GEBHARDT FlexConveyor - decentralized conveyor technology

With GEBHARDT Flex Conveyor the idea of a fully decentralized, modular and industrially durable conveyor system becomes a reality. The integrated GEBHARDT ConveyorConnect technology enables mechanical and electrical coupling with just one handgrip, true Plug-and-Play without the use of tools.

Problems of conventional continuous handling equipment

The use of automated material handling equipment in Intra-logistics is being increasingly characterized by the use of individual components joined together to create a high degree of flexibility. The individual components are designed, produced and assembled in accordance with the customer's requirements. However, despite numerous advantages this traditional concept also has several disadvantages. By fulfilling individual customer requirements limitation arise in the area of autonomous process, increased costs in planning, realization and above all in readjustment in the event of a change in the customers requirements.

The lack of flexibility of conventional conveyor technology thereby prevents further growth of automation in Intra-logistics due to:

- Material flow systems that are firmly linked with infrastructure
- Greater programming outlay due to complex layouts
- A lack of redundancy demands costly individual components
- Modification or reuse is uneconomical
- High dependency on mechanical suppliers  / system integrators -> "lock-in" effect

A high degree of customization required for automated material handling systems accounts for up to 50% of overall implementation costs:

"True" modular system

The revolutionary GEBHARDT Flexconveyor offers decisive advantages with all of these points. As the name suggests, this modular system consists of predefined, standardized conveyor modules with different functions and dimensions. The individual modules can be independently coupled by the customer both mechanically and electrically using just a handgrip, and decoupled in the same way. A long term operation of the system in the same configuration can naturally be combined with the hall floor - as present systems as well. Through the combination of various modules any topologies can be created. Thereby the project scale only plays a subordinate role.

 

Applications and GEBHARDT ConveyorConnect

The GEBHARDT FlexConveyor for example is suitable for simple dispatch lines with a small number of  modules, but also in AS/RS prezone areas right through to large material handling systems comprising many hundreds of modules. It is up to the customer to decide whether to expand upon existing systems with the FlexConveyor, use the FlexConveyor exclusively or in combination with conventional systems. Complete systems can be individually expanded and modified in just a short period of time. Lengthy assembly and installation times are a thing of the past. The GEBHARDT FlexConveyor therefore facilitates a rapid reaction to a change in basic conditions. The previously described GEBHARDT ConveyorConnect technology enables defective modules and those requiring maintenance to be exchanged for replacement modules within a matter of minutes. Potential system downtimes are reduced to a minimum and productivity is maximized. Industrial safety is increased due to the safe electrical connections and the customarily high GEBHARDT safety standards.

Examples:

Standard systems	Seasonality
Distribution	Expansions
Production

 

Unique selling point: Control

However, the outstanding advantage is that the system recognizes the actual physical topology independently and without the need for programming (autonomous layout adjustment). We are able to control the material flow on a decentralized basis as a result of this. Routing of the goods takes place automatically while considering alternative routes. The system works free of collisions and deadlocks (blockages that lead to a system standstill). A central material flow computer is entirely unnecessary. With open interfaces, communication with existing systems, peripherals such as weighing scales or labelling and superior WMS or ERP host systems takes place without issue. The individual modules are equipped with decentralized, robust control units and there is no requirement for the use of a central programmable logic controller (PLC). The FlexConveyor modules contain all of the required sensors, actuators and the logical control. The individual control units are mechanically identical and differ only in terms of the software used, which can be individually uploaded, updated and exchanged by the customer. With the use of low-energy 24V motors and avoidance of pneumatics, operation is energy-saving and conserves resources. On request a configuration with 400V technology is also available. All conventional technologies such as barcodes or RFID can be used for the purpose of identifying the conveyable goods.

With the standardization of the mechanical, software and control elements it is possible to reduce the operating and maintenance costs of the complete material handling system. The adjustment of existing GEBHARDT FlexConveyor systems can be carried out by customers themselves or with the aid of the manufacturer. The independence and flexibility of the FlexConveyor is thereby not accompanied by greater investment costs. Example calculations have shown that a FlexConveyor system with a price level comparable to a conventional system will have a considerably lower total cost of ownership. In terms of the "Internet of Things", the GEBHARDT FlexConveyor is orientated by the decentralized control concept of information technology (e.g. internet). The GEBHARDT FlexConveyor is therefore the first effective, financially viable realization of flexibility and modularity in the field of automated handling equipment.

This flexibility means that the automated handling equipment penetrates entirely new application areas that were denied because of the disadvantages mentioned before. Now, seasonal use - for example via a rental or leasing model - e.g. in packaging centres or dispatch handling for Christmas business is now possible. The peaks that arise during this period can be compensated for. Logistics service providers (in particular 3PL) can also increase their productivity through the use of FlexConveyor automated handling equipment, without needing to fear the associated return on investment costs. When service contracts expire the GEBHARDT FlexConveyor can simply be used for the next customer. In particular due to the flexibility, the GEBHARDT FlexConveyor automated material handling equipment can revolutionize the assembly and production processes, where the use of traditional conveyor systems has recently decreased significantly due to organizational developments such as lean production. The area of tension between flexibility and productivity is decisively minimized by the FlexConveyor.