm 2000 mm
● Weights
■ Drive sidewards 86 kg + 32 kg/m (incl. drive)
■ Drive below 105 kg + 32 kg/m (incl. drive)
The standard drive type is a slip-on geared motor with disk brake. Other designs
are possible, depending on the application.
Discontinuous conveyor belt type (high friction)

■ Toothed belt type 50ATK10/K13 V PUL820
■ PU V WEDGE K13 MBF30A
Tray Manual 3_8.doc

Figure 44 Main dimensions of tooth belt

50 ATK-10 K13 V PUL820 Pitch: AT10
Width [mm]: 50
Thickness [mm]: 4,5
Cord members [pieces]: 35
Cord material: Steel cord, ∅ 0,9 mm
Color: White
Height: ± 0,2 mm
Pulley
± 0,5
diameter 189,10 Length:
mm/m
[mm]:
Weight 0.50 kg/m
V-guide K13 MBF30A
max. perm. tensile load [N]: 3750
PU with wear
Material:
protection “F”
Color: Transparent
Tolerance:
height
Coating: PUL820 embossing
Color: Transparent
Tolerance: ± 0,5 mm in height
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Standards and material of timing belts

fulfilled.
are fulfilled.
Figure 45 Photo of metering conveyor belt type
Metering conveyors always have the highest-grip belt that is permitted in the
order. Examples include:
● Dubai, Paris, Madrid: PU layer with longitudinal grooves 2 mm (µ = 0,72

between carrier coating and metal tray base)
● UPS: without coating (average friction coefficient)
Performance data
● Standard speed: 1 m/s, 1.5 m/s, 2 m/s, 2.5 m/s
Special configuration for conveyors clearing fire doors: 5 m/s
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8.3 Drive ratings

Length/conveyor speed 1.0 (m/s) 1.5 (m/s) 2.0 (m/s) 2.5 (m/s) 5.0 (m/s)
Theoretical drive speed (rpm) 100.0 150.0 200.0 250.0 500.0
1200–3000 mm 1.5 kW 1.5 kW 1.5 kW 1.5 kW 2.2 kW

Pulses standard drive 1200 1200 1000 690
Pulses high performance 1800 1400 + 800
drive FC
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TRAY System User Manual 9 Accumulation conveyor
9 Accumulation conveyor

ACCUMULATOR

● Number of accumulator locations 1 to 8
Illustration of the accumulation conveyor in the layout
This is an example for 6 accumulator locations.

Accumulation conveyors consist of a straight conveyor with integrated brake
strips which can be raised. Each of the brake strips lifts one tray and is driven by
a motor.
The benefits are as follows:
● Increased package density in the storage locations

● Provision of buffer lines at the entrance to a storage location in order to
prevent back-ups on the main line
● Provision of buffer lines at the entrance to a main conveyor line in order to
prevent back-ups
● Stacking capability behind branch switches ensuring successful transport of
baggage which has changed direction
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TRAY System User Manual 9 Accumulation conveyor
● Availability of buffer locations before a loading station
Figure 46 Photo of accumulation conveyor
9.2 Technical data

● A conveyor with 8 locations per 1600 mm measures approx. 14,000 mm in
length.
● Each location adds 30 kg to the weight of the straight conveyor.
Limits
● The max. speed is currently 1.5 m/s
● The number of accumulator locations is limited to 8 (or 12 for empty trays)
9.3 Drive ratings

Drive ratings of the straight conveyor: see separate section
Drive rating per accumulator location: 90 W

400 V three-phase drive
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TRAY System User Manual 10 Wheel conveyor
10 Wheel conveyor

WHEEL CONVEYOR
Illustration of the wheel conveyor in the layout

Wheel conveyors are used if the required conveyor length does not permit the
use of metering conveyors. Wheel conveyors do not have a separate drive
motor. A wheel conveyor operates similar to a turn. It is slave driven by the
previous or the following conveyor.
Wheel conveyors are supplied with black wheels (with a high friction coefficient).
Figure 47 Drawing of wheel conveyor
As in the case of turns, the wheel diameter is D = 195 mm.
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TRAY System User Manual 10 Wheel conveyor
10.2 Technical data

The layout program CONCEPTIX generates a wheel conveyor if the length of the
straight conveyor is less than 1300 mm.
Lengths from 250 to 1300 mm are used.
Equipment designation Weight kg
WHEEL CONVEYOR L=500 mm 40

WHEEL CONVEYOR L=1000mm 63
WHEEL CONVEYOR L=1505mm 87
The wheel conveyor L=1505 mm is the delivered length that is shortened on the
construction site to 1300 mm max. Intermediate lengths other than those
mentioned are not standardized and also need to be adapted on the construction
site.
● Wheel conveyor belt types

■ Type SUPER-T-LINK V-belt A/13
■ with LEAVES
■ Color: BLUE
(Direction of belt travel: tip at internal diameter is at front)
Figure 48 Photo of wheel conveyor belt types
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TRAY System User Manual 11 Adapter and normal traverse
11 Adapter and normal traverse

Being a part of the conveyor, traverses are not shown separately.
Illustration of the adapter and normal traverse in the layout

Being a part of the conveyor, traverses are not drawn separately.

An adapter traverse is an element with adjustable length that is used to
interconnect two conveyors. It bridges gaps between conveyors without the need
to install a new piece of equipment. The length between the theoretic conveyor
interfaces is adjustable between 0 and 250 mm.
A normal traverse is not adjustable in length. It bridges a gap of 200 mm.
Basically, adapter and normal traverses do not have a separate drive; i.e. the
rollers are not driven.
Figure 49 Drawing of adapter traverse
The adapter equipment can be fitted with a passive friction roller, depending on
the length to be bridged.
The adapter traverse can be used with straight conveyors, wheel conveyors, and
turns.
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TRAY System User Manual 11 Adapter and normal traverse
Traverses are always placed at the conveyor’s tail end:
Figure 50 Photo of adapter traverse
The adapter traverse weights 23 kg.
Normal traverse
A normal traverse connects two conveyors without length variance.
Figure 51 Photo of normal traverse
Normal traverse installed on standard head tensioning station.
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TRAY System User Manual 12 Slave drive for wheel conveyors and turn
12 Slave drive for wheel conveyors and

turn

No separate designation.
Using CONCEPTIX a slave drive is configured in the driving straight conveyor.
Illustration of the slave drive in the layout

The slave drive connects wheel conveyors or turns to the drive shaft of a straight
conveyor.
Slave drives are also used as connecting elements between turns and between
switches and turns.
Figure 52 Layout of slave drive after a turn
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TRAY System User Manual 12 Slave drive for wheel conveyors and turn
Figure 53 Layout of slave drive between turn segments
12.2 Technical data

The slave drive comprises the following components:
● Slave drive belt

● Slave drive module
The slave drive module consists of the slave drive wheel 77403547 and the
tensioning set 65020547.
Limits
The driven element can be a turn of 45o max. (or equivalent number of wheels).
12.3 Drive ratings

Not applicable because slave drives have no separate drive.
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TRAY System User Manual 13 Inclined conveyor
13 Inclined conveyor
Designation of an inclined conveyor 1 in the Bill of Quantities

INCLINE
DECLINE

● Inclination/Declination 8° / 19°
:NOTE: The inclination and the number of any necessary intermediate

conveyors depend on the desired height difference.
Illustration of the 19° inclined conveyor in the layout
:NOTE: The number and position of drives is determined during layout planning
with CONCEPTIX. This is important for the planning of the maintenance
platforms.
1
’Inclined conveyors’ is used as a generic expression for uphill (inclined) and for downhill (declined) conveyors.
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Illustration of the 8° inclined conveyor in the layout

13.1.1 19o inclined conveyor
19o inclined conveyors are available for height increases from 1400mm to
8000mm (in steps of 200mm).
The design must take account of the differing behavior of the tray guide rollers in
concave and convex bows. The equipment has flexible center guides. In the
lower bow, a special toothed belt is used with a raised profile to absorb impacts.
Figure 54 Drawing of a lower bow with special toothed belt
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Figure 55 Photo of special toothed belt in of inclined conveyor lower bow
Figure 56 Drawing of an upper bow with high-grip toothed belt
The same toothed belt is also used for metering conveyors. The friction
coefficient is approximately µ = 0.7.
Figure 57 Photo of metering toothed belt in inclined conveyor with high grip
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Figure 58 Drawing of upper bow/metering conveyor/lower bow
Lower bow Intermediate conveyor Upper bow
Complete inclined conveyors are available as:
● A single piece
● Composite inclined conveyor comprising a lower bow, 0-1-2 intermediate
conveyors (fitted like metering conveyors) and an upper bow. For greater
lengths, more intermediate conveyors are installed in the inclined section.
Each section in a composite inclined conveyor has a separate drive.
The drives are always arranged at the top. In exceptional cases, e.g. where, due
to the room columns, no space for the drives is available, a straight section less
than 2.5m in length may be used on a downhill conveyor with the drive mounted
at the bottom (special design).
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Figure 59 Photo of an inclined conveyor
A distinction is drawn between uphill (INCLINE) and downhill (DECLINE)

conveyors. Downhill conveyors are pushed by the drive.
Inclined conveyors are available complete or with upper and/or lower bow. The
number of drives depends on the difference in height (see drive ratings section).
The usual drive type is a slip-on geared motor fitted with disk brake. Other
13.1.2 8° inclined conveyor

8° inclined conveyors are used for height differences of 200, 400, 700 or 800mm.
Figure 60 Drawing of a complete inclined conveyor
8° inclined conveyors up to height difference of 700mm are only available

complete, i.e. without separate upper and lower bows (one drive only). Longer
inclined conveyors (800mm) have two drives.
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13.2 Technical data

● Standard radius lower bow R=3.300 mm
● Standard radius upper bow R=10.000 mm
● Special radius Paris upper bow R=7.000 mm
● Standard length at the top drive station is 1400 mm
● Weight (for both types) 60 kg/m +30 kg (drive)
Belt specification
The following types of belt are used in inclined conveyors:
● Belt with rubber coating (raised web, high friction)

■ Toothed belt type 50ATK10/K13
■ PU V-BELT MBF30A
Figure 61 Main dimensions of timing belt
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50 ATK-10 K13 V
Pitch: AT10
PAR/PAZ/PAK/WLK15
Width [mm]: 50
Thickness [mm]: 4,5
Cord members
PAR: Polyamide on backside 35
[pieces]:
PAZ: Polyamide on tooth side Cord material: Steel cord, ∅ 0,9 mm
Color: White
Hardness: 92° Shore A
Height: ± 0,2 mm
Pulley diameter [mm]: 189,10 Length: ± 0,5 mm/m
max. perm. tensile
3750
load [N]:
weight 0,58 kg/m
V-guide K13 MBF40A
PU with wear
Material:
protection “F”
Color: Transparent
Hardness: 85° Shore
Tolerances:
height
Sidewall WLK 15
Material: PU
Color: Black
Height [mm]: 15
Hardness: 85° Shore
Tolerances: ± 1 mm in height
Material of timing belts:
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fulfilled.
are fulfilled.
This type of belt is used
● as the only type of belt for 8° inclined conveyors

● if a 19° inclined conveyor has only one motor and consists of an S piece
● if a 19° inclined conveyor contains several motors: for the lower bow:
Figure 62 Photo of belt type for lower bow
● Belt with longitudinally grooved PU layer, 2 mm

■ Toothed belt type 50ATK10/K13
■ Pitch 10.00 mm
■ Width 50 mm
■ PU V-BELT MBF30A
■ Coating P820/UF75/2 (µ = 0.72 between carrier coating and metal tray
base)
This type of belt is used for 19° inclined conveyors with several motors for the
intermediate conveyor and for the top bow.
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Performance data
● Standard speed: 2.5 m/s (e.g. installation Paris)
13.3 Drive ratings

Equipment/conveyor 1.0 1.5 2.0 2.5 Remarks
speed (m/s) (m/s) (m/s) (m/s)
Theoretical drive 100.0 150.0 200.0 250.0
speed (rpm)
19° inclined conveyor 2.2 kW 2.2 kW 2.2 kW 2.2 kW 2.2 kW
for each 2 meters in height commenced
(50–110 pulses/h possible but not desired)
8° inclined conveyor 2.2 kW 2.2 kW 2.2 kW 2.2 kW 2.2 kW
for each 1.5 meters in height commenced
(30–130 pulses/h possible but not desired)
The power requirements of the 8° inclined conveyors are higher because the
conveyor line is longer for the same height difference.
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TRAY System User Manual 14 Turn
14 Turn

TURN angle all driven turns

● Turn angle 30o / 45o
● Turn direction right / left
● Turn radius 2550 / 2000 mm
● Drive on both sides yes / no
TURN PASSIVE angle Turn without separate drive
● Turn angle 15o / 30o / 45o

● Turn direction right / left
● Turn radius 2550 / 2000 mm
Illustration of standard turn R=2550mm in the layout
Turn with drive Turn for slave drive
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14.1.1 Standard turns R = 2550 mm Vmax = 2.5 m/s
The driven wheels of these turns are located at the external radius. The black
rubber coating on the external wheels increases the friction of contact with the
tray. The wheels at the internal radius rotate freely.
Figure 63 Drawing of turn 45 deg
Figure 64 Photo of turn
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Driven black wheels outside (= high friction coefficient), freely rotating white
wheels inside.
Special version with wheels also driven at internal radius:

If high acceleration rates are required, a special version is available with driven
wheels at the internal radius as well, e.g. as a substitute if a metering conveyor
cannot be installed.
The conversion of the standard turn R = 2550 mm is to be made on the

construction site (conversion kit for R2550: 32971343). It requires to replace the
shaft, to install rollers, mount protective covers and to replace the drive with a
1.5 kW unit.
14.1.2 Standard turns R = 2000 mm Vmax = 1.5 m/s

Turns with center radius R = 2000mm can be used up to a maximum speed of
Vmax = 1.5 m/s (standard).
These are supplied with black wheels (=high friction coefficient). The wheels at
the external radius are driven.
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Special version with wheels also driven at internal radius:

If high acceleration rates are required, a special version is available with driven
wheels at the internal radius as well, e.g. as a substitute if a metering conveyor
cannot be installed.
Turns that are driven on both sides are configured in the layout program
CONCEPTIX.
The conversion of the standard turn R = 2000 mm is to be made on the

construction site (conversion kit for R2000: 32972543). It requires to replace the
shaft, to install rollers, mount protective covers and to replace the drive with a
1.5 kW unit.
It can be necessary in specific situations to replace the initiator for the switching
of the trays with a light barrier. The radius is too small to read the initiator.
14.2 Technical data

Turn R = 2550 mm

Turn R2550 driven 30 right 113
Turn R2550 driven 30 left 113
Turn R2550 driven double 30 right 136
Turn R2550 driven double 30 left 136
Turn R2550 passive 15 right 52
Turn R2550 passive 15 left 52
+ Drive 30
Turn R = 2000 mm

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+ Drive 30
Belt types (multi-section V-belt) for turns
● Type SUPER-T-LINK V-belt A/13

● with LEAVES
● Color BLUE
Figure 65 Photo of turn belt type
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:NOTE: The same belt is also used for switches, wheel conveyors, and slave
drives.
Performance data
● Standard speed 1.5 – 2.5 m/s (e.g. installation Paris)
Limits
● 30o turns with R = 2550 mm Vmax = 2.5 m/s
o
● 45 turns with R = 2000 mm Vmax = 1.5 m/s
to be avoided where possible because of centrifugal force
Exception for empty trays Vmax = 2.5 m/s.
14.3 Drive ratings

● Standard turns R = 2550 mm
Equipment/transport speed 1.0 (m/s) 1.5 (m/s) 2.0 (m/s) 2.5 (m/s)
Theoretical drive speed (rpm) 112.0 168.0 224.1 280.1
30° R2550 with drive single side 1,1 KW 1,1 KW 1,1 KW 1,1 KW
45° R2550 with drive single side 1,1 KW 1,1 KW 1,1 KW 1,1 KW
30° R2550 with drive two sides 1.5 kW 1.5 kW 1.5 kW 1.5 kW
45° R2550 with drive two sides 1.5 kW 1.5 kW 1.5 kW 1.5 kW
● Standard turns R = 2000 mm

Equipment/transport speed 1.0 (m/s) 1.5 (m/s)
Theoretical drive speed (rpm) 115.8 173.7
30° R2000 with drive single side 1,1 KW 1,1 KW

45° R2000 with drive single side 1,1 KW 1,1 KW
30° R2000 with drive two sides 1.5 kW 1.5 kW
45° R2000 with drive two sides 1.5 kW 1.5 kW
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TRAY System User Manual 15 Switches
15 Switches

MERGE Merge switch
● Merge from right / left

● Motor side right / left
(Standard: Motor on straight-on side)
DIVERT Divert switch
● Divert to right / left

● Motor side right / left
(Standard: Motor on straight-on side)
Illustration of the switches in the layout
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15.1.1 Standard switches
Switches divert the conveyed goods from one line to another or merge two lines
into one.
Divert and merge switches are used. The difference depends on the
configuration of the center piece with its movable blade. In the case of divert
switches, a solenoid changes the position of the blade in order to alter the travel
direction of the tray. The end position of the blade is monitored by initiators. The
solenoid is driven electrically on both sides, but has a mechanical return spring
for straight-on conveyance.
A change in direction is initiated when the blade in the merge swivels horizontally
to deflect a tray’s guide roller or, more accurately, the elongated pilot pin of the
front roller.
Figure 66 Drawing of a switch
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Figure 67 Photo of a switch
The driven wheels of the switch have a black rubber coating. The other rollers
are free and are made of white plastic. In addition, switches have further smaller
support rollers. The individual wheels are driven by alternate-step multi-section
V-belts.
The drive on standard switches is mounted on the straight-on side. The standard
drive type is a slip-on geared motor with disk brake. Other designs are possible,
depending on the application.
15.1.2 Special switches

Special switches with the drive on the merge or branch side (i.e. on the inside)
are used in locations where insufficient space is available for a drive in the usual
position. This arrangement should be avoided where possible, because the
major proportion of the drive force is transmitted across a cardan joint.
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15.2 Technical data

Switch with motor on straight-on side:
● Merge switch left

● Merge switch right
● Divert switch left
● Divert switch right
Switch with motor on divert/merge side:
● Merge switch left

● Merge switch right
● Divert switch left
● Divert switch right
Weight of switch: 513 kg (incl. drive)
Belt types (multi-section V-belt) for switches
● Type SUPER-T-LINK V-belt A/13

● with LEAVES
● Color BLUE
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Figure 68 Photo of switch belt type
:NOTE: The same belt is also used for turns, wheel conveyors and slave drives.
Performance data
● Standard speed 1.5 – 2.5 m/s (e.g. installation Paris)
Limits
:NOTE: Before turns and switches, the speed must be reduced from a possible
5 m/s to 2.5 m/s at least 5-6 m in advance. (Braking conveyor 5-6 m long)
After turns and switches with 2.5 m/s, trays can be discharged to straight
conveyors running at 5 m/s.
In exceptional cases, divert switches can be used in reversing mode as a merge

switch for trays that travel in the opposite direction.
15.3 Drive ratings

Equipment/transport speed 1.0 (m/s) 1.5 (m/s) 2.0 (m/s) 2.5 (m/s)
Theoretical drive speed (rpm) 97.9 146.9 195.9 244.9
Merge switches 1,1 KW 1,1 KW 1,1 KW 1,1 KW
Divert switches 1,1 KW 1,1 KW 1,1 KW 1,1 KW
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TRAY System User Manual 16 Compact tilter
16 Compact tilter

TILTER COMPACT
Illustration of the tilter in the layout

Tilters incline the trays to one side and unload the baggage onto a chute. In this
process the tray is supported by a tilting conveyor. The compact tilter is designed
as a standard tray conveyor with a longitudinally arranged shaft to tilt the
conveyor sideways.
While in horizontal position the compact tilter accepts the arriving tray from the
previous metering onto the tilter conveyor, which then tilts along the longitudinal
axis. By the tilting process, which is possible to both sides, the bag slips from the
tray onto the chute. With a tilter angle of 50o max. the lower guide rollers hold the
tray within the center guide. Due to the continuous Z-profile a guide rail
monitoring system is not necessary. Technically the tilter conveyors is almost
identical to a metering.
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Figure 69 Schematic of Compact Tilter with tray
Figure 70 Photo of Compact Tilter
Chutes
No standard chute is provided. Chutes are custom designed and built for specific
projects.
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The following general requirements apply:
● Chutes must have an inclination of at least 30o (better 35o).

● The length must be at least 1.5 times the length of the bag.
Figure 71 Photo of Compact Tilter with chutes at both sides
16.2 Technical data

Product specification
● Self-supporting steel design
● Steel parts painted/galvanized
● Size
■ System length (insertion length) of compact tilter 2100 mm
■ Total length of compact tilter 2286 mm
■ Height from lower edge of rubber buffer to top edge of belt 775 mm
■ Width of compact tilter frame (excluding tray) 900 mm
● Weight of compact tilter incl. drives: 640 kg
● Sensors monitor the unloading process. The tilter swivels back as soon as
the unloading is completed.
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Performance data
The achievable throughput depends on the compact tilter arrangement, the size
of trays and the conveying speed. For further details please refer to section 21.3.
Limits
● Tilter throughput 1200 bags/hr max.
This is the theoretical machine throughput. The achievable process output is
approx. 20% lower.
This relates to both tray sizes (1.5 - 2.5 m/s with FC).
16.3 Drive ratings

Tilter main drive 1,5kW (1,5 m/s)
Tilter tilting drive 2,1 kW Servo drive
The tilting drive is a frequency controlled motor linked to the tilting conveyor with
a toothed belt.
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TRAY System User Manual 17 Roller checking station
17 Roller checking station
This station checks the tray guide rollers for wear. When used at the loading
stations, it also provides the possibility to specify the destination ‘Servicing
station‘.
Figure 72 Functional principle of roller checking station
S1
& 63 mm
S2
Q
During the passage of the tray, the monitoring facility views the roller using two
RF-clocked light barriers through a slotted sheet metal plate. The slot spacing is
adjusted to the permitted minimum diameter of the rollers (roller diameter in new
condition 70 mm, permitted minimum diameter e.g. 63 mm, slot spacing 63 mm).
The control system reads whether both light barriers are covered twice at the
same time during the passage of the tray. If not, the roller diameter is <63 mm
and therefore too small.
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TRAY System User Manual 17 Roller checking station
Figure 73 Photo of roller checking station
:NOTE: The roller monitoring station is often used at loading stations but can
also be used at any other points of the system.
Checking station for roller stop

This checking station is used at points where missing tray guide rollers may
cause hazards for personnel, e.g. in locations where service personnel works
underneath of conveyor lines. The station has the same design as the roller
checking station.
During the passage of the tray, the checking station views the roller using two
RF-clocked light barriers through metal slots. The slot spacing is adjusted to 55
mm. The control system reads whether both light barriers are covered twice at
the same time during the passage of the tray. If not, this means that the roller is
missing, and the conveyor will be stopped.
:NOTE: The use of this checking station is not limited to the loading station but
is used where potential hazards are present for personnel in the baggage
handling system.
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TRAY System User Manual 18 Steel support system
18 Steel support system
The support system breaks down into the support of the conveyors proper, the
steel platforms that may be installed at intermediate levels, as well as escape
and service walkways for the operating personnel. This system comprised of
supports and platforms is generally referred to as the steel structure and forms
the interface between the conveyors and the building.
The economical planning of the steel structure is performed by ascertaining, on

the one hand, the necessary support points of the conveyor lines as well as
accessibility for servicing and operation and, on the other hand, reconciling these
with the structural possibilities and local conditions.
18.1 Clearance dimensions

The clearances required for the baggage to be transported in the trays is
fundamental in the planning of the supports. Depending on the customers'
specifications, whatever is required can be provided.
Figure 74 Drawing showing clearances
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Standard dimensions that have found wide acceptance are 1600 mm in width
and 450 mm + maximum bag height in height for payload sections as well as
1400 mm in width and 650 mm in height for empty tray sections. These
dimensions relate to the inside clearance of the supports and the distance from
the top of the lower cross-beam to the bottom of the upper cross-beam.
For the layout, this means that the minimum center distance between two
conveyors arranged one above the other in the case of payload sections is 500
mm + maximum bag height, whereas 700 mm are sufficient for the empty tray
sections.
The dimensions indicated are based on the dimensions of the standard tray
conveyor, the Madrid-type tray, and the standard support system.
:NOTE: In the area of curves and switches, it is necessary for geometric

reasons to allow 80 mm extra space on the right hand and left hand sides so that
the horizontal clearance increases to 1760 mm.
18.2 Attaching the conveyors

The conveyors are fixed to a cross beam with rubber buffers interposed, the
cross beam consisting of a channel section with the open side up. This channel
section fully accommodates the cross-beam of the conveyor and, consequently,
provides a most space-saving solution. In order to prevent dirt accumulation, it is
possible to cover the edges of the cross beam with plastic caps.
The cross-beam is provided with oblong holes at both ends which, in conjunction
with suitably spaced holes in the supports, permit stepless vertical adjustment of
the bolted joints.
Figure 75 Drawing of cross-beam with buffers
Buffer Cable duct Buffer
The bolted joints are made with self-locking nuts in order to prevent loosening of
the bolts in operation.
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18.3 Supports
The standard system provides for three different situations of supporting the
conveyors: The single-strand conveyor close to the ground, the single-strand
conveyor crossing overhead, and two-tier conveyor lines.
Supporting three-tier conveyors and more conveyors with support frames has
proved to be uneconomical. In addition to the problem of the “forest of supports”
problem there would be the need to provide a walkway to service the upper
conveyor. Therefore, it is common practice to have two conveyors each on one
level.
Ground support
The ground support essentially consists of a cross-beam with lateral support
plates and, considering the lesser requirements, represents the simplest variant.
It is suitable for conveying heights of 300 mm to 450 mm.
Figure 76 Ground support
Single support frame

The single support frame is used to support single-level conveyors at heights of
400 mm to 2000 mm. It comes with cross-beams of 1200 mm, 1600 mm or 1760
mm widths depending on whether or not there is a conveyor underneath or a
straight-line or a curve situation exists.
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Figure 77 Single support bed section
Single support frames may also be used in the case of two-tier lines for the
upper conveyor where the support spacing of the two lines dictated by the
conveyors does not coincide or in order to obtain low concentrated loads on
platforms.
:NOTE: In the region of ascending and descending sections , it is possible to

use a tubular section instead of the channel section in order to be able to better
conform to the slope.
Double support frame

The double support frame is the standard application for two-tier conveyor lines.
It is a material-saving solution compared to two individual supports and also
provides greater stability due to the additional frame effect compared to the
single support frame. The double support frame enables heights of up to 4000
mm to be safely covered in order to run conveyor lines up to platforms or other
building parts at different levels. Depending on the clearances required for the
lower conveyor line, the cross-beams have a width of 1600 mm or 1760 mm.
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Figure 78 Double support frame
:NOTE: In the region of ascending sections, it is necessary to stabilize the

double support frame horizontally by additional measures, e.g. by tying it laterally
to the building or providing diagonal bracing underneath the lower conveyor line.
18.4 Hangers
Top-hung systems are standard with the same cross-beam as with supports, but
they are connected directly to the conveying element by means of bolted joints,
the connection being at the sides to the hangers with buffers interposed. The
hangers consist of an angle section with threaded rods connected which provide
sufficient stability and stepless vertical adjustment.
Figure 79 Standard hangers
The use of hangers breaks down into two different situations, namely a first
where they serve to connect conveyors to a steel platform to be planned and a
second where the hangers are attached to existing parts of the building either
directly by means of embedded plates or load-distributing girders.
Tray Manual 3_8.doc

The first situation may be encountered where some sections of the conveyor
lines cannot be placed directly on the ground, say, in order to negotiate
obstacles, bridge roadways, or in the case of sloping sections. At the same time,
this is the less expensive variant because the hangers can be anchored either in
the flooring of the platform or in reinforcing bracing.
Figure 80 Top-hung platform
The second situation represents the common application of hangers. Where no

large areas on the building floors are available for supports or, generally, where
the distance from the ceiling is less than that from the floor, top-hung systems
are adopted which may range from a single conveyor line and two-tier conveyor
lines through to a complete steel platform. The characteristic feature in this case
is that the complete maintenance of the conveyors is from walkways. Therefore,
the designers should consider the possibilities of combining the service
walkways and the need for escape routes right in planning the layout.
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Figure 81 Top-hung platform system from the building ceiling
:NOTE: Attachment to the building is either by embedded plates or plugs

installed in the ceiling or ceiling joists and, in most cases, carrying capacity is
very limited. Therefore, it is important to clarify this interface with the building
with the customer in the very early stages of a project to determine the location
and permissible loading of the connection points.
18.5 Steel platforms

The standard platform system provides for two variants. Firstly, a platform of
medium-weight construction providing ample floor space for any arrangement
required of up to two conveyor levels and associated escape and service paths.
This concept provides for daylight grating or chequered plate flooring that bears
on so-called top-hat sections spaced one meter apart which, in turn, are
supported on auxiliary girders spaced two meters apart. These are each 4
meters long and are connected to the main girders which rest on supports at the
same spacing. This basic spacing can be changed at any point, i.e. providing
openings for descending sections and stairs is no problem. This variant may be
added to alongside the main girders and has been adopted in the case of the
SAC and MUC projects.
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Figure 82 Standard wide-surface platform
The second variant is a platform of light-weight construction which provides the

possibility of running individual conveyor lines or two lines on top of each other
across a level that lends itself to many uses; even the arrangement of curves
and merge situations is possible. The system consists of support frames erected
at regular distances which are connected by three trussed longitudinal girders.
These support both the supports proper of the conveyors and the walkway.
This method of construction is distinguished by its very low material consumption

but is less flexible in planning and less suitable for a spacious layout of the
conveyor lines such as, for example, for an early bag store. To a limited extent,
the system lends itself to add-ons in the area of the large support frames and
has been used in practice in Beijing T3A.
:NOTE: Steel platforms have to be secured against lateral displacement. This

can be provided for, where possible, by tying them to the building or by bracing
which, however, will detract from the possibilities of using the level below.
Generally, it is necessary to perform a structural design review and, in most
countries, certification is required in addition by an independent authority.
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Figure 83 Standard platform of light-weight construction
18.6 Service walkways

Access to a conveyor system for maintenance and to work stations provided in
the system is ensured by service walkways. These are practically required
wherever locations higher than approx. 1.60 m above a walk-on level have to be
reached or obstacles have to be negotiated on the way to them. They may be
constructed as segregated areas on platforms or alongside conveyors as part of
their support or hanger system.
Figure 84 Service walkway, example Madrid
Whereas the areas for servicing and the walkways themselves are mostly
equipped with daylight grating for the flooring, solid surface flooring, for instance,
made of chequered plates is specified for work stations, such as those for
manual encoding.
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Crossovers are invariably required where service routes cross conveyor lines.
There are two variants, one being the classical crossover which consists of two
step-up and step-down flights that are connected by a piece of walkway. The
other version is the so-called cross passage where steps on both sides provide
access to the level of the conveyor where the person then steps on the conveyor
belt to cross. This variant has an advantage in that much less headroom is
required and the amount of material for the steelwork is reduced. But then there
is the disadvantage of having to stop the conveyor before crossing by pressing a
push button which interferes with the operation of the system and calls for
additional provisions in the control system.
Figure 85 Crossover
Access to platforms and suspended levels is provided by stairs or ladders.

Ladders are cheaper and a space-saving alternative but are awkward to
negotiate when the maintenance personnel have to carry tools or replacement
parts with them. Generally, stairs are to be preferred for access to work stations.
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Figure 86 Ladder, stairs
Provision must be made to prevent accidents in areas where servicing is to be

carried out and at work stations as well as accessways. Where there is a hazard
of falls, railings are provided with hand, knee rails and toe boards or fences or
chains to guard the conveyors and machine elements. These features are
designed according to international regulations for safety at work and are chosen
to meet the special requirements of the specific project.
Figure 87 Railings
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TRAY System User Manual 19 Systems
19 Systems
19.1 Introduction to Systems

Baggage handling systems with their complex structure can be discussed on
different levels of abstraction.
The different levels are of varying importance for the various teams working on a
project.
While the team handling the mechanical installation is more focused on the
individual conveyors, the simulation and IT teams work essentially on a material
flow basis.
A transparent project structure that uses the same terminology across the board
is key to good communications between teams.
We have chosen the following structure for the different levels in the I&S AL
baggage handling systems:
System
System At this level the entire baggage handling
Early Bag Stock
(EBS)
Distribution Loop
Interface to other
systems
system is described in terms of material flow
and system functions such as tray storage, tray
Loading
Empty Tray
Stock (ETS)
Tilting
loading stations, etc.
Sub-system
Sub-System Different design approaches are described to
Tilting
realize the system functions as shown at
ETS
system level. The description of the sub-system
is the basis for an effective design process
where a layout – based on material flow – is
drawn up.
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Function group
Function Group The function groups consist of combinations of
FG_Merge FG_Tilt_C conveyors that provide the necessary material
flow functions with predictable performance
characteristics. Whereas the system and sub-
system specifications refer to functions in terms
of material flow and are systems based, the
purpose of function groups is to provide the
required throughput from the given
arrangement of conveyor lines.
Device
Device Individual devices used to build the baggage
handing system are described.
:NOTE: The section 22 Devices as part of the configuration rules contains the
configuration rules specific to certain devices.
The devices consist of components that may be mandatory (e.g. drive station,
conveyor belt) or optional device elements (e.g. RFID, empty/full control).
The drawing below illustrates the design process for a dynamic tray store,
starting with the decision to design the system right up to the system layout.
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Figure 88 Example of the design process for a tray store
System
Need for Tray Storage
in Materialflow
Sub-System
Choice of
Storage Concept
static dynamic static - cross

(SS_EBS_SL) (SS_EBS_D) (SS_EBS_SQ)
Function
Groups Identification of allowed
Function Groups
Divert: Gap-Optimization: Merge:

FG_Divert_L FG_GapOpti FG_Merge_TP
Devices
(concrete design
within building
constraints)
Tray conveyor systems are well suited for transport over larger distances. Delays
can occur at the system transitions and at the loading and unloading points.
Benefits are the higher transport speed and the safe tracking of bags within the
system.
Closed-loop circuits contribute significantly to making a system less susceptible

to faults. It has been demonstrated that sorting and distribution circuits are very
beneficial.
In most cases, tray conveyor systems require a higher control system effort. A
key issue in tray conveyor systems is the control of the empty trays.
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The additional load resulting from empty trays on lines that are used to a high
degree by full trays at the same time is estimated to be 20-30 %. This value
should be seen as a function of the specific layout.
19.2 Basic system design assumptions

Unless indicated otherwise, the configuration rules relate to the following tray
sizes:
● Tray length (standard): 1680mm

● Tray length (small): 1350mm
● OOG tray length: 2600mm
19.3 Throughputs
Theoretical machine throughput
This is the maximum throughput of the isolated machine based on an optimum,
i.e. uninterrupted supply and discharge. The limiting factor is the machine itself
rather than its environment in the system implementation.
Achievable process output

In a system environment, the theoretical machine throughput is usually not
achieved. Gaps in tray supply or a back-up of trays after the corresponding
conveyor can interrupt the continuous transport flow and reduce the throughput
to the achievable process output. Within a chain of sequential conveyors, the
conveyor with the lowest machine output will determine the throughput of the
entire chain. This means that all other conveyors in the chain will not be able to
achieve their full machine output.
Based on the results of simulation, it can be assumed that the process output is
about 77 % to 83 % of the theoretical machine output. The actually achievable
throughputs may be even lower.
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The values below apply to a tray length of 1350 mm.
Table 1 Relationships between speed, tray spacing and throughput
Conveyor Max. speed Head-head Theoretical Process Utilization

[m/s] spacing of throughput output in %
trays [m] min [bags/hr] max. [bags/hr]
Standard area 2.5 3 3000 2500 83
High-speed area 5 6 3000 2500 83
Storage (full, empty) 1.5 2 2700 2200 81
Tilter 1.5 2 2700
Merge switch 2.5 max. 3 3000
Divert switch 2.5 max. 3 3000
Manual Encoding In 1 1,6 2250
Manual Encoding 0.5-Stop 1.6 900 (not 450
including
electronic
reading)
Loading, tray speed 2 1.6 2900 1800 62
Loading, bag speed 1.7 1.5 2900 1800 62
Writing to code carrier >2/2.5 2.4 3000
Reading of code >2,5 3000
carrier
Turns R = 2.550 m 2.5 max. 3 3000
Turns R = 2.000 m 1.5 max. 2 2700
Recalculation of values is required for tray lengths of more than 1350 mm.
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19.4 Energy consumption of a tray conveyor system

The energy consumption of a tray conveyor system installed depends on the
system’s parameters as well as its operation (e.g. hours of operation, load
profiles etc.). An approximation of the energy consumption would be:
W [kWh] =
 P ⋅ 0,45 ⋅ 1,1 ⋅ T
η
P Sum of drive ratings in [kW] (as per name plate)
T Number of annual hours of operation
η = 0,82 Average degree of efficiency of the drives
0,45 Partial load factor (deducted by BL Solutions from current

measurements)
1,1 Factor to compensate lower efficiency of the drives during partial load
operation
19.5 Considerations for the system control system

19.5.1 PLC limits
The PLC limits should be selected on the basis of the following four rules:
1. PLC limits should always be located on simple lines without function

elements (straight conveyors).
2. Merges, induct conveyor and discharge conveyors should be managed in
the same PLC.
3. Diverts, induct conveyor and discharge conveyors should be managed in
the same PLC; if this is not possible, hardware elements (Initiators) should
be installed in the area of the adjacent PLC.
4. Accumulation sections that are located between a branching point and a
merging point, e.g. at entrances to stores or at induct conveyor line to
circuits, should be managed on the same PLC as the branch. This facilitates
an availability check at the diversion point.
19.5.2 Number of initiators

The number of initiators that are required to detect the trays on the conveyors is
approximately Number of drives * 1.2.
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Plus approx. 4+3=7 initiators at each tilter.
For safety reasons, initiators can be used for guide pin monitoring after each
tilter and each interruption at a fire door.
For the monitoring of the tray guide rollers, 2 initiators are required to enable the
detection light barriers.
The location of the initiators at straight conveyors and metering conveyors

largely depends on the transport speed. In this context, both the nominal speed
and, with high-speed conveyors, also the start-up speed should be considered.
In pulsed mode, it can often occur that the conveyor has only run up to half its
nominal speed until the next conveyor is reached. In Dubai, the variation is high
due to humidity and weight variations of the bags alone. Cycle time variations
cause the stopping points to vary up to 180 mm.
Initiators are required at divert switches to monitor the switch blade.
In inclined conveyors, each drive must be equipped with an initiator. This makes
it possible in case of a stop to request more than one tray per inclined conveyor,
and each element is a single position. The drive rating of each section of an
inclined conveyor must permit a start-up.
:NOTE: Light barriers are also used in tray conveyor systems. For example, the
trays are detected in narrow turns by means of light barriers because the metal
base would not fully cover an initiator that is mounted from the bottom. The light
barrier replaces the initiator in this case.
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TRAY System User Manual 20 Sub-systems
20 Sub-systems
20.1 Introduction to sub-systems

Sub-systems (SSs) are a combination of material flow function groups.
Some of the functions covered are:
● Loading/unloading
● Sorting
● Transporting trays
● etc.
The objective of sub-system descriptions is to highlight critical configuration rules

to be applied and to list designs already proven in earlier projects.
The following general configuration rules apply for all sub-systems:
● only function groups listed in the Sub-System  Function Group

application matrix (Table 2) may be used.
● only concepts described in this document may be used to design the
different functions in the sub-systems (e.g. tray storage, etc.)
Sub-System – Function Groups application matrix

The SSFG application matrix defines which function groups may be used in
the different sub-systems.
The conveying functions carried out by the function groups will require different
conveyor layouts depending on the purpose of the overall system.
For example, the design of a tray merge when deployed in a dynamic storage
loop will be different to a tray merge not deployed in a dynamic storage loop. In
all cases where a tray merge is not deployed in a dynamic storage loop, the
merge has to perform the same function for each of the two upstream lines.
However, for tray merging within a storage loop, the loop always has priority. In
this case, the meterings needed to accumulate tray trains upstream of the merge
are not needed on the loop side, but an additional sensor is needed to detect
trays arriving in the loop. These two different design approaches are reflected in
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the SSFG application matrix where the FG_Merge_TP design is indicated

for dynamic storage loops, and the FG_Merge_R design for all other
applications.
Table 2 Sub-System  Function Group Application Matrix
Manual Operations
Loading Zone
Tilting Zone
Transport
Storage
Sorting
SST_EBS_SQ/SST_ETS_SQ
SST_EBS_SL/SST_ETS_SL
SST_EBS_D/SST_ETS_D
SST_TRANS_SD
SST_TRANS_LD
SST_LOAD_M
SST_SORT_R
SST_SORT_P
SST_LOAD_A
SST_TILT_M
SST_TILT_C
SST_TILT_D
SST_MES
SST_MS
Loading Stations FGT_Load_A x
Tilter FGT_Tilt_C x
FGT_Tilt_D x
Divert FGT_Divert_S x x x x x x x x x x x
FGT_Divert_TP x x
Merge FGT_Merge_R x x x x x x x x x
FGT_Merge_TP x x x x x x x
Accumulation FGT_Accu_M x x x x x x x x
FGT_Accu_A x
High-Speed track FGT_HighSpeed x
Buffer FGT_Buffer x x x x x x x
Gap Optimization FGT_Gap-Opti x x x
Security FGT_FireDoors x x x x x x x x x
FGT_CrossOver x x x x x x x x x
Manual Operation FGT_MES x
FGT_MS x
FGT_Load_M x
FGT_Tilt_M x
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20.2 Tray loading

As this release is preliminary, the sub-systems providing tray loading operations,
along with their symbols, are listed below. A detailed design description will
follow in the next release.
Figure 89 Sub-systems for tray loading
SST_LOAD_A
Loading Zone -
Top Load
Before loading
Before the loading station, a sufficient number of empty trays must be provided
at all times. For this reason, a buffer for empty trays should be provided next to
the station. Empirical value: 1 buffer position for every 100 bags/hr loading rate.
The empty tray buffer must not be a static accumulator. Gaps in the flow of
conveyed bags will occur because it is not possible to fully synchronize the input
and output of empty trays without compromising the maximum possible loading
rate.
If empty trays are not available, the belt conveyor will begin to pulse for every
incoming tray. This will cause increased wear and raise the temperature in the
drives. In addition, the bag may roll, slide ors swing during the pulsing. This can
result in loading errors and errors during data tracking.
During loading
Suitable equipment should be used to ensure that bags are placed in the center
of the belt conveyor and loaded into the center of the tray. In this case, the
sliding distances on the tilters are identical on both sides. The correct loading of
the bag must be monitored at the sides and at the top. The centered loading is
supported by the fact that the belt conveyors are narrower than the trays.
● General monitoring of loading (1 initiator, 1 light barrier)

● Controls for faults:
■ “Softstop” pushbutton
■ “Fault acknowledge” pushbutton
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After loading
● A distance of minimal 6 m needs to remain between the load station and the
next divert switch to ensure sufficient time for the necessary data exchange
between the host computer and the PLC level.
● An inclined conveyor must not be installed after a loading station, because
the bags in the tray may still move and may roll out of the backside of the
tray.
20.3 Tray tilting

As this release is preliminary, the sub-systems providing tray tilting operations,
Figure 90 Sub-systems for tray tilting
SST_TILT_C SST_TILT_D
Tilting - Compact Tilting - Dynamic

Tilter Tilter
Tilter
There are currently three implemented concepts for the arrangement of the
tilters:
No. Tilter arrangement Functionality Cost

1. Tilters decoupled from each other on ● High throughput high
main line ● High availability
2. Tilters in series on secondary line Good medium
3. Tilters in series on main line Susceptible to faults low
An acceptable trade-off between effort and value is achieved with a small

number of tilters in series on a secondary line.
Tilters should not be installed on the main transport line but rather on secondary
lines. Three metering conveyors with V=1.5 m/s should be installed before the
first tilter. Additional tilters that are installed in series should each be preceded
with a metering conveyor. The minimum transport length after the tilter and
before a turn must be equal to the length of one tray.
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Tilter arrangements in series are unfavorable. Each tilter normally provides a

throughput of 2400-2700 bags/hr. This means that each element in this series
must be able to handle 2700 bags/hr.
However, losses occur due to synchronization and availability issues. If a tilter

fails, all other tilter in that series will also stop. In addition, all tilters in this
configuration are required at their maximum performance. Tilters that are
connected in series must be synchronized. If one of these tilter is switched off, all
tilters must be resynchronized (which will take about 10 secs per tilter).
A series of tilters should not contain turns. A line must not contain more than 3
tilters.
The downstream (discharge) line after a series of tilters must have a significantly
higher performance than the induct conveyor line to the series of tilters.
Please refer to chapter Function Groups for a detailed design of the tilting zones.
Figure 91 Position of tilters in bypass lane
SST_TILT_D Design 3
FGT_Divert_S FGT_Merge_TP
FGT_Tilt_D FGT_Tilt_D FGT_Tilt_D
Due to the bypass for the tilter, a lower tilter performance can already be
sufficient. It may be possible to use a low-cost compact tilter.
It is advantageous to use at least two metering conveyors before each tilter. If a

merge is installed after the tilters, two single locations should be provided after
each tilter
If a tracking for the ejected bags is required, it can be helpful to reduce the tilting
performance by using e.g. only every other pair of arms. This ensures a safe
singulation of the bags.
The take-away belt conveyors are to be placed alongside the compact tilter,
because the tipping does not turn the bag.
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After the tilter, also at interruptions at fire doors, a run-in for the guide rail must
be provided. This run-in point must be provided with a guide rail monitoring
system (pin detection).
20.4 Transfer
As this release is preliminary, the sub-systems providing tray transfer operations,
Figure 92 Sub-systems for tray transfer
SST_TRANS_LD SST_TRANS_SD
Transfer Transfer
Long Distance Short Distance
Figure 93 Drawing of sorting area and tunnel sections
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In the tunnel area

● Conveyors up to 30 m can be used in the tunnel area.
● At the end of the tunnel and before entering the sorting area, the conveyors
must be graded in length. Refer to tunnel exit in Figure 93 (e.g. ...x 30 m +
Braking conveyor + 2 x 15 m + 2 x 10 m).
Example for tunnel length 400 m: ...x 30 m (5 m/s) + Braking belt (2.5 m/s)
+ 2 x 15 m (2.5 m/s) + 2 x 10 m (2.5 m/s)). The standard length of the
braking conveyor is 6 – 8 m.
● The higher the throughput in the tunnel is expected to be (determined by
contract / simulation) the more buffer positions shall be provided before en-
tering the next sorting area to avoid tunnel pulsing. Detailed numbers to be
determined by simulation.
● The only exception is the unconditional priority from the tunnel area. This
will require a braking conveyor of 6 m length at 2.5 m/s maximum.
● For shorter tunnel lengths (approx. 200 to 300 m) it does not make sense to
use conveyors that are longer than 20 m. (e.g. ...x 20 m + Braking conveyor
6 m).
Example for tunnel length 86 m: 4 x 20 m (5 m/s) + Braking conveyor 6 m

(2.5 m/s))
This makes it possible to accumulate in the tunnel in case of congestion at the
entrance to the sorting area. The number of these short conveyors are to be
determined by simulation.
This takes the experience from Dubai into consideration.
:NOTE: Never use pulsing in the tunnel! Limit the start-up current and use only
controlled braking. The use of frequency converters is highly recommended.
Linking the tunnels to a conveyor ring

Baggage tunnels are installed as underground connections between separate
areas. Often they need to bridge larger distances and are then built as high-
speed lines (Dubai 5 m/s, Madrid 10 m/s).
Tunnel lines often lead to a conveyor ring. The following, seemingly conflicting
requirements apply in this case:
● Distribution circuits must never stop

● Tunnel lines (high-speed lines) must not be stopped
This means that the tunnel line must be equipped with a bypass with
intermediate accumulator to the conveyor ring. This intermediate accumulator
handles the redistribution. Starting approx. 50 m before the end of the tunnel, the
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long conveyors must be broken down into shorter sections. The handling ratio
should be 2:1 (two trays from the tunnel vs. one tray from the conveyor ring).
Even though look-ahead control is difficult, the control system should be able to
dynamically vary this ratio. Switching off a tunnel would block the line with a
small number of trays, in the extreme case with only one per conveyor.
Figure 94 Layout of tunnel-conveyor ring link
Bypass Tunnel
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20.5 Tray storage

As this release is preliminary, the sub-systems providing tray storage operations,
Figure 95 Sub-systems for empty tray storage
SST_ETS_D SST_ETS_SL SST_ETS_SQ
ETS - dynamic ETS - static ETS - Cross Store
Figure 96 Sub-systems for early bag storage (tray)
SST_EBS_D SST_EBS_SL SST_EBS_SQ
EBS - dynamic EBS - static EBS - Cross Store
20.5.1 Conveyor lengths in the dynamic storage location

When selecting the conveyor lengths, the design of the entrance to the storage
location must be clarified. Without causing interruptions in the main flow lines,
the following elements can be used to properly fill a storage location:
● Main distribution circuit around the dynamic circuits.

● From the main distribution circuit, direct conveyors with a minimum length of
20-30 m for entrance to the dynamic storage location. 10 m conveyors and
metering conveyors are to be used for this purpose.
● With the exception of gap optimizers, no accumulator locations, metering
conveyors or shortened conveyors are required in the storage loops.
Accumulator locations are only necessary in the induct conveyor lines to the
storage loops.
● The storage location itself contains 20 / 22 m conveyors at a speed of
1.5 m/s.
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:NOTE: Never stop in the dynamic storage location! Merge only if the gap is
large enough. Divert only if the divert operation can safely be completed.
The fill level of the storage location without gap optimization with a special
control is only 70 % of the mechanical capacity. In order to fill the storage
location with as many trays as possible, the metering conveyors can be
controlled with frequency converters. This optimizes the loading of the empty
spaces.
Gap optimization
The regulation of the spacing of trays should occur before merge switches and
after divert switches. This reduces the probability of back-up stops.
20.5.2 Overview of storage types
Empty tray storage

A storage location for empty trays is exclusively designed for empty trays.
While it has a similar layout as the storage location for early baggage, the empty
tray store is functionally different from the early bag store.
An essential feature of the empty tray store is the requirement to supply a

loading station with empty trays in the shortest possible time in order to maintain
a continuous flow of baggage at a loading point. In addition, a high packing
density is also essential in order to provide the possibility to evacuate the trays
from the transport lines in the case of low system utilization; this avoids having to
move an unproportionally high number of empty trays for a small number of
transport jobs.
For dynamic empty tray stores, the following applies:
● The number of trays stored decreases when the system utilization

increases.
● The entrance should be located shortly before the exit so that the trays
quickly become available again (can be diverted) in case of a low fill level.
Contrary to the early bag store, the fill level is always low in the case of a
critical system utilization, which means that the trays can be easily merged
into the store.
● The loading station should be linked directly.
● Multiple accumulator loops and loading stations should be interconnected.
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● A gap optimization station should be used to achieve a high packing

density.
For a layout example, please refer to Figure 93.
For static dynamic empty tray stores, the following applies:
● All storage sections should be of identical length.

● For pulsing up, the following combination of sections should be provided:
Accumulation section – two shorter pulse-up sections that can

accommodate a half-train – storage sections – pulse-down section – buffer
before loading station that can accommodate at least one train length.
The accumulation section, the pulse-down section and the buffer before the
loading station can be implemented by means of accumulation conveyors.
● Parallel accumulation sections offer an advantage.
● The packing density is high.
● Control requires a high effort and is susceptible to faults.
● The technology is subjected to high stress levels (pulsing).
● Low energy consumption
Early bag store (EBS):

An early bag store in a tray conveyor system is utilized by full and empty trays.
Static stores buffer the trays in tracks that are served on a first in first out basis.
The storage track is connected to the main transport line at both ends and does
not form a closed loop. A tray can only be accessed after all preceding trays
have been removed. The trays are moved only when the storage track is filled or
emptied.
A static store comprises transfer conveyors, accumulation sections, metering

conveyors or accumulation conveyors. A distinction is made between 30°
merges and diverts by means of switches and turns and 90° right-angle transfer
conveyors.
● Advantages:
■ Low space requirements
■ Easy arrangement
■ Low energy consumption
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● Disadvantages
■ Only suitable to store batches (based on flights or time slices) because
individual trays cannot be accessed directly
■ High space requirements at entrance/exit
■ Requires many drives
■ Poor organization may require frequent rearrangements of the store.
For static early bag stores, the following applies:
● The packaging density can be high.

● A cluster segmentation is necessary.
● Possible clusters include: flights or departure time intervals.
● From the logistics perspective, a large number of parallel tracks should be
used.
● A loop is required for rearrangements of the store.
● The more dispersed the departure times are, the more rearrangements are
necessary.
● Empty and full trays should be managed in different areas.
Dynamic stores are designed as closed loops in parallel with the main transport
line. The trays are moved continuously. Trays to be stored are inserted into
gaps. When an individual tray is accessed to be retrieved from the store, this is
transported from the loop back to the main conveyor line.
● Advantages:
■ Requires a smaller number of drives
■ Rearrangements not required
■ Easy access to specific trays
● Disadvantages:
■ Fill level max. 70 % without special functions such as gap optimization
■ High space requirements for loops
■ High energy consumption
For dynamic early bag stores, the following applies:
● The throughput can be high.
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● The store can contain a maximum number of bags at full system load, which
can result in lower merging rates.
● The entrances should be located shortly after the exits to facilitate merge
operations.
● Loops and accumulation sections should be located before the entrances.
Recommended storage
From a functional perspective, dynamic stores are to be preferred, especially
for the empty trays. They provide high performance, control is easier than with
static stores, and their principle of operation makes them less susceptible to
faults and load variations.
Within a dynamic store, the storage loops can be long and only require one
metering conveyor to regulate the spacing of the trays. The storage loops have
always priority at the entrances because otherwise their capacity could not be
used.
Within the storage loops, a metering conveyor for gap optimization is required for
two reasons:
1. The merge gap is larger than the minimum gap in the store.
2. The spacings created during the merge into the store are random.
The metering conveyor is used to reduce small spacings that are still larger than
the minimum gap in relation to the preceding item by means of brief acceleration.
To increase the capacity of a dynamic store, it is possible to reduce the speeds

after the turns and to increase it before the turns.
To plan a functional system, the determining parameters of throughput and

distribution of departure times should be accurately analyzed for static stores.
Control system and technology require more effort than with a dynamic store.
20.5.3 Implementation examples of static and dynamic stores

There are different basic types that use accumulation sections along with a
conveyor ring system or also inside the ring.
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Figure 97 Layout of a static store with parallel accumulation sections
Figure 98 Layout Longitudinal static store with switches
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Figure 99 Layout of a dynamic store
Install Gap
Optimizer
Figure 100 Layout of a dynamic store with distribution circuit
Install Gap
Optimizer
Summary of criteria and issues:
● What must be observed?

● What are the advantages / disadvantages?
● How much space is required?
● What is the cost of one storage position?
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● How much wear does occur?

● How high are energy consumption and operating costs?
It can be dangerous to assume that stores can be filled properly by pulsing to

conveyors. The design of the control system must be coordinated between
simulation, control and mechanical layout. If the pulsed trains ‘lose the beat’, the
worst-case result can be that there is only one tray on each conveyor.
Flow-through stores, i.e. conveyor rings, always have priority!
Gap optimizers are used to optimize the density of the trays in the store. These
are metering conveyors with variable speed, similar to sorter inductions. A
feasible solution is a pole-changing drive with three speeds: 0 m/s, 1.5 m/s,
2 m/s.
20.5.4 Storage capacities

It is generally an advantage if all trays that are circulating in the system can be
accommodated in the store. Otherwise, it will always be required to move empty
trays even with a low baggage load. If e.g. the entrance to a tunnel line fails, the
tunnel line will run empty and the trays may crowd other areas of the system if
they cannot be accommodated in a store.
For selecting a system, the parameters that are described below must be
determined.
Definitions:
● The capacity indicates the maximum number of storage positions.

● The discharge indicates the output that is normally used at the connected
loading stations.
The parameter 1 is the ratio of capacity/discharge*3600, i.e. an indicator for how

long a store can supply the loading stations without any afflux.
The throughput is the performance of the lines in the store.
The parameter 2 is the ratio of throughput/discharge, i.e. a performance metric.
The evaluation is a subjective estimation of the overall performance of the

stores. The following can serve as a guideline:
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A good store should have a parameter 1 greater than 300 and a parameter 2
greater than 1.
20.6 Sorting
As this release is preliminary, the sub-systems providing tray sorting operations,
Figure 101 Sub-systems providing tray sorting
SST_SORT_P SST_SORT_R
Sortation Loop Sortation Loop

by priority by ratio
Please refer to Figure 93 Drawing of sorting area and tunnel sections.
Conveyors with a preferred length of 10 m up to 15 m should be used in the

sorting area. Experience from the project in Dubai has shown that the following
should be observed:
● L ≤ 3 m: Pulsing and accurate positioning is possible due to the high-grip

belt.
● 3 m < Length ≤ 10 m: Pulsing is possible. Due to the smooth belt surface,
however, extended skidding (approx. 1-1.5 m at 2.5 m/s) must be expected.
Bags may skid past the initiators.
● 10 m < Length ≤ 15 m: If pulsing is required here, i.e. if the permitted
switching frequency as specified in the table above is exceeded, it will be
necessary to use drives with frequency converters .
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20.7 Manual operations

As this release is preliminary, the sub-systems providing manual operations,
Figure 102 Sub-systems for manual operations
SST_MES SST_MS
Manual Encoding Maintenance

Station Station
SST_TILT_M SST_LOAD_M
Manual Loading
Manual Tilting Zone
Zone
Manual Encoding (ME)

The following section assumes that the ME stations are a part of the tray
conveyor system.
The manual encoding station is often also called a no-read station.
Multiple accumulator locations or metering conveyors should be provided before

the ME station.
Trays that are rejected at an overloaded ME station need to be rerouted to

(other) ME stations. A parallel arrangement of the stations should be preferred
for reasons of utilization and availability.
Data provided by the airport operators about the achievable automatic reading
rate for passenger baggage vary over a wide range. Above all, the achievable
reading rate depends on the label quality (which is usually much better for
check-in baggage than for transfer baggage), the visibility of the label at the
scanner (reduced if reading does nor occur 360o) as well as the percentage of
labels that do not comply with the ten-digit IATA code.
The percentage of no-read baggage varies accordingly:
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● For check-in baggage, the percentage varies between 2 % and 10 %.

● For transfer baggage, the available data range from evenly distributed 25 %
(Madrid) to 50 % no-read baggage arriving on specific flights (Paris).
It is recommended to reserve space for additional ME stations.
When determining the dimensions, the time required to change positions should
be considered. This time is approx. 2 sec for a bag length of 1 m and a speed of
0.5 m/sec max. in public areas.
The nominal performance of an ME station varies from 450 bags/hr (Paris) to

600 bags/hr (Dubai).
Maintenance area
If inspection stations are planned next to tilters or within the conveyor system,
the elevation of the conveyors should be selected to allow an inspection of the
trays and the guide roller from below. The accumulator location for the trays
should be designed for 10 trays. Trays that weigh 50 kg will require the
installation of lifting devices. Maintenance and inspection intervals can only be
determined by the control system based on the operating hours. It is not possible
without additional efforts to keep track of the number of loading or tipping
operations.
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TRAY System User Manual 21 Function Groups
21 Function Groups
21.1 Introduction to function groups

Function groups (FGs) are a combination of devices that perform a given
conveying function.
A combination of a number of devices is often needed to perform a given

operation. Even basic single device functions such as merging, diverting, tilting,
etc. involve interaction with several other devices.
Take the standard tilter, for example, it will only work if at least one metering
(tilter metering) is installed before and after the tilter. In order to enhance the
performance of the tilter, about 3 meterings upstream and downstream are
needed. These processes are described in the "Function groups."
The objective of the FG descriptions is to highlight critical configuration rules to

be applied so that the performance of the devices is predictable and optimized.
Besides the configuration rules, which are listed specifically for each individual
"Function group," there are overall configuration rules which apply for all the
FGs. These rules are listed below.
The following rules apply for all FGs

● No PLC boundary should cross the FG.
● Operations listed in the FG descriptions apply exclusively for the layouts
shown in the description.
● Devices combined other than indicated in the FG description are not
covered by the performance specifications and need additional analysis by
PE Solutions.
● If the proposed layout design for the FG cannot be installed for whatever
reason, this variation has to be examined and evaluated by BL in order to
estimate the risk involved with respect to performance and functionality
● The FGs are used to design sub-systems. FGs that can be used in a given
sub-system are listed in the FG application matrix shown in 2.1.2. Other
combinations are not approved or will, at least, need additional analysis by
PE Solutions.
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● The devices and additional components approved to create the FGs are
listed in the application matrix in 3.1.2. Other combinations are not approved
and will result in unpredictable performance.
FG application matrix
Table 3 Function Group  Components Application Matrix
Manual Operation
Gap Optimization
FGT_HighSpeed High-Speed track
Loading Stations
Accumulation
Security
Merge
Buffer
Divert
Tilter
FGT_CrossOver
FGT_Merge_TP
FGT_Divert_TP
FGT_FireDoors
FGT_Merge_R
FGT_Gap-Opti
FGT_Divert_S
FGT_Load_M
FGT_Accu_M
FGT_Load_A
FGT_Accu_A
FGT_Tilt_M
FGT_Buffer
FGT_Tilt_C
FGT_Tilt_D
FGT_MES
FGT_MS
Metering x x x x x x x x x x x x x x x
Straight Conveyor x x x x
Turn R2550 x x x x x x x x x
Turn R2000 x x x x
Turn R2550 driven double x x x x x x x x x x x
Inclined Conveyor
GapOptimizer x
Accumulator x
Divert x x
Merge x x
Maintenance Conveyor x
Manual Encoding Conveyor x
Loading Conveyor x
Tilter x
Compact Tilter x
Slave Drive x x x x x x x x x x x x x x
Empty/Full control x x x x
Heightcontrol x x x
RFID x x x x x x x x x
Roller Checking Station x
21.2 Loading stations: FGT_Load_A

FGT_Load_A
Function
The loading station is used to load bags onto empty trays. The loading station is
one of two tray conveyor system interfaces to other systems (belt conveyor
system). The other interface relates to the tilters.
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Performance
High throughput at the FG_Load is determined by three design factors:
● the design of the belt line to provide sufficient bags

● adequate supply of empty trays
● fast evacuation of loaded trays out of the loading zone
:NOTE: Design parameters that assure correct operation and predicted

throughput for a FG_Load_A are typically active at sub-system level due to the
close interaction of the loading stations with the empty tray store, the belt
conveyor system and the downstream system next to the loading.
The maximum performance at a loading station can only be achieved over a

longer period if the belt conveyor to load the trays is running continuously.
Stop & go on the belt line is critical due to the unpredictable behavior of different
bags. Different bag behavior on the belt makes it necessary to use long
acceleration and deceleration ramps to stop and restart the belt conveyor. This is
very time consuming and causes a massive drop in performance.
Under ideal conditions – which means optimization of the three performance

indicators mentioned above - a permanent loading rate of 1800b/h can be
achieved.
Higher performance can only be achieved by an individually designed

solution for the arrangement in place at sub-system level. Such a solution
would need to be agreed with all engineering teams working on the project.
:NOTE: Loading performance can be a crucial part of the customer

specification. If acceptance tests aim to check whether a specified loading
performance has been achieved, the design of the loading station should also
take into account the necessary performance to be shown during tests. This test
performance should be the minimum for which a loading station has been
designed.
Layout
The drawing below shows the standard configuration of an FG_Load_A.
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Figure 103 FGT_Load_A – Design 1
FGT_Load_A Design 1 1,5m/s
2,0m/s
Belt-Meterings shown with Frequency
Converters (adjustable between 1 - 1,5 m/s) 2,5m/s
Belt-Metering Belt-Metering
Metering Metering Metering Metering Metering

...
> response
time MFC
Meterings with
Frequency
Converters
conveying direction
The number of meterings before the metering where the trays are loaded
(marked with the black arrow) determine how many trays can be stored without
the need for an external empty tray supply from the empty tray store behind the
loading station or from other parts of the system.
To ensure safe loading, the first TRAY conveyor after the loading station is
equipped with additional side panels.
The platform after the loading station must still be at least 3 m long so that the
area is accessible in case of loading errors.
:NOTE: If the contract demands a very high loading rate within a short period of
time we will need to establish whether a sufficient number of meterings can be
installed upstream of the loading station to enable the loading test to be run
without external tray supply.
The distance between the loading station and the next merge should be large
enough to allow the IT system time to respond and to allow an RFID writing
station to write the destination on the code tag.
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Figure 104 FGT_Load_A – IT response time
Me
ter
ing
Me t > response time MFC
ter
ing
Metering
conveying direction
Example:
● IT response time (max.): 3s

● Conveyor speed: 2.5m/s
● Space necessary for RFID writing station: 1m
 necessary length of conveyor after loading station line and before next merge:
3s*2.5m/s + 1m = 8.5m
Inclines cannot be installed directly after a loading station as they decrease

throughput during pulse operation due to the extra distance; and because bags
loaded on trays may not have settled down; and they may fall off the tray if a turn
or an incline is met immediately after loading.
On the belt conveyor system at least 2 meterings have to be installed in order to

create the distances between the bags needed to load the trays continuously
without stopping the belt line.
IT
It is important that there is sufficient space in the installed system to allow the
destination to be written on the code tag before the next merge downstream of
the loading station is reached. The detailed geometrical layout is described in the
"Layout" section
Controls
Frequency converters are needed as shown in the "Layout" section.
At the loading station a destination is assigned to the bag which is loaded on a

tray. In the current software configuration, the destination is physically written on
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the RFID code tag for the tray. In order to do this, a command is sent from the
PLC to the IT during the loading process. The destination obtained from the IT
must then be written on the tag.
For optimal communication times the FGT_Load_A and the next ReRouting
station have to be under the control of the same PLC. This is an important issue
as the FGT_Load_A does not necessarily include the writing element of the
ReRouting station.
The PLC boundary rule (no PLC boundary should cross a FG) is therefore
extended to include the whole ReRouting station in the case of the FGT_Load_A
in the downstream direction.
Mechanics
no configuration rules apply
21.3 Compact Tilter: FGT_Tilt_C

FGT_Tilt_C
Function
The compact tilter has the following advantages over the standard tilter:
● higher redundancy (due to the ability to tilt on two different belt lines from
one tilter)
● easier start-up due to simple programming (no highly dynamic process)
● simpler system design around the tilter
● more reliable tilting process (no limitations in terms of tilting time)
Tilting rate
The FGT_Tilt_C should be able to tilt at a rate of about 900t/h. Throughput is
increased if every tray is not tilted. No extensive testing carried out as yet.
Layout
The drawing below shows the standard configuration of the FGT_Tilt_C
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Figure 105 FGT_Tilt_C – Design 1
FGT_Tilt_C Design 1
Metering Tilter Metering
Tilter with
Frequency conveying direction
1,5m/s 2,0m/s 2,5m/s converter
The design of the upstream and downstream lines is not very critical for the
operation of the compact tilter. Nevertheless, a higher number of single positions
and meterings around the function group increases throughput up to 900t/h –
which is the theoretical machine throughput.
IT and Controls
Currently there we have no project using compact tilters in operation. Information
will be added as soon as reliable data is available.
Mechanics
1. In a conveyor line with a tilter the throughput can not exceed the machine
output of the tilter. With two tilters in line the achievable throughput is shown
at the performance data table. Three and more compact tilters in line do not
make sense, because the throughput is less than with two tilters.
2. Instead of meterings turns with driven wheels at both sides are applicable
(only for 1.5 m/s and same friction factor μ0.5).
3. The take-away belt conveyors are to be placed alongside the compact tilter,
because the tipping does not turn the bag.
21.4 Diverting
21.4.1 Standard Divert: FGT_Divert_S
FGT_Divert_S
Function
A divert is used to split up tray conveyor lines.
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Depending on the final destination, the control system decides the direction each
tray will take by reading the RFID code tag attached to the tray. The
FGT_Divert_S is used for all diversions except those in dynamic storage loops
such as ETS and EBS.
Performance
In terms of material flow, the divert does not restrict throughput as the trays from
one upstream line are distributed onto two downstream lines.
Nevertheless, the distribution of trays can be subject to restrictions depending on

operational requirements and PLC control strategy. This will determine both
diverting and default directions.
The throughput obtainable has to be determined by simulation.
For details on control strategy, please see also the "Layout and controls" section.
Layout
1. Slave drives to downstream sections must not be used before a divert
switch because this increases the probability that a divert decision is not
completed in the case of a back-up in the downstream lines, this causing a
blockage of both lines.
with slave drive: affects performance (avoid)
with separate drive (acceptable)
with slave drive from downstream conveyor

push metering 3 m max. (acceptable)
2. The turn after a divert switch should be slave-driven from the reversed, i.e.
pushing downstream straight conveyor (length 3 m max.).
This enables the further use of the switch in the straight-on direction in case
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of a stop of the diverted line because the tray can be stopped on the
downstream conveyor.
The drawing below shows the standard configuration of an FGT_Divert_S
Figure 106 FGT_Divert_S – Design 1
FGT_Divert_S Design 1
Metering
conveying direction
The design of the downstream lines influences to a high degree whether high
diversions rates can be achieved.
The key rule is that the downstream line of the divert direction should have at
least 5 stop positions before the next FGT_Divert or FGT_Merge (accumulation
meterings of a subsequent FGT_Merge are not taken into account) to achieve
high throughput.
Typically, this rule does not apply for low throughput (up to 1200t/h).
Nevertheless, all positions in the layout where less than 5 positions are available
should be discussed during the layout review.
If this is not the case, conveyor length should be reduced so that an additional
stop position can be added.
:NOTE: There are often requirements that the divert should always be free. This
is to ensure that an alternative unblocked line is available if the downstream line
is unavailable.
If a high throughput rate is required for the divert, this condition cannot be
fulfilled. A “free divert” strategy reduces the maximum throughput obtainable to
less than 1800t/h at 2.5m/s, and 1100t/h at 1.5m/s if one metering is provided in
every downstream direction. Otherwise the throughput drops even more as a
function of the length of the downstream conveyors.
The downstream lines are used to check their ability to accept the next trays
passing the divert. The more single slots available; the higher the obtainable
throughput.
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Design 2 should generally be preferred to the design of diverts where a

throughput greater than 900t/h is expected.
Figure 107 FGT_Divert_S – Design 2
FGT_Divert_S Design 2
Metering or at least
single place
Metering
conveying direction
IT
Controls
The diverting sequence at the control level is described below.
1. The code tag on the tray is scanned by the RFID reader. This information is
used to decide which direction the tray will take.
2. After passing the RFID reader the tray arrives at the proximity switch at the
divert. At this point, the information from the RFID tag is processed and
used to move the guide pin on the divert in the direction the tray will take.
3. The tray passes the divert and a notification telegram is sent to the IT.
In order for the divert to operate correctly the scanned data must be available for
the divert block before the PS for the diverting function is reached. Otherwise, or
in case of a no-read, the tray is diverted into the default direction which has to be
assigned for each divert.
During pulse operation a tray may have to stop in front of the divert. This
stopping operation does not impact the control sequence mentioned above.
A clearance of less than a tray length is mandatory between the proximity switch
starting the diverting process and the divert guide pin. This is to ensure that,
under all circumstances, the tray that passed the PS is diverted into the direction
chosen for it.
The above clearance ensures that if the tray stops anywhere this does not
impact the control sequence.
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It is always difficult to start up again on roller-driven merge and divert switches.

An additional effort required in the control system to monitor this process and to
prevent a crash especially at merge switches. This requires additional read
operations (e.g. additional light barriers). In addition, it must be ensured at the
PLC level that, after a stop, the switch is cleared first before the induct conveyor
can be restarted. This requirement is independent of any performance
requirements. In this case, safety takes priority over performance.
Function of the single slots

The single slots on the FGT_Divert_S are needed to avoid the situation shown
below, where a tray has been diverted into a direction where the downstream
system is occupied. The last tray going in direction 1 is now blocking the divert in
both directions.
Figure 108 FGT_Divert_S – Problem in the control strategy at a divert
1 Tray for destination 2. Tray has already

passed the RFID reader but is not able
to move on because the last tray to
destination 1 is blocking the divert.
2 Metering
conveying direction
RFID Reader
Look-ahead control
To avoid the problem described above the availability of the downstream lines is
checked. If one of the lines is not available, the divert will not route any more
trays to this line (if possible).
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Figure 109 FGT_Divert_S – Routing strategy
Situation 1
1
2 2
Metering
conveying direction
Situation 2
1
2 1
Metering
conveying direction
In situation 1 the next tray entering the divert has to be directed to downstream
line 2. This line is free so the tray can continue its journey across the divert.
In situation 2 the downstream line is full. The tray has to wait in front of the
divert. Redundancy can be improved however: if downstream line 1 remains
unavailable over a longer period, the tray can be routed to downstream line 2. As
long as line 1 remains blocked all trays can be routed to line 2.
In order to determine the occupancy of a downstream line more than one

conveyor has to be tracked. The system can be optimized with multiple single
slots in the downstream lines. This will result in the following:
● maximize the slots available

● track all available slots
● in relation to tray capacity, less space will be needed than for long
conveyors
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The drawing below shows the function of the "look-ahead" control which decides
whether a tray can be routed in a given direction or not. There must be 2 free
slots on the downstream line as there may be 2 trays on the divert. With only one
slot fee it may be too late for the second tray to stop.
Figure 110 FGT_Divert_S – Look-ahead control of a divert
tak
eo
co >= ver i
nv f
eyo 2
r fr
ee
take over if
>= 2
conveyor free
Mechanics
The read head for the RFID system has to be placed at a set distance on the
upstream conveyor. As the RFID system is incapable of reading in turns or on
inclines a metering has to be placed in front of each divert.
The distance between the PS for diverting and the divert device is fixed.
Figure 111 FGT_Divert_S – Position of PS for divert routine
PS for diverting
function
Metering
conveying direction
RFID Reader
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21.4.2 Total Priority Divert: FGT_Divert_TP
FGT_Divert_TP
Function
To save hardware costs for dynamic storage loops, such as dynamic EBS and
ETS loops, a cheaper version of the FGT_Divert_S can be used.
Performance
With the FGT_Divert_S the two downstream lines can have equal priorities. For
the FGT_Divert_TP, however, the main line has overall priority and is not
stopped during normal operation. The throughput on the main line is therefore
not limited by the FGT_Divert_TP. Trays are only diverted to the divert direction
if the control system is satisfied that the tray can be transferred and will not stop
on the divert – thus blocking the main line.
The performance of the FGT_Divert_TP is therefore a function of the throughput

obtainable in the divert direction. This throughput is only limited by the availability
of the downstream line and has to be determined in each individual case.
Figure 112 FGT_Divert_TP – Application
div
ert
dir
ec
tio
n
main direction
ETS / EBS loop
The performance figures for the FGT_Divert_TP are not critical in terms of
system stability. Trays not diverted remain in the loops until the divert route is
available. There is no system stop due to an occupied line.
Layout
The drawing below shows the standard configuration of an FGT_Divert_TP. The
same configuration rules apply as for the FGT_Divert_S. In the downstream line
which leads out of the loop (this is the divert direction; remaining in the loop is
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the default direction) at least 5 stop positions should be provided before the next
FGT_Merge or FGT_Divert (meterings of these subsequent FGTs are not
counted for the 5 positions).
If high throughput is expected, long conveyors can be replaced by shorter ones

to increase the amount of stop positions.
The FGT_Divert_TP does not need a metering upstream of the divert but either
a straight conveyor or a roller conveyor should be installed to protect the rollers
on the tray from excessive wear (as would happen if the divert were connected
to a turn).
For diverting performance above 900t/h "Design 2" becomes mandatory.
Figure 113 FGT_Divert_TP – Design 1
FGT_Divert_TP Design 1
conveying direction
Figure 114 FGT_Divert_TP – Design 2
FGT_Divert_TP Design 2
1 single place is mandatory on

the diverting line out of the loop .
To increase the throughput
which can be diverted out of the
loop.
conveying direction
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IT
Controls
see FGT_Divert_S
Mechanics
see FGT_Divert_S
21.5 Merging
21.5.1 Standard Merge with ratio: FGT_Merge_R
FGT_Merge_R
Function
The FGT_Merge_R is used to bring together two tray lines.
The design of the upstream lines determines the throughput that can be handled
by the merge.
Stop & go operation is needed most of the time on the upstream lines to build
tray trains. A vital parameter is the gap between trays. These gaps can be
minimized by metering conveyors.
:NOTE: The tray ratio and, therefore, the performance obtainable are
determined by the mechanical layout.
To obtain high throughput rates it is also vital that the downstream line is able to
handle the merged tray flow.
Performance
The key factor impacting performance at a merge is that the gaps between trays
are reduced as much as possible so that the downstream tray flow is maximized.
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Based on the control restrictions needed for safely operating the merge and due
to geometrical preconditions, the minimum gap obtainable for trays from the
same upstream line is smaller than between trays of different origins.
For different origins the time needed to accelerate the trays has to be taken into
account as well. Typically, a gap of 1.5 – 2m is produced by acceleration.
The goal is therefore to build tray trains on the upstream lines to maximize
throughput.
For performance calculation, every metering or DoubleDriven turn counts as one

upstream metering conveyor.
The throughput obtainable varies significantly for different designs. The

performance is listed in the "Layout" section.
The drawing below illustrates the differences in using tray trains of 2 and 3 trays.
Figure 115 FGT_Merge_R – different ratios
Different Tray Trains
1
a b c d a
1
a a b c c d
distances between trays from

a) 1  1 c) 2  2
b) 1  2 d) 2  1
conveying direction
:NOTE: The maximum performance for a FGT_Merge_R (tray length: 1680mm)

is shown be-low. The indicated performance is valid for "Design 1" only (see
"Layout" section). For all other designs, restrictions lowering the performance
apply.
The last conveyor upstream of the FGT_Merge_R can also be included in the
calculation of the maximum possible ratio. Nevertheless, the throughput is
reduced due to the different acceleration behaviors.
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Example
Upstream line 1: Turn => 2 meterings => Merge  max. train of 3 trays
Upstream line 2: Incline => 2 meterings => Merge  max. train of 3 trays
Maximum ratio obtainable: 3:3
Due to the significant impact of different layouts on performance, detailed

performance figures for different designs will be given in the "Layout"
section.
:NOTE: Besides the tray trains which are formed upstream, the actual
performance of a merge may also be reduced by software parameterization
(minimum gaps, etc.).
The assumed values should be close to real-life conditions. However, the values
have not been verified for all combinations of conveyors!
The throughput figures are only valid if the trains are always available. If less
trays arrive as are needed for the formation of trains, performance will be lower
than indicated above!!!
Layout
The drawings below show the standard configurations of an FGT_Merge_R
applicable under certain conditions listed below.
A straight conveyor or at least a roller conveyor (length 1000mm+) should be

installed downstream of a merge to prevent excessive wear of tray guide rollers.
After a merge, a straight section with a minimum length of 1000 mm should be

provided before a turn in the main direction of travel.
Tray Manual 3_8.doc

Design 1 application:
Merge with highest possible throughput – should be used if very high
performance is needed and adequate space is available.
Figure 116 FGT_Mege_R – Design 1 (max. ratio 3:3)
FGT_Merge_R Design 1
Me
ter
i ng
Me
te r
in g
Metering Metering
conveying direction
Performance of FG_Merge_R (Design 1)

speed (m/s) 1,5 2,5
meterings (1:1) 1400 2300
upstream 2:2 1700 2800
3:3 1800* 3000*
The performance values show the possible throughput if the next upstream
conveyor is a straight conveyor or a double driven turn. Otherwise these values
are inapplicable.
Tray Manual 3_8.doc

High throughputs are needed but space requirements (as for design 1) are
unavailable.
Figure 117 FGT_Merge_R – Design 2 (max. ratio 3:3)
Me
te rin
g
Me
t er
in g
Meterings can be replaced by

DoubleDriven Turns Metering Metering
conveying direction

speed (m/s) 1,5 2,5
meterings (1:1) 1400 2300
upstream 2:2 1700 2800
3:3 1800* 3000*
The performance values show the possible throughput if the next upstream
are inapplicable.
A 90° infeed can be realized by replacing one of the meterings with the 60°
double driven turn. The same performance figures apply.
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High throughputs are needed while merging parallel conveyors. Often found at
level exchanges
Figure 118 FGT_Merge_R – Design 3 (max. ratio 3:3)
Meterings can
be replaced by
DoubleDriven
Turns
Metering Metering
Metering Metering
conveying direction

speed (m/s) 1,5 2,5
meterings (1:1) 1260 2070
upstream 2:2 1530 2520
3:3 1620* 2700*
The performance values show the achievable throughput if the next upstream
are inapplicable.
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Low throughputs
Figure 119 FGT_Merge_R – Design 4
Me
t er
in g
Metering
conveying direction

speed (m/s) 1,5 2,5
meterings (1:1) 1400 2300
upstream 2:2 1700* 2800*
3:3 not applicable not applicable
are inapplicable.
Tray Manual 3_8.doc

Low throughputs are needed, but space requirements as for Design 1 are
unavailable
Me
ter
ing
Meterings can be replaced by

DoubleDriven Turns Metering
conveying direction

speed (m/s) 1,5 2,5
meterings (1:1) 1400 2300
upstream 2:2 1700* 2800*
are inapplicable.
A 90° infeed can be realized by replacing one of the meterings with the 60°
double driven turn. The same performance figures apply.
Tray Manual 3_8.doc

Low throughput while merging parallel conveyor lines.
Metering
Meterings can be Metering

replaced by
DoubleDriven Turns
conveying direction

speed (m/s) 1,5 2,5
meterings (1:1) 1260 2070
upstream 2:2 1530* 2520*
are inapplicable.
Building trains of two or three trays has been found to be the best compromise
between throughput and function group size. This means that the size of the
function group still remains applicable, in most cases, in terms of space
consumption.
The single slot downstream of the merge is used to check the status of the
merge after a stop. Before the next tray starts, the merge has to be cleared. As
this is no longer possible using the timer, the next conveyor is used to verify that
the last tray has left the merge.
:NOTE: The last upstream conveyor before the meterings shown in the designs
can be used to build tray trains if this conveyor is one of the types listed below
● Straight conveyor
● Turn
Tray Manual 3_8.doc

The design shown below should be avoided. It can only be used as a

redundancy option. The lines can not be switched if one of the downstream lines
is unavailable. In this case crossing the flows would not be possible
Figure 122 Merge – Crossing for redundancy
IT
As described above, the performance obtainable depends to a large extent on
the length of the tray trains and therefore on the ratio which is programmed in
the PLC.
This ratio can be modified by the IT system as it is possible to download a new

ratio definition to the PLC in order to adjust the FGT_Merge_R rules to suit the
current throughput.
:NOTE: The degree of freedom available for defining tray trains is limited by the
mechanical preconditions of the FGT_Merge_R.
Controls
The drawing below illustrates how the trays on a merge are handled at PLC
level.
Tray Manual 3_8.doc

Figure 123 FGT_Merge_R – PLC control
conveying direction
Me
t er
ing
Me
ter
ing
Metering Metering
The control sequence is as follows:
1. There are tray queues on both upstream lines

2. The last tray of the previous train starts a timer (performance!) which is the
start signal for the train on the other upstream line (a 1s timer has been
found to be adequate in practice)
3. The other line is started and the train moves over the merge.
The photo cells serve as crash protection. During normal operation at least one
photo cell is not activated. As soon as both are activated a crash has occurred.
Photo cells have also been used as an alternative to timers for starting tray
trains. But starting with timers has proven the better solution. Furthermore, the
timer can be adjusted more precisely than photo cells.
After a restart, the photo cells have to be cleared before the next trays are fed
into the merge.
The meterings forming the tray train should restart without the delay between
conveyors. This delay is set by default. In this way gaps between trays remain at
a minimum and throughput across the merge can be increased.
Basically there are 2 different control strategies for the FGT_Merge_R.
Standard
A ratio between 1 and 3 is set up depending on the layout
Tray Manual 3_8.doc

Priority
A ratio of “0” is set up for one line. This option ensures that a tray coming
from this line always has priority. This function is similar to the
FGT_Merge_TP but also allows the priority line to stop briefly to wait until
the merge is free.
:NOTE: Especially at the merge, PLC boundaries should not be placed inside
the function group because PLC boundaries imply a longer time for
communication between conveyors and therefore reduce the throughput which
can be obtained on the FGT_Merge_S. PLC boundaries should be placed
upstream of the meterings of the FGT_Merge.
Mechanical
Passive overdrives are always attached to the upstream conveyors – never to
the merge itself.
21.5.2 Total Priority Merge: FGT_Merge_TP
FGT_Merge_TP
Function
The merge strategy employed at the FGT_Merge_TP ensures that the priority
line is always running. This function has to be used in EBS and dynamic ETS
as a loop stop could cause a deadlock.
Under the following conditions the use of a total priority function can be taken
into account:
1. one line always has priority and does not stop under any circumstances
2. the line to be merged in is not a main material flow line (no high throughput
and not affected by a transfer time to be maintained)
:NOTE: The mechanical design should be reviewed to establish whether the

FGT_Merge_TP can be implemented as an FGT_Merge_R with two meterings in
all upstream lines.
The strategy can be changed to a ratio as well, at a later date. To replace the
FGT_Merge_TP with a FGT_Merge_S mechanical modifications would be
necessary (installation of additional meterings in the total priority line).
Tray Manual 3_8.doc

Performance
The performance of the FGT_Merge_TP depends primarily on the traffic on the
main line. As soon as the priority line offers no windows sufficient for the
induction of a tray from the induct conveyor line, the throughput from the induct
conveyor line is zero.
Nevertheless, the throughput can be improved if the probability of a tray being

available to be merged in is increased when a window to merge in a tray passes
by. This performance can be improved by adding several more meterings to
deliver these trays. Therefore the following definition can be made:
● Design 1-3: High throughputs

● Design 4-6: Throughputs of less than 1200t/h to be merged in the loop
depending on the availability of gaps in the loop.
Layout
The drawings below show the standard configuration of a FGT_Merge_TP.
A straight conveyor or at least a roller conveyor (length 1000mm+) should be

installed downstream of every merge to prevent excessive wear of the tray guide
rollers.
Figure 124 FGT_Merge_TP – Design 1
FGT_Merge_TP Design 1
Me
te r
i ng
Me
te ri n
g
Length of Merge-Window
conveying direction
Tray Manual 3_8.doc

Me
ter
ing
Me
ter
ing
Meterings can be Length of Merge-Window

replaced by
DoubleDriven Turns
conveying direction
Metering Metering
conveying direction
Tray Manual 3_8.doc

Me
t er
in g
conveying direction
Me
ter
ing
Meterings can be Length of Merge-Window

replaced by
DoubleDriven Turns
conveying direction
Tray Manual 3_8.doc

Metering
conveying direction
IT
Control
Trays are only merged onto the total priority line if the window between two trays
on the main line is sufficiently wide to allow the tray to be merged in without
stopping the priority line.
The window is detected by the pre-notification proximity switch which is installed

as close as possible upstream in the main line to merge in a tray from outside.
The drawing below illustrates the function in detail.
Figure 130 FGT_Merge_TP – Minimum window
minimum window
to merge in an
addtional tray
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Figure 131 FGT_Merge_TP – Zone of prenotification
zone supervised by
prenotification PS. If zone is
free of trays from the metering
can be released in the merge
Me without stopping the
ter
ing prenotification line
Me
ter
ing
prenotification PS
conveying direction
Mechanics
see FGT_Merge_R
21.6 Tray accumulation: FGT_Accu_A

FG_Accu_A
Function
The accumulation conveyor is an additional component which is installed in a
standard straight conveyor. The accumulation conveyor is controlled by an IM-
151 CPU which is installed next to the conveyor line.
Accumulation conveyors are currently unable to handle highly dynamic

processes. They are restricted by the conveyor speed which is limited to 1.5m/s
on accumulation conveyors.
Current applications for accumulation conveyors are
● entrance to static stores

● exit from static stores
● waiting slots in front of operator stations
● infeeds for prenotification merges to dynamic stores
Tray Manual 3_8.doc

Accumulation conveyors cannot be used for the following applications:
● at loading stations
● to buffer trays on high traffic lines
● to handle other highly dynamic processes
● to buffer trays in front of merges, tilters, etc.
Performance
The performance of the FGT_Accu_A depends primarily on correct installation. If
all configuration rules are followed it should be possible to achieve design
throughput (approximately) without the accumulation function
Layout
The drawings below show different designs of the FGT_Accu_A and the
application of the FGT_Accu_A in the different designs.
The length of the conveyor depends on the number of accumulator locations and
the length of the accumulator locations.
1. Clarification of the number of required accumulator locations

2. Clarification of tray length
With this information the planning program CONCEPTIX will already draw the
accumulation conveyor in the correct length.
Figure 132 FGT_Accu_A – Design 1
FGT_Accu_A Design 1 (Entrance Store)
n
...... 2 1
conveying direction
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Figure 133 FGT_Accu_A – Design 2
FGT_Accu_A Design 2 (Exit Store)
n
...... 2 1
Metering
conveying direction
The maximum speed of the accumulation conveyor is 1.5m/s.
:NOTE: Accumulation slots should be used if at least 5 positions can be used.
IT
Controls
Accumulation slots can either be controlled by a separate box with ProfiBus
connection or integrated in the PLC program.
In the current configuration one of the external boxes is able to control 2 or 3

accumulation slots.
:NOTE: It is essential for quick and smooth start-up that all mechanical
configuration rules below are followed.
Mechanics
The following drawing indicates the key issues. The detailed installation guide
can be found in the description of the mechanical components.
Non-adherence to the configuration rules for the accumulation conveyor

can considerably hike start-up costs!
Calculating the length of the accumulation conveyor

1. Position of the first accumulator position near the drive station (C ):
Distance between end of drive station to middle of accumulator location =
half the tray length + 330 mm
2. Distance between the accumulator locations (B) = tray length + 160 mm
Tray Manual 3_8.doc

3. Position of last accumulator position near the tensioning station (A):

Distance between end of tensioning station to middle of accumulator
location = half the tray length + 230 mm
:NOTE: The length of the adapter traverse must not be taken into
consideration. To find the end of the conveyor, the length must be
decreased to a multiple of 200 mm (e.g. for a conveyor with length of 6380
mm, the tensioning station ends at 6200 mm (D)).
Figure 134 Drawing of accumulation conveyor
:NOTE: The conveyor shall not be longer than calculated above.
In order to accommodate a larger number of accumulator locations, the speed

e.g. of the empty tray lines can be reduced to 1.3 m/s. However, it should be
observed that the conveyor directly before a turn and the turn itself should be run
at the main speed of 1.5 m/s.
21.7 Highspeed track: FGT_HighSpeed

FGT_HighSpeed
Function
High-speed conveyor lines consist of cascaded conveyors with different speeds.
The current top speed of 10m/s has been attained in the project Madrid.
Typically, high-speed lines are used to connect different terminal buildings or to

cover other large distances without distribution functionality.
Performance
Basically the throughput of a tray line should not be decreased by running it at a
higher speed. Currently insufficient data is available to evaluate whether there is
a reduction in performance. In practice, some issues need to be addressed when
designing highspeed lines in order to prevent malfunctions.
Tray Manual 3_8.doc

Key issues requiring further examination are:
● trays traveling at different speeds

● the long distances needed to stop trays
● high noise levels
:NOTE: At this time, highspeed tracks should not be used to handle more than
1800t/h.
Layout
Layout designs for high speed lines are currently under investigation. The
drawing below shows the beginning and end of the FGT_HighSpeed.
Figure 135 FGT_HighSpeed
FGT_HighSpeed Design 1
conveyor speed : 2,5m/s < v 2 < v 3 < v4
v2 v3 v4 … v4 ... v4 v3 v2
conveying direction
The layout of the intermediary section (v4 section) is currently under

investigation. Up to now this section consisted of conveyors of different lengths
(20m – 30m). In the future, correction conveyors with lengths of the order of 10m
will be installed to correct gaps between the trays. The number of correction
conveyors needed has not been specified yet.
IT
Controls
The same rules as for dynamic tilters also apply (almost identically) for high
speed lines. A high-speed line should not stop under any circumstances. Apart
from a massive drop in performance in terms of throughput, a controlled stop
and restart of a high-speed line causes problems at PLC level:
● significantly varying braking distances for the trays (15 – 25m)
Tray Manual 3_8.doc

● difficulties in stopping trays on the same conveyor where they pass the stop
proximity switch. This is due to the long braking distance.
● trays crashing due to trays approaching each other while passing the high
speed line (different traveling speed on high speed lines)
The evacuation of trays when leaving the high-speed line has highest priority at
PLC level. Ideally, a buffer should be installed downstream of the high-speed line
to accept trays which cannot be handled by the downstream system.
The use of a braking resistance should be mandatory as it shortens the braking

distance.
Mechanics
High-speed lines are very restricted in terms of layout flexibility. Only straight
conveyors can be used and the vertical angle between two conveyors must not
exceed 0.5°.
All high-speed conveyors with speeds greater than 2.5m/s always need
frequency converters.
At present there is no high-speed line in continuous operation in any project.
Conveyors running at speeds of 10m/s currently need to have a length of 30m,

as trays need about 25m to come to a halt from a speed of 10m/s. If the
conveyors are designed shorter than this, the trays would stop on the next
downstream conveyor which is not tracked by the PLC. At present, we have no
solution for this problem.
:NOTE: In the Paris project the resonance frequency of the high speed system
is reached if the system runs at 7m/s (with tray: 1350mm).
21.8 Buffer: FGT_Buffer

FGT_Buffer
Function
A buffer is a temporary store for trays which equalizes different input or output
rates at the interface of sub-systems for a short period. Without a buffer the
upstream sub-system would stop if the downstream sub-system becomes full.
Buffers are needed in the following situations:
Tray Manual 3_8.doc

● at the end of high speed lines (FGT_HighSpeed)

● in front of loading stations (FGT_Load_A)
● on main lines where pulse operation is likely to happen.
Figure 136 FGT_Buffer - application
Sub-System 1 Sub-System 2
Without buffer an occupied Sub-System 2 causes

Sub-System 1 to stop as well immideately
With a buffer the Sub-System 1 can continue to run for a certain time
without stopping directly. If the jam in Sub-System 2 is cleared up within this
time, no stop of Sub-System 1 is necessary at all.
Buffer
Sub-System stopped Sub-System running

(occupied) (free)
A buffer has up to 20 storage slots for trays. A buffer with more than 20 slots is
referred to as a store and is a sub-system in its own right.
Performance
A buffer does not restrict line throughput. On the contrary, it increases the total
throughput and availability as it equalizes temporary peaks and avoids brief line
stops due to full conveyors.
Detailed performance figures need to be evaluated for each specific case.
Layout
The FGT_Buffer does not have a specific layout. The only condition is that it
should consist of meterings or at least single slots. The drawing below shows a
Tray Manual 3_8.doc

proposed layout for a buffer connected between a high speed line and a
distribution loop.
A buffer has less than 30 positions, consists of single positions only and has a
high throughput.
The drawings below show a high speed line directly connected to distribution
loops and how this type of configuration should be avoided.
Figure 137 Incorrect interconnection Highspeed <> Distribution
no buffer - every tray not merged

in immideately causes high-speed
line to stop!!!
High-Speed
Buffer
Interconnection
Distribution Loop
Tray Manual 3_8.doc

Figure 138 FGT_Buffer - Example 1
High-Speed
Buffer
Interconnection
Distribution Loop
IT
Controls
Mechanics
Tray Manual 3_8.doc

21.9 Gap optimization: FGT_Gap_Opti

FGT_GapOpti
Function
The distribution of trays in dynamic stores is influenced by the trays leaving a
storage loop or being inducted to it. The gap optimizer is used to optimize
distances between trays and build tray trains.
The aim is to reorganize the random distribution of trays to tray trains. There
should be a minimum distance between trays in the same train; and the gaps
between trains should be as large as possible to allow additional trays to be
merged in.
Performance
The gap optimizer increases the maximum filling level of a dynamic store from
about 65% – without the use of a gap optimizer – to 85 – 90% with at least one
gap optimizer.
The critical issue is the number of rotations needed to optimize the trays. The
shorter the time available – due to high peaks in trays to be stored – the greater
the number of gap optimizers needed in the same store.
The number of optimizers needed has to be determined by simulation. However,

at least one gap optimizer is needed in every dynamic store.
Layout
The standard layout for an FGT_GapOpti is shown below.
Figure 139 FGT_GapOpti – Design 1
FGT_GapOpti Design 1
Gap-
Low-Friction/Curve Optimizer
Low-Friction
conveying direction
Adapter traverse Adapter traverse
Tray Manual 3_8.doc

IT
Controls
To increase the packing density in a dynamic tray store, a metering conveyor
with frequency converter should be used before the merging point, which serves
to optimize the gaps in the dynamic store as follows:
● Measurement of the gap between the preceding tray and the current tray
● If the gap is smaller than the minimum gap in the system: no response
● If the gap is larger than the minimum gap in the system and larger than the
merging gap and a tray is present at the merging point: no response, gap is
used for merging
● If the gap is larger than the minimum gap and smaller than the merging gap
for the tray that is present at the merging point: Gap cannot be used for
merging, therefore max. speed forward to reduce the gap
● If the gap is larger than the minimum gap and no tray is present at the
merging point: max. speed forward to reduce the gap
A general gap correction should always occur during the allocation at the
merging points and during the restart of conveyors. It can also occur after
branches. A gap correction should not be made after merging points because
this could result in undesirable back-up switch-offs.
The gap optimizer can be controlled by the PLC or by an external IM-151 unit.
The IM-151 controls the FGT_Gap_Opti better than the PLC but it is more
expensive. The necessity to use an IM-151 should be evaluated by the cycle
time of the main PLC and the ProfiBus response time. These two parameters
influence the precision of correction.
The layout of the FGT_GapOpti is shown below along with the necessary
proximity switches etc.
Tray Manual 3_8.doc

Figure 140 Functional scheme of Gap Optimizer
Conveying direction
Signal input for sensors
LO-1 SI-1 LO-2 LO-3 LO-4 LO-5 SI-2
Conveyor 1 Gap Optimizer Conveyor 2
Output signal to control drives
PLC with program Conveyor drive Conveyor drive for Conveyor drive
for Gap Optimizer (constant speed) Gap Optimizer
(variable speed
PLC controlled)
= Stop Initiator (to control stop at conveyor end
= Initiator Gap Optimizer (to detect gaps between trays)
The detailed installation of the proximity switches is described in the "Gap

optimizer" documentation.
:NOTE: The tray length determines where proximity switches are installed.
Mechanics
Tray Manual 3_8.doc

21.10 Fire Doors: FGT_FireDoors

FGT_FireDoor
Function
Fire doors are mandatory where the conveyor system passes a fire intersection.
Fire doors must close securely and the conveyor system should not be damaged
by the closing fire door.
:NOTE: The design of fire doors will be governed by pending government

health and safety regulations.
Performance
The fire door does not impact system performance under normal operating
conditions.
Layout
Before the fire door, a metering conveyor should be installed to properly clear
the door. The conveyor after the door must always be able to accept the tray
that is located in the fire door area. An emergency power supply may be
necessary.
Figure 141 Layout of situation at the fire protection gate
Key
1 Situation at the fire protection gate
2 Straight conveyor 30 m max.
3 Metering conveyor 1900 mm min.
4 Straight conveyor 4000 mm min.
5 Fire wall
The transition at the fire door is formed by an interruption of the straight

conveyor line. However, the interruption shall not be drawn in the layout. The
Tray Manual 3_8.doc

connecting sleepers and the traverse must be removed on the construction site.
The metering conveyor must be reversed so that two tensioning stations face
each other. After the fire door, the center guide must be widened in the same
manner as after every tilter. A guide roller monitoring station can be used.
Figure 142 Drawing of the transition at the fire door
Direction of travel → → →
The left metering conveyor pushes (drive at tail end).
Figure 143 Photos of top view of the transition at the fire door
Tray Manual 3_8.doc

Figure 144 Photo of side view of the transition at the fire door
A roller monitoring station can be connected to the widened center guide.
IT
to be completed
Controls
The FGT_FireDoor needs no control activities during normal operation. Due to
health and safety concerns the functions of the FG are to be wired directly or
controlled by the Safety PLC.
The basic function sequence should be:
● A fire alarm activates the sequence of the FGT_FireDoor

● The control system checks that the door can close safely by means of a
photo cell installed at the fire door
● The conveyors are shut down and the door is closed
If, at the time of the alarm, a tray is situated in the fire door zone, the tray is
evacuated. The next tray stops on the metering conveyor so that the door can be
closed safely.
Mechanics
The motor at the metering has to be mounted at the rear of the conveyor so that
the conveyor is pushed rather than pulled.
The conveyor directly behind the intersection has to be equipped with a roller
guide, as used behind the dynamic tilter, because of the interruption in the Z rail
in the fire door zone.
Tray Manual 3_8.doc

The interruption between the metering and the next conveyor is not to be drawn
in the layout. During layout design ensure that the end of the metering is at the
same location as the fire door so that the door can close safely between the two
conveyors.
Tray Manual 3_8.doc

TRAY System User Manual 22 Devices
22 Devices
22.1 Straight conveyors

22.1.1 Calculation of lengths
It is desirable to configure the lengths to full meters. However, lengths can be
produced with a 200 mm pitch. Intermediate lengths are achieved by using
adapter traverses.
In the case of odd lengths, the conveyor shall be drawn like this in the layout. An
adapter traverse is then inserted during detailed design if the length deviates
from the conveyor length pitch by 0.2 m. This results in a standardization of the
belt length of the conveyor to sections of 0.4 m.
Standard adapter traverses are currently available with the following lengths:
Equipment designation
Intermediate bed section, standard L=1200
Example of length calculation (conveyor with standard intermediate

section):
Drive 800 mm + Intermediate section 2800 mm + Tensioning station 800

mm = 4400 mm
Tray Manual 3_8.doc

:NOTE: The length of drive station and tensioning station may vary according to
project specific requirements:
Paris Dubai Dubai T3 Madrid
Drive station 800 800 300 800
Tensioning 800 800 700 800
station
The drive station 800 and tensioning station 800 are needed for the high speed
line.
22.1.2 Minimal vertical displacement

Due to the short standard tray’s height, stacked empty tray lines need to
maintain a minimal displacement of 800 mm (top edge – top edge)
22.1.3 Knee conveyors
Vertical knees downward (convex)

Vertical knees downward are permitted on straight conveyors at 2.5 m/s to max.
0.5°.
No knees are permitted before or after turns, switches, tilters, compact tilters,
inclined conveyors and wheel conveyors because they would cause shocks on
the wheels. Another reason is that this would cause an inadmissible obstruction
of the diversion for the directional change.
A 2° knee is not permitted. Instead, 4 knees with 0.5° must be used; each
subsection must be able to accommodate a full tray length.
Figure 145 Schematic drawing of vertical knee downward

0.5 deg
At 5 m/s, consultation with BL Engineering is required.
Tray Manual 3_8.doc

0.5 deg
0.5 deg
Vertical knees upward (concave)

Vertical knees upward up to 0.5° are permitted at 2.5 m/s maximum on straight
conveyors. The discharge conveyor may also run at 5 m/s instead of 2.5 m/s.
No knees are permitted before or after turns, switches, tilters, compact tilters,
inclined conveyors and wheel conveyors because they would cause shocks on
the wheels. Another reason is that this would cause an inadmissible obstruction
of the diversion for the directional change.
Figure 146 Schematic drawing of vertical knee upward
0.5 deg
0.5 deg
For 5 m/s, consultation with BL Engineering is required. At this speed, the

second (convex) knee is permitted up to 0.5o.
:NOTE: In exceptional cases, a knee upward may also work up to 1° at speeds

of less than 2.5 m/s (consultation with BL Engineering required).
Horizontal knees to the side

Horizontal knees to the side are permitted at 2.5 m/s and also at 5 m/s on
straight conveyors up to 3° maximum.
The conveyor must not have a horizontal and vertical knee in the same location.
Figure 147 Drawing of horizontal knee
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At 5 m/s, consultation with BL Engineering is required.
Horizontal knees are not allowed before or after switches, tilters or compact
tilters.
Central guide rail

Knees of the central Z-guide rail must be avoided. Where necessary, the guide
rail must be cut well before and after the knee of the conveyors and the gap be
closed by a guide rail section.
22.2 Metering conveyors (discontinuous)

The required length of the metering conveyor depends on the length of the tray
and the stopping distance of the tray.
The stopping distance results from the response distance (PLC, fieldbus, brake
application time) and the slipping distance.
The slipping distance varies due to the different masses (full or empty tray) and
also depend on whether a tray must be decelerated from full speed or whether it
must stop during the transition from one metering conveyor to the next. In this
case, the location initiator is already tripped although Vmax has not yet been
reached.
Because, in this process, the slipping distance is shorter than with a stop from
full speed, the tray will still be on the induct conveyor. This causes collisions or
can mean in the worst case that the feeding metering cannot be used as
accumulator location .
Length of the standard metering

● For tray length 1350 mm 1600 mm
● For tray length 1680 mm 2000 mm
22.3 Slave drive for wheel conveyors and turns

Undriven turns, switches and wheel conveyors are always equipped with slave
drive disks at both sides. With non-driven turns and wheel conveyors, the slave
drive belt is also included in the standard scope of supply. Only with straight
conveyors it is necessary to configure the slave drive disk via the attribute entry.
The slave drive connects wheel conveyors or turns to a drive shaft of the straight
conveyors. Here, a slave drive wheel 77403547 with tensioning set 65020547
must be installed on the drive shaft.
Tray Manual 3_8.doc

The actual slave drive is implemented via multi-section V-belts from wheel to
wheel or from shaft to wheel.
The multi-section V-belts are prestressed with 9 % (hand mount minus 1/11).
Certain rules apply to slave drives before divert switches or merge switches.
For this reason, it is not possible to generally use slave drives to save a number
of drive units.
22.4 Traverses with slave drive

Traverses are not allowed where slave drives are used. In this case the
unprotected slave drive belt could become a hazard to the operators or service
staff.
Should a traverse become necessary, it should be installed at the next transition

point between conveyors. If this is not possible due to space restrictions, then
the slave drive belt needs to be covered with a hood. This will only be possible
on site where the size of the gap is known.
Figure 148 Wrong application of slave drive with traverse
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22.5 Inclined conveyors

1. Inclined conveyors should be avoided if the application requires frequent
pulsing, e.g. before highly frequented loading stations or induct conveyor
lines to storage locations, or at the entrance to tilter lines.
The simulation clarifies if the use of an inclined conveyor makes sense at

the desired point.
2. Although it is handled as a single module in the layout, the 19° inclined
conveyors can consist of multiple, individually driven sections.
From a control system perspective, the inclined conveyor used to be

considered as a single station.
Because every accumulator location in the system improves the system
performance, it should be clarified if each section that has a separate drive
could be used as a station. This was implemented with UPS, and is planned
in this manner for Paris. With inclined conveyors, it is also possible to
accumulate in the inclination, but with a lower pulse rate. Due to the risk of
tray slippage at 19o incline this is to be avoided.
3. Inclined conveyors at empty tray sections can be operated with a standard
motor starter. All inclines conveying loaded trays have to be operated with a
frequency converter.
4. In the case of ascending sections, it should be borne in mind that the upper
line in each case starts 500 mm earlier at the bottom end, referred to the
start of the rise. Otherwise, the clear height would be too small for the bag
to pass.
Figure 149 Schematic support arrangement of two-tier ascending section
5. Within inclines adapter traverses are not allowed. The passive support
rollers reduce the friction to support the tray movement up or down. If the
adapter traverse can not be avoided, then it must not be placed at one of
the bows, but only between straight sections.
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22.6 Turns
Arrangement of standard turns
Turns can be directly linked to straight conveyors and can even be slave-driven
by these. Turns are not allowed:
● Directly after merge switches

● Before and after tilters
● Before and after compact tilters
● Before and after inclined conveyors.
Non-specified angles
:NOTE: For standard turns R = 2550 and R = 2000, only those types will be
recognized during the evaluation of the drawing in the lists by the partlister
program that have been defined in the Prg_Pabi.xls (main program). The
program will mark all other turns as ‘unknown‘. No parts list will be generated in
this case. This turn will then not be included in manufacturing.
The nearest standard turn (15 30 45 degrees) will then be manufactured, with
an approximation of –2° plus X°.
New “odd” angles must only be opened in the program. Otherwise no conveyors
will be recognized and supplied!
Wheel turns with smaller than the specified angles must be shortened on the
construction site, because the factory will not supply them.
22.6.1 Turns with slave drive
Drive Slave drive
Turns with slave drive can be used to save one drive unit. However, it is difficult
to stop and start on the slave-driven turn (avoid it, at least at positions with
pulsing). A slave-driven turn is not an accumulator location.
:NOTE: In combinations with turns make sure that the stop position is a
motorized turn.
Tray Manual 3_8.doc

22.6.2 Turn combinations

Illustration of the equipment in the layout
Turns of 60°, 75°, 90° are achieved by using combinations of 15°, 30°, and 45°
turns.
The driven turn should be in front in the direction of travel and thus apply tractive
force to the upper belt strand.
Pulsing should be avoided on turns. It space restrictions in the layout require

pulsing, a turn can also be equipped with driven rollers on the interior radius.
22.6.3 Segmentation of 180° turns

The optimum solution is the use of turns that are driven on both sides in order to
achieve the best possible friction between the tray and the drive wheel.
A 180° directional change by means of turns results in:
2 positions using 4 times 45°,
3 positions using 6 times 30°
If many positions are required, 180° turns can also be formed of 2x3x30°
instead of 2x2x45°, using three drives and three slave drives. This will require
more drives and encoders. In any case, stopping or even pulsing on should be
avoided in turns and wheel conveyors.
Tray Manual 3_8.doc

2 positions formed of 2 x 2 x 45° 3 positions formed of 3 x 2 x 30°
22.6.4 Speed transitions at turns

Before turns and switches, the speed must be reduced from a possible 5 m/s to
2.5 m/s at least 5-6 m in advance. (Braking conveyor 5-6 m long)
After turns and switches with 2.5 m/s, trays can be discharged to straight
conveyors running at 5 m/s.
22.6.5 Installation rule

If a turn and a high-friction metering conveyor are mounted to each other, the
turn should be adjusted approx. 2 mm higher than the feeding metering
conveyor.
Tray Manual 3_8.doc

22.7 Switches
Table with lengths for switches and slave-driven turns:
Switches with turns of radius R = 2550 mm
Switch mm Turn 15° Turn 30° Turn 45° Turn 60° Total mm
2995 mm 2995 mm
2995 mm 667 mm 3662 mm
2995 mm 1335 mm 4330 mm
2995 mm 2002 mm 4997 mm
2995 mm 2670 mm 5665 mm
Switches with turns of radius R = 2000 mm
Switch mm Turn 15° Turn 30° Turn 45° Turn 60° Total mm
2995 mm 2995 mm
2995 mm 523 mm 3518 mm
2995 mm 1047 mm 4042 mm
2995 mm 1570 mm 4565 mm
2995 mm 2094 mm 5089 mm
Although a return spring is provided, switch solenoids are activated at divert

switches in both directions. Activation of these solenoids reduces the release
time.
Tray Manual 3_8.doc

TRAY System User Manual Index
Index
Data carriers ............................................... 21, 33, 34

A Dubai TD 57 ..................... 31, 49, 102, 109, 119, 121
Accumulation sections ..................113, 115, 116, 117 E

Accumulator location
Length ............................................................... 154 Early baggage store ............................. 112, 113, 114
Number.............................................................. 154 Empty tray buffer ...................................................105
Accumulator locations......51, 52, 120, 121, 154, 156, Empty tray store ........................................... 112, 113
172, 174, 175 Energy consumption..............................................101
Attributes................................................................. 12 Environmental conditions ........................................12
Aufträge
ADP Paris............................................................ 31 F
DXB Dubai TD57................................................. 31
NAT Barajas in Madrid ........................................ 31 Fire door ....................................... 108, 165, 166, 167
UPS Louisville ..................................................... 31 Fire protection gate .............................. 165, 166, 167
Availability ............................................. 106, 107, 120 Frequency converter ............................ 109, 112, 119
Friction coefficient .......................... 40, 49, 53, 61, 70
B
G
Baggage identification
Bag code ....................................................... 22, 34 Gap optimization .......................... 112, 114, 115, 163
Baggage code ..................................................... 37 Guide roller monitoring ................................. 166, 167
IATA label................................................ 25, 28, 35 Guide station ...........................................................40
Belt types .................................................... 54, 72, 77
Belts H
Friction coefficient ................................... 49, 53, 70
Friction coefficients.............................................. 40 Height difference .................................................8, 63
Types............................................................. 64, 66 Horizontal knees....................................................171
Buffer lines .............................................................. 51
I
C Initiator.................................... 71, 101, 102, 105, 119
Center guide ......................................................... 108 Initiators ...................................................................75
Code carrier ........................22, 25, 28, 29, 34, 35, 37
Code carriers .............................................. 21, 33, 34 K
Code reading station......................................... 22, 34
Code scanner.................................................... 22, 34 Knees
Color........................................................................ 12 horizontal ...........................................................171
CONCEPTIX .................................12, 43, 54, 71, 154 vertical....................................................... 170, 171
Construction site .........................54, 70, 71, 166, 175
Crash .................................................................... 132 L
Length calculation .................................................169
D Light barrier ............................................ 71, 102, 105
Data carrier .........................22, 25, 28, 29, 34, 35, 37
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M Site ..........................................................................11
Slipping distance ...................................................172
Machine output ............................................... 12, 128 Speed
Madrid NAT Barajas.......................... 31, 49, 109, 121 Maximum .............................................................70
Maintenance platforms............................................ 59 Standard ................................................. 42, 49, 78
Manual Encoding .......................................... 100, 120 Standard- .............................................................67
Maximum speed...................................................... 70 Standard- .............................................................73
Memory Standard speed .............................. 42, 49, 67, 73, 78
Capacity ........................................................ 22, 34 Storage
Metering conveyors Fill level ..............................................................112
Shortened............................................................ 47 Main distribution circuit ......................................111
Monitoring Metrics ...............................................................119
Guide rollers .............................................. 166, 167 parameters.........................................................118
Support stands ........................................................11
N Switches
Reversing mode...................................................78
No Read Station............................................ 100, 120 Synchronization .....................................................107
O T
Orders Tensioning station .................................... 39, 43, 169
ADP Paris.....29, 30, 31, 32, 37, 42, 49, 67, 73, 78, Throughput ..................... 99, 100, 106, 114, 118, 160
121, 174 Track width ..............................................................40
DXB Dubai TD57...........31, 49, 102, 109, 119, 121 Tray
NAT Barajas in Madrid .................. 31, 49, 109, 121 Guide roller ................................................. 83, 102
UPS Louisville ....................................... 31, 49, 174 Minimum distance on straight track .....................31
Output Service tray for spare parts..................................32
machine....................................................... 12, 128 Tray code...................................................................1
Machine output.............................................. 82, 99 Code carrier .........................................................29
process................................................................ 12 Tray codes.......................... 21, 22, 25, 28, 34, 35, 37
Process output .................................................... 99 Code carrier .......................... 22, 25, 28, 34, 35, 37
Code carriers .......................................... 21, 33, 34
P Trays
Fire stability..........................................................32
Paint ........................................................................ 12 Guide rollers.........................................................60
Paris ADP 29, 30, 31, 32, 37, 42, 49, 67, 73, 78, 121, Tunnel area ...........................................................109
174 Tunnel line .............................................................118
Positions ............................................................... 176
Process output ........................................................ 12
Pulse rates ...................................................... 44, 119
U
Push operation........................................................ 43 UPS Louisville .......................................... 31, 49, 174
R V
Reversing mode...................................................... 78 Vertical knees ............................................... 170, 171
Right-angle transfer .............................................. 116
Right-angle transfer conveyors............................. 113
Room supports........................................................ 62
W
Waterfall effect.........................................................36
S Weights................................................. 40, 47, 77, 81
Servicing station...................................................... 83
Shortened metering conveyors............................... 47
X
Simulation ............................................. 109, 118, 174 X-ray screening .......................................................33
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For internal use only

TRAY Conveyor System

Siemens Industry - Mobility

This is a copyrighted documentation of Siemens AG. It may not be altered, amended or

Responsible for the contents:

Devices J. Bruett Phone +49 (0) 911 145 7602

Postal address Siemens AG

The right to make modification to design and equipment is reserved.

Industry, IL LS September 15, 2010 V. 3.8

Version Date Change/Comment

This version supersedes all previous versions of the manual.

The TRAY user manual is available in a German and an English version.

Tray Manual 3_8.doc

1 Introduction and overview .............................................................1

2 Cross Belt Tray .............................................................................20

3 Static loading / unloading station................................................25

4 Dynamic loading / unloading station ..........................................27

6 Loading station .............................................................................35

8 Metering conveyor (discontinuous) ............................................46

9 Accumulation conveyor ...............................................................51

Tray Manual 3_8.doc

9.2 Technical data.................................................................................52

10 Wheel conveyor ............................................................................53

11 Adapter and normal traverse .......................................................55

12 Slave drive for wheel conveyors and turn ..................................57

13 Inclined conveyor .........................................................................59

16 Compact tilter ................................................................................79

17 Roller checking station.................................................................83

18 Steel support system....................................................................85

Tray Manual 3_8.doc

18.6 Service walkways............................................................................93

21 Function Groups .........................................................................122

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22.6 Turns .............................................................................................175

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Figure 1 Loading of the cross belt tray ............................................................3

Tray Manual 3_8.doc

Figure 44 Main dimensions of tooth belt .........................................................48

Tray Manual 3_8.doc

Figure 93 Drawing of sorting area and tunnel sections .................................108

Tray Manual 3_8.doc

Figure 142 Drawing of the transition at the fire door .......................................166

Tray Manual 3_8.doc

Table 1 Relationships between speed, tray spacing and throughput.........100

Tray Manual 3_8.doc

1 Introduction and overview

Automatic conveyor systems are used at airports to transport incoming and

Tray Manual 3_8.doc

According to throughput needed the load or unload station can be

static i.e. while the tray stops on the conveyor, or

The CrossBeltTray conveyor system is 100 % compatible to the well proven

Conveyor advantages of high speed system

This means that the application of the rules is mandatory. If it is absolutely

Tray Manual 3_8.doc

1.1 The main components and their application

Cross Belt Tray

Figure 1 Loading of the cross belt tray

Tray Manual 3_8.doc

Static loading / unloading station