TOYOTA ADVANCED LOGISTICS Bastian SOLUTIONS Shoe Sorter Manual

Installation and Maintenance Manual
Model: Shoe Sorter
Effective February 2022
Rev. D

Installation and Maintenance Manual: Shoe Sorter
___________________________________________________________________________________
Install ati on a nd Maint ena nce Manual : Sh oe S o rter
Published February 2022
Rev. D
2
Contributions
ROLE
NAME
TITLE
Author Ben Baker Senior Design Engineer
Checker Evan Grimes Customer Service Engineer
Approver Sam Osterhout Design Team Lead
Revisions
DATE
REVISION
REVISION DESCRIPTION
AUTHOR
10/21/2019
A1
Initial document creation
Ben Baker
9/22/2020 B
Added info on sprocket alignment and
replacement; added info about decel
settings; crash gates added to
installation section; added tailshaft
encoder info to Controls section; added
several part numbers to GA drawings.
Changed all references to “ZiPline” to
“BSC” or “Bastian Solutions Conveyor”.
Ben Baker
5/3/2021 C
Updated GA drawing for divert switch;
revised distance recommendations
between knife edge and sorter infeed;
revised torque callouts on shoe bolts.
Ben Baker
10/12/2021
C1
Reformatting and Brand Update
Katie Smith
1/7/2022 Review D MKT final review Mark Fishback
2/18/2022
D
Document Formatting
Andrew W. Jones

Installation and Maintenance Manual: Shoe Sorter
___________________________________________________________________________________
Install ati on a nd Maint ena nce Manual : Sh oe S o rter
Published February 2022
Rev. D
3
Term and Acronym Definitions
TERM/ACRONYM
DEFINITION
AC
Alternating current
Accumulation The collection or staging of multiple cartons, cases, or totes of product on
conveyor.
Back pressure Pressure against carton(s) in the direction of carton flow resulting from
weight of densely accumulated cartons.
BF Between frame; this refers to the distance between conveyor bed side
frames.
BHCS Button head cap screw
BOM
Bill of Materials
BRBDC Belted Roller Bed Direct Current; DC roller conveyor format driven by
brushless DC servo motors.
BSC
Bastian Solutions Conveyor
Carton or Case
Term for conveyable items generally contained in cardboard boxes.
CB
Carriage bolt
CCW
Counter-clockwise
CW
Clockwise
DC
Direct current
DC Card
A control card used to power and control the logic used when operating a
MDR in DC conveyor applications.
Diffuse
A photoeye format that houses both the emitter and receiver and senses
an object when the light beam is reflected back to the sensor. This type of
photoeye is a standalone unit and does not use reflectors.
Discharge The point where cartons, cases, or totes exit a conveyor or similar unit
used in a material handling system.
Divert
(noun) A conveyor unit used to change the direction of a carton, case, or
tote in a controlled manner. (verb) To change the direction of a carton,
case, or tote in a controlled manner.
Drive Pulley
A motor-driven pulley used to transmit rotational energy to linear motion in
AC belts.
E-stop A highly visible button or pull cable designed to shut down equipment in
the case of an emergency.
ETO
Engineered to Order; Orders requiring custom Engineering
FAT
Factory Acceptance Testing
Flange A feature in sheet metal consisting of a face and bend connected to an
existing face along a straight edge.
Gapping
The separation of cartons, cases, or totes which are initially in contact with
one another. Generally done by progressively increasing the speed of
consecutive zones, forcing cartons, cases, or totes to "pull a gap."

Installation and Maintenance Manual: Shoe Sorter
___________________________________________________________________________________
Install ati on a nd Maint ena nce Manual : Sh oe S o rter
Published February 2022
Rev. D
4
TERM/ACRONYM
DEFINITION
Guide Rail Mechanism used to maintain the desired position of conveyable cartons,
cases, or totes on their respective conveying surface.
HHCS
Hex head cap screw
HMI
Human-Machine Interface; an operating console or control panel of a
conveyor system.
HTL High Threshold Logic. In the context of an encoder, a differential push-pull
output intended to operate on 24VDC.
ID
Inner diameter of a circular, cylindrical or arced body.
Idler Roller Cylindrically-shaped material handling component that is unpowered and
used to support a belt.
Infeed The point where cartons, cases, or totes enter a conveyor or similar unit
used in a material handling system.
LOTO
Lockout Tagout
Mark Number
A numeric or alphanumeric term used to uniquely identify a conveyor bed
or collection of beds (of similar model type) within a material handling
system.
Match
A mark made on mating conveyor assemblies to assist in identifying
orientation and placement within a system.
MDR
Motorized drive roller; DC powered conveyor roller with an internally
mounted motor which may be controlled via internal or external
commutation.
MSD Master specification document; a document used to describe a product's
intended capabilities, appearance, and interaction with users.
NO
Normally Open
OAW
Overall width of any given conveyor bed.
OD
Outer diameter of a circular, cylindrical, or arced body.
O-Ring A plastic ring with a circular cross section used for power transmission in
DC conveyor applications.
OSHA Occupational Safety and Health Administration
OTD
On-Time Delivery
Photoeye
Device used to detect the presence of an object-such as a carton, case, or
tote-by use of an emitter and receiver (not necessarily in the same unit as
one another).
PM
Project Management (or Project Manager)
PO
Purchase Order
PPE Personal protective equipment
Proximity Sensor
(“Prox”)
A sensor able to detect the presence of nearby objects without any
physical contact. Typically an inductive sensor that detects nearby
electrically conductive (metal) objects.
Pulley Mechanical device used to change the direction of the belt in a conveyor
system, to drive and/or tension the belt.

Installation and Maintenance Manual: Shoe Sorter
___________________________________________________________________________________
Install ati on a nd Maint ena nce Manual : Sh oe S o rter
Published February 2022
Rev. D
5
TERM/ACRONYM
DEFINITION
Reflector A reflective component needed for retroreflective photoeyes to receive
transmitted light or radiation when no object is in front of the photoeye.
Retroreflective Of or relating to a surface or device that reflects light or other radiation
back to its source.
Return Idlers
Belt-routing rollers on the underside of any given AC conveyor.
RLSDC Roller Live Spur Direct Current; DC roller conveyor powered by live MDRs
and configured as a spur.
Roller
Powered or unpowered cylindrically-shaped material handling component
used for mechanical power transmission, a conveying surface, and/or
support for a belted conveying surface.
Shingling
Event in which surfaces of adjacent cartons, cases, or totes are forced to
lift off the conveyor due to elevated uneven carton, case, or tote back
pressure.
Shoe
A sliding element that engages with cartons, cases, or totes to divert from
a shoe sorter onto a spur.
Side Cover A PVC cover used to conceal and protect electrical components and wiring
from foreign debris and moving obstacles.
Side Frame
Structural member used to support rotating components needed for
conveyor beds.
Singulation
The active separation of cartons, cases, or totes.
Skatewheel Small unpowered wheels used to replicate nearly frictionless guidance or
support of conveyable cartons, cases, or totes.
Skew
A format of DC conveyor where one end of all rollers are shifted one roller
position to provide an angled conveying surface for left or right justification
of cartons, cases, or totes.
SKU Stock Keeping Unit; Product and service identification code for a product
(i.e. bar code).
Slug Collection of two or more cartons, cases, or totes that are in contact with
one another.
Snub Roller
A roller or pulley mounted to increase the arc of contact between a belt
and drive pulley. Additionally, this can be used to change the direction of
the return belt travel.
Sorter
Any piece of conveyance equipment used to divert a series of cartons,
cases, or totes simultaneously.
Splice Assembly
A five-component assembly-consisting of a plate (or formed plate), two
bolts, and two nuts-that is used to secure a piece of guide rail to an
adjacent piece of guide rail, or a side frame to an adjacent side frame. This
is used to provide additional structural rigidity and ensure relative position
of components is maintained.
SPST
Single Pole Single Throw; a type of electrical switch.
Spur
A format of DC conveyor used to create linear transitions into intersecting
lines of conveyor positioned at a non-perpendicular angle. Typically
includes 30deg and 22deg configurations.