Movex 553 FLEXTOP Installation and operation manual

553 FLEXTOP
ENGINEERING MANUAL
Multidirectional Modular Belt
PATENT
PENDING

2

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Manual N° M999579
The digital version of this manual is available on www.movexii.com

EMPLOYEES
AROUND THE WORLD
23.000+200+
DIFFERENT
PRODUCTS AVAILABLE
REFERENCE YEAR 2018
16.500 Mq2
OF PRODUCTION SPACE
PRODUCTION
CAPACITY
+40%
+35%
WAREHOUSE
CAPACITY
+40%
+35%
MISSION
Creating value through innovative development of
ideas, supporting our partners with professionalism,
exibility and effectiveness.
VISION
Reaching market leadership as a reliable and precise
supplier. Planning the future without losing sight of
our history and the values that allow our growth.
Logistics Center Headquarter

FACTS
Movex around the world
Movex S.p.A. | Headquarter
Via lndustria, 22 - 24060 Castelli Calepio (BG)
P [phone] | F [phone]
[email protected]
Movex S.p.A. | Logistics Center
Via Repubblica, 25
24060 Castelli Calepio (BG)
Movex UK Ltd.
P [phone]
Movex Nederland
P [phone]
Movex Russia
P [phone]
Movex CIS countries
P [phone]
Movex AG India
P [phone]
Movex France
P [phone]
Movex GmbH
P [phone]
Movex USA Inc.
P [phone]
Movex Brasil Ltda
P [phone]
Movex SA de CV
P [phone]
A top service level is the goal of a qualied Engineering and Sales team
with the objective of presenting Movex as a supplier of excellence to
all clients.
Through a distribution/network which spans the globe, Movex offers
technical support and a careful after-sales service, always at your disposal.
WE SUPPORT YOU
Customer service Dept.
The rich experience that Movex has acquired over the years shows
that care and innovation of products are essential to guarantee costant
quality.
Thanks to the investments as well as developing strategic departments
Movex has created new space where research and innovation become
concrete tools to satisfy customers’ requirements.
RESEARCH & DEVELOPMENT
Research & development meeting
In the new headquarters Movex designs and manufactures high quality
components for the food, beverage, packaging, automotive and automation
industries.
Movex meets your needs for standard and custom products in a dynamic
and responsive way ensuring the best performance product with an attractive
market price.
WE CREATE SOLUTIONS
Engineering Dept.

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553 FLEXTOP
Multidirectional Modular Belt
12,7
152,4
25,4
25,4
152
12,5
0
-0.2
33,5
16,75

can improve
the performance of your job
Changing direction

TABLE OF CONTENTS
INTRODUCTION
Overview ..........................................................................................................................................................................................................................
Features ...........................................................................................................................................................................................................................
Suitable goods ...........................................................................................................................................................................................................
Application examples and Industries .....................................................................................................................................................
MAIN FUNCTIONALITIES
Belt and Sprockets specification ...................................................................................................................................................................
Basic controls ...............................................................................................................................................................................................................
Goods dimensioning ...............................................................................................................................................................................................
MOVEMENTS
Divert ..................................................................................................................................................................................................................................
Static Rotation................................................................................................................................................................................................................
Dynamic Rotation .......................................................................................................................................................................................................
Accumulation .................................................................................................................................................................................................................
Acceleration/Deceleration ....................................................................................................................................................................................
ADVANCED CONTROLS
Divider – Merger .........................................................................................................................................................................................................
Sorter ..................................................................................................................................................................................................................................
Divider - Merger - Sorter - Complete dimensioning solution and Example .................................................................
Static Rotation - Complete dimensioning solution and Example .......................................................................................
Dynamic Rotation - Complete dimensioning solution and Example ................................................................................
CONVEYOR CONSTRUCTION & MAINTENANCE
Sprockets position ....................................................................................................................................................................................................
Wear Strips and Machined Plates ................................................................................................................................................................
Return rollers ................................................................................................................................................................................................................
Maintenance .................................................................................................................................................................................................................
NOTES
....................................................................................................................................................................................................................................................
10
11
12
13-14
15
16
17
18
18
19
19
19
20
21
22-23
24-25
26-27
28
29
30
31
32
A page for your notes
ENGINEERING MANUAL
553 FLEXTOP
Multidirectional Modular Belt

The new Movex® 553 FlexTop modular belt
with self-locking spheres is specifically
designed for high-precision material
handling, suitable for several applications
like logistic centers, packaging stations (food
and beverage) and corrugated industries,
easily to be integrated into existing systems.
The 360° movement possibility makes
the belt suitable for diverting, rotating,
accumulation and acceleration applications
and minimize required maintenance and
downtimes.
The small pitch between the spheres
(diameter 12,7 mm and pitch 25,4 mm) allows
every type of good transfer and is ideal for
small and light packages, unlike traditional
roller conveyors.
Density: 1.600 spheres/m2.
The complete closed sliding belt surface
is the perfect solution to carry carton
boxes, crates, cans and bottles shrink-wrap
packaging and any kind of polybag with Top-
Accuracy package control.
ENGINEERING MANUAL 10
Overview

11
With a directional belt underneath the FlexTop belt you
can control the direction and more precisely the speed
of the spheres, making this belt 100% versatile.
This function is very useful when goods must be separated
from each other but also to transfer your package laterally
without external guides and pushers. This scenario is ideal
for several applications requiring rapid 90° transfer of
the conveyed items.
Using two parallel running belts positioned
underneath 553 Flextop belt, and running in opposite
directions, goods in the middle of the belt will rotate
quickly without interrupting the main transport movement
(rotation with good moving).
553 FlexTop belt can also be used in combination with
a rotating plate to have an optimum control of the
rotation of the good (rotation with item stopped).
In this manual, you will find more details for each option.
The small pitch between the spheres allows for a great
goods control.
A complete closed sliding surface , in combination with
self-locking spheres, makes the belt design flexible and
robust.
Design and features of 553 FlexTop make it ideal for
the transport of several type of goods
(e.g. polybags,
shrink-wrap packaging).
High
strength
Perfect
good
control
Self
cleaning Great versatility Long durability Reduced downtimes
Features
ENGINEERING MANUAL
553 FlexTop belt can be used over a xed support area
to accelerate transport speed or with additional belts
and rotating plates to fully express its potential.

The main advantage of the Movex® 553 FlexTop
modular belt is its maximum flexibility to
meet your needs.
Ideal to transport cardboard boxes and
small packages, the 553 FlexTop belt is also
the right solution when you have to transport
polybags, papers, plastic cases, containers,
rubber parts (tires), shrink packs of bottles
and cans, etc…
What’s important is understanding if the
good sliding surface is suitable with the 553
FlexTop surface, because that will determine
the success of the application.
To do this, the goods bottom surface must
have flat parts able to run completely on at
least one sphere with a minimum of 6 spheres
per good.
Another important aspect is the total weight
of the good: most of the times is suitable with
the max working load of the belt, especially
of the spheres. Anyway, we always suggest
to double check that the total weight of the
good does not exceed the max load of the
spheres, 15N/ea.
We have several machines in our showroom
that can be used for testing your goods with
all the type of movements available with 553
FlexTop belt (sorting and rotation).
ENGINEERING MANUAL 12
VERSATILITY
Suitable goods

ENGINEERING MANUAL 13
GOOD ORIENTATION
• Casing machines
• Palletizers
REJECT STATION
• Inspection equipment
• Measuring devices
The goods can be oriented on the right
side. This can be done by static rotation or
dynamic rotation, based on the required
quality output and the process speed.
AUTOMATIC STORAGE SYSTEM
• Distribution system
• Sorting
• Lane divider
The goods can be guided over the 553
Flextop in 3 dierent directions: straight,
left or right, bases on the correct exit to be
taken.
GOOD POSITIONING
• Labelling
• Printing
• Barcodes Reading
The goods can be rejected on its left/right.
Application examples and Industries
The goods needs to be guided first on the
right and then on the left. This can be done
by using two separate modules or one single
solution.

The 553 FlexTop modular belt is ideal for all those applications where a dedicated movement
is required.
Its versatility with dierent movements oer great use in dierent application areas.
The most used are logistic and distribution centers, food and beverage and corrugated.
At the same time, whevener a dedicated movement is required and the good sliding surface is
suitable to the 553 FlexTop belt, it can be used as well.
Logistic and distribution centers
With more and more consumers buying from
the web, logistics and distribution centers
are becoming more ecient. The 553 FlexTop
modular belt is ideal when dierent product
sizes and sliding surface are running over,
keeping the eciency at the maximum value
and avoiding machines and robots which may
result very expensive.
Safe design, very high speed, low noise.
Food and beverage
In the packaging area of the food and
beverage industries, the 553 FlexTop modular
belt can help creating dierent actions with
one machine only: orientate the package to
the right side, align with the group, reject in
case of non-conformity, move side to side,
everything done by keeping always one eye
on safety aspect.
Safe design, high speed, high working load.
Corrugated
The corrugated industry is the most traditional
system where the 553 FlexTop can be used.
With this belt all type of stack of cardboards
can be easily handled and with only one
machine the good can have 3 dierent exit
directions: straight, left or right, without the
needs of having dierent conveyors, head to
tail transfers and the risk of downtimes.
Safe design, low speed, very high working load.
ENGINEERING MANUAL 14
Application examples and Industries

15
ENGINEERING MANUAL
Supplied coil length: Width ≤ 30” : 1.524 m (60 pitches) - Width > 30” : 1.016 m (40 pitches)
On request wider belts are available with 3” increments.
25,4 1.00
8,7
0.34
6”
W (inch)
M=3”
12,7
0.5
25,4
1.00
8,7
0.34
6”
W (inch)
M=3”
12,7
0.5
Material
LFG - Code 27
Low friction Acetal
Sphere material
High-tech Polyamide
Max working load:
Weight:
Temp. range dry:
Temp. range wet:
Pin material:
Belt available also in RAL 5005 (Blue)
Max working load:
Sphere Diameter:
27500 N/m (1850 lbs/ft)
10 Kg/m² (2.04 lbs/ft²)
-40÷80 °C (-40÷176°F)
-0÷65 °C (+32÷149°F)
PBT white
15 N (3.37” lbs)
12,7 mm (0.50”)
Belt and Sprockets specification
Backflex radius min.: 25 mm
25.4mm
PITCH
Version A - Standard
Continue >>
Series Material Width Version
5530 27 0003 A
5530 27 0006 A
5530 27 0009 A
5530 27 0012 A
5530 27 0015 A
5530 27 0018 A
5530 27 0021 A
5530 27 0024 A
5530 27 0027 A
5530 27 0030 A
5530 27 0033 A
Continue >> Continue >>
Series Material Width Version
5530 27 0069 A
5530 27 0072 A
5530 27 0075 A
5530 27 0078 A
5530 27 0081 A
5530 27 0084 A
5530 27 0087 A
5530 27 0090 A
5530 27 0093 A
5530 27 0096 A
5530 27 0099 A
Series Material Width Version
5530 27 0102 A
5530 27 0105 A
5530 27 0108 A
5530 27 0111 A
5530 27 0114 A
5530 27 0117 A
5530 27 0108 A
5530 27 0111 A
5530 27 0114 A
5530 27 0117 A
CODE STRUCTURE GUIDE
(Example)
5530 27 0042 A
Series *Material Width Version
Art-Nr. Z- Bore
(mm-in) PD (mm-in) OD (mm-in) S (mm-in)
166108 12 40x40
1.57x1.57
98,1
3.86
97,6
3.84
44,5
1.75
166208 15 40x40
1.57x1.57
122,2
4.81
121,9
4.80
56,5
2.22
166210 60x60
2.36x2.36
166308 18 40x40
1.57x1.57
146,3
5.76
146,0
5.75
68,5
2.70
166310 60x60
2.36x2.36
166311 65x65
2.56x2.56
Material: Reinforced polyamide
Material: Polyamide
Screws: Stainless steel Nuts: Zinc plated steel
S
OD
PD
B
6
24
S
OD
PD
B
6
21
• Optimized hygenic
• Quick replacement
• Easy clean and installation
• Heavy duty design
Drive split sprockets - Machined and molded
Series Material Width Version
5530 27 0036 A
5530 27 0039 A
5530 27 0042 A
5530 27 0045 A
5530 27 0048 A
5530 27 0051 A
5530 27 0054 A
5530 27 0057 A
5530 27 0060 A
5530 27 0063 A
5530 27 0066 A
Machined sprockets with round
bore are available on request.
Art-Nr. Z- Bore
(mm-in) PD (mm-in) OD (mm-in) S (mm-in)
166511 18 40x40
1.57x1.57
146,3
5.76
146,0
5.75
68,5
2.70
166510 60x60
2.36x2.36

Basic controls
When the 553 FlexTop modular belt is running over a static
support, directional belt or rotating plate, its spheres start
changing direction and speed. It is very important to give
enough friction to the spheres to better control them.
In case of acceleration, 553 FlexTop belt spheres can run
on a Polyethylene support plate (wear strips or machined
plate, min 15mm thickness). In case of lateral movements,
553 FlexTop belt spheres can run on a PVC or Polyurethane
coating belt with hardness of 60-70ShA.
To guarantee the same speed of the spheres (then of the
goods), it is always suggested to cover the support plate
with the same material of the directional belt (dierent
friction may cause dierent goods speeds).
Basic formulas to control goods speed/direction
553 FlexTop belt with directional belt mounted perpendicularly
The dierence in speed between the 553 FlexTop belt and the
directional belt determines the direction angle of the good.
Fixed strip or conveyor
553 FlexTop belt
Rotating sphere
Good
553 FlexTop belt
Directional Belt
553 FlexTop belt with a 360° rotating plate underneath
Useful option used to easily positioning the good.
Rotating plate
553 FlexTop belt
αY = αX
ENGINEERING MANUAL 16
553 FlexTop belt mounted over a
longitudinal conveyor running in
opposite direction.
Y= 2X + Z
Transport Speed
X
Z
X
Z
553 FlexTop belt mounted over a
longitudinal conveyor running in the
same direction.
Y= 2X - Z
Transport Speed
553 FlexTop belt running over fixed
surface.
X
Belt spheres run in the opposite direction of the directional belt (to go on the left the directional belt must run
on the right) and of the rotating plate (to go clockwise the rotating plate must turn counter clockwise).
!
Y=√2 2
(2X) + Z
For a better indication of possible directional belts,
their performances (maximum speed), as well as
minimum thickness of the coating, please enquire your
belting supplier.
Legend:
553 FlexTop belt direction
FlexTop belt
Directional belt or Rotating plate
Directional belt or Rotating plate direction
Transported good by 553 FlexTop belt
Belts speed and direction
Y= 2X
Transport Speed
Y
X
Z
Combine different movements to get the required direction for your business!

Goods dimensioning
Goods contact surface
ENGINEERING MANUAL 17
The type of the goods to be transported over the 553 FlexTop belt must be checked carefully.
In general, there are a few recommendations need to be followed to check if the good can be transported:
• Bottom surface of the goods – relatively flat
• Center of gravity of the goods – relatively distributed (+/-20% around the nominal one)
• Weight – suitable with spheres – maximum 15N per sphere
• Contact – goods running on at least 6 spheres
To guarantee sliding properties, it is very important to calculate the sliding contact surface of the good.
It must be bigger than 38cm2.
!
For more support or particular applications you can contact our engineering department.
Possible solutions to meet the requirements:
• Increase the dimension of the box to achieve 76,8 cm2 sliding surface (12 spheres x 6,4 cm2).
• Reduce the box weight to maximum 120N (8 spheres x 15N).
Contact with the spheres is a necessary condition
As a rule, there must be at least 6 spheres in contact with the good surface at the same time, so almost 6in2
(38cm2) 1in2per sphere (6,4cm2per sphere).
Good suitability assessment of a polystyrene box weight 18kg
with bottom surface – external contact.
• External Length
• Internal Length
• External width
• Internal width
Calculation:
Surface in contact: (10x16) - (8x13) = 56cm2> 38cm2OK
This can be transformed in N° of spheres in contact 56/6,4=8,75 8 spheres (would result 8 full sphere in contact)
Weight: 18Kg * 9,81= 176,6N 176,6/15=11,77 minimun 12 spheres required
Output:
This type of goods can’t be transported.
10cm
8cm
16cm
13cm
Example:
!
Because of the weight, this
box cannot be transported.
You have two options to
solve the problem:
!

Movements
ENGINEERING MANUAL 18
Divert – lateral movement
By using a directional belt underneath the 553 FlexTop
belt, running square to the travel direction, the goods
can be transferred left and right.
The combination of the speed of modular belt and
directional belt will determine the direction of the exit.
Static Rotation
By using a rotating plate underneath the 553 Flextop
belt, the goods will start rotating.
Such a movement can be done by having a Rotating
Plate turning at the opposite direction than what has
to be the good direction. For a high-precision rotation,
it is suggested to active the Rotating Plate when the
modular belt is stopped.
Controlled rotation
To get a controlled roation, the rotating plate must be activated when 553
FlexTop is not running.
Uncontrolled rotation
If the rotating plate get activated while the modular belt is running, the
good will rotate in more space.
Be sure the product is running over the plate till its rotation is completed.
Straight exit
To get a completely straight exit, the
directional belt must be activated when 553
FlexTop is not running.
Curved exit
To get a straight exit without loosing relatively
too much time, the directional belt can be
activated also when the 553 FlexTop is
running, while is reducing speed.
The combination of the two speeds will
determine the exit curve dimension.
Inclined exit
To get a 45° inclined direction, the speed of
the directional belt must be the same as
the speed of the 553 FlexTop and they have to
work contemporary.
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
1
2
3
4
5
6
7
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
1
2
3
4
5
6
7
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
1
2
3
4
5
6
7
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
1
2
3
4
5
6
7
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
1
2
3
4
5
6
7

Movements
Dynamic Rotation
By using two directional belts underneath the 553
Flextop belt, running at opposite direction, the good
will start rotating.
This option is ideal for high speed lines, while the
goods needs to be rotated to correct sides without
slowing down the production line. Based on the
combination of speeds between the 3 belts, the good
will rotate in a dierent distance. It is suggested to
keep the directional belts speed always the same.
Accumulation
For a limited time, in case of needs or special application
(e.g. rejected table), the 553 FlexTop belt can work as
accumulation.
In that case spheres must be free to run, so the belt
has to be supported by wear-strips positioned between
spheres (see page 29).
Maximum wear-strip width 8mm.
Acceleration/Deceleration
By using a static plate or a directional belt underneath
the 553 FlexTop belt, the good can accelerate or
decelerate.
Static plate
By using a static plate, the
good speed will result
double than the 553
FlexTop belt speed.
Directional belt
By using a directional belt,
the good speed can be
accelerated or decelerated
independently from the 553
FlexTop belt speed.
Counter clockwise direction:Clockwise direction:
To get a dynamic rotation to the right, the two directional belts must
run like the picture.
To get a dynamic rotation to the left, the two directional belts must run
like the picture.
ENGINEERING MANUAL 19
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
1
2
3
4
5
6
7
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
PRECISION
SPEED
1
2
3
4
5
6
7

Advanced Controls
ENGINEERING MANUAL 20
DIVIDER - MERGER
Below sketch of the typical schemes can be done with
the 553 FlexTop belt.
In case of dierent movement required, please
provide information to your sales representative
and you will receive required support.
1 to 3 - aside
1 to 3 - centered
1553 FlexTop belt - 1Directional belt1553 FlexTop belt - 1Directional belt
1 to 2 - centered 1 to 2 - aside
1553 FlexTop belt - 1Directional belt1553 FlexTop belt - 1Directional belt
1553 FlexTop belt - 2Directional belts1553 FlexTop belt - 2Directional belts
2 to 3 - centered 2 to 3 - aside
DIVIDER MERGER DIVIDER MERGER