en DEC/2008 ® MEX (55) 53 63 23 31 MTY (81) 83 54 10 18 DIST. AUTORIZADO QRO (442) 1 95 72 60 [email protected]

Manufacturing Units Sales Units of the Interroll Automation Business Unit of the Interroll Automation Europe Asia North and South America Business Unit Singapore USA Interroll Automation GmbH Interroll (Asia) Pte. Ltd. Interroll Automation, LLC Tel. +49 7261 938-0 Tel. +65 6266 6322 Tel. +1 812 284-1000 Headquarters and Centre of Excellence Fax +49 7261 938 124 Fax +65 6266 6849 Fax +1 812 284-1001 for Conveyor Modules and Subsystems [email protected] [email protected] [email protected] Manufacturing and Sales Europe/Middle East China Interroll SAS Interroll (Suzhou) Co. Ltd. Germany Tel. +33 6 82 56 65 16 Tel. +86 512 6256 0383 Interroll Automation GmbH Fax +33 2 98 24 41 02 Fax +86 512 6256 0385 Untere Au 4 [email protected] [email protected] D-74889 Sinsheim Tel. +49 7261 938-0 Japan Fax +49 7261 938 124 Interroll Ltd. Interroll Japan Co. Ltd. [email protected] Tel. +44 1536 748520 Tel. +81 42-764-2677 Fax +44 1536 748585 Fax +81 42-764-2678 [email protected] [email protected]

Poland Korea Manufacturing and Sales Interroll Polska Sp. z o.o. Interroll (Korea) Co. Ltd. North and South America Tel. +48 22 741 741 0 Tel. +82 2 2231 19 00 Fax +48 22 741 741 1 Fax +82 2 2254 36 83 USA [email protected] [email protected] Interroll Automation, LLC 4650 New Middle Road Bridgeport Business Center Interroll España S.A. USA-Jeffersonville, IN 47130 Tel. +34 90 21 00 8 61 Tel. +1 812 284-1000 Fax +34 93 586 48 95 Fax +1 812 284-1001 [email protected] [email protected] Czech Republic Interroll CZ s.r.o. Tel. +42 519 330 210 Fax +42 519 330 211 Manufacturing Asia [email protected]

China Interroll (Suzhou) Co. Ltd. Unit 10B, Modern Xian Dai Industrial Square Africa ® No. 333 Xing Pu Road Suzhou Industrial Park South Africa DIST. AUTORIZADO Jiangsu Province Interroll S.A. (Pty. Ltd.) People’s Republic of China Tel. +27 11 281 9900 MEX (55) 53 63 23 31 Postal Code: 215126 Fax +27 11 252 9083 QRO (442) 1 95 72 60 Tel. +86 512 6256 0383 [email protected] Fax +86 512 6256 0385 MTY (81) 83 54 10 18 [email protected] Middle East [email protected]

Israel Comtrans-Tech Ltd. INTERROLL Tel. +972 5 44272747 Fax +972 3 7440864 [email protected] TE RR O N I L . L

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INTERROLL INTELLIGENT – FLEXIBLE – ZERO PRESSURE: CORPORATE ART ț THE MODULE KIT FOR YOUR INTRALOGISTICS. For further addresses of the Interroll group please view

www.interroll.com en DEC/2008. 5000/OY/BU Untitled-3 Sarah Pontius

TABLE OF Interroll Corporate Art ...... Inside Front Cover INTERROLL CONTENTS Interroll Automation – a business unit of the Interroll Group ...... 2-3 Markets move within the pulse of time. Globally connected with a focus on local markets ...... 4-5 CORPORATE Intelliveyor matches the rhythms of markets. A central organization meets a modular structure ...... 6-7 At first glance, industrial products and works of staff and capturing the imagination of the Z-Card and RollerDrive – the heart of the Intelliveyor ...... 8-9 of art would appear to have little, if anything, public. Art has a positive influence on the ART in common. However, when one considers work environment and the internal processes Communication within the Intelliveyor. Plug and Play ...... 10-11 that creativity, optimisation, finetuning and the governing these structures. Each moment Characteristics and overview of the Intelliveyor modules ...... 12-15 pursuit of perfection are qualities associated of interaction, even if controversial, generates with both disciplines and that each project dynamism, openness and creativity; it kindles Interroll – total flexibility ...... 16 is driven initially by an idea, a moment of a spark of innovation, rouses venturesome Addresses of the Interroll Automation Business Unit...... Back Cover inspiration, a seed that requires nurturing, spirits and shows ways of breaking the then one will recognise that artist and shackles of convention and charting new entrepreneur often share the same traits. territory. The declared In combination, purpose of Interroll inspired, provocative Corporate Art is art and innovative, to channel this state-of-theart immense creative products provide a potential, to create company with those a dialogue that distinctive contours, embraces art and that unique cultural business as vehicles identity that no of communication balance sheet, no and to establish an income statement environment in can capture. which the spirit of thought is allowed It is precisely these to flourish. intangibles, however, that have the The mission: capacity to infuse to accompany, TE RR O N I L all aspects of life, advise and act. . L

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INTERROLL CORPORATE ART ț ® MEX (55) 53 63 23 31 MTY (81) 83 54 10 18 DIST. AUTORIZADO QRO (442) 1 95 72 60 [email protected] 1 MARKETS MOVE WITHIN THE PULSE OF TIME. GLOBALLY CONNECTED WITH A FOCUS ON LOCAL MARKETS.

If the conveyor logistics chain is to function The company founded in 1959 has approxi- smoothly, the process must be correct right mately 1,400 employees in a global network down to the last link. and is listed on the Swiss stock exchange SWX. Especially in a fast pace, global world, in which just-in-time deliveries and orders delivered in Within the Interroll Group, the business unit 24 hours are high on the agenda and a perfect Interroll Automation specialises in economic logistical process should always be consistently solutions in the field of intra-logistics. efficient especially in times of full order books, there must be no interruptions in the logistics It develops, produces and sells subsystems chain. and conveyor modules worldwide, such as crossbelt sorters, merges, belt curves, belt Interroll conveyor modules and subsystems conveyors and Intelliveyor roller conveyor mod- were developed for this requirement. ules for unit load handling with zero pressure They are in use wherever goods and materials accumulation. are conveyed and distributed: all around the world, in all industries and throughout the value Interroll Automation added chain. A business unit of the Interroll Group With selected products and solutions, www.interroll.com Interroll aspires to become the world leader for intra-logistics.

® MEX (55) 53 63 23 31 MTY (81) 83 54 10 18 2 DIST. AUTORIZADO QRO (442) 1 95 72 60 [email protected] 3 INTELLIVEYOR MATCHES THE RHYTHMS OF MARKETS. A CENTRAL ORGANIZATION MEETS A MODULAR STRUCTURE.

Interroll Intelliveyor – • Simple connection to adjoining conveyor Connectable conveyor modules from Interroll supports customers around the the intelligent, well thought technology Interroll round off the range of the world as a strategic partner: out modular system Intelliveyor advantages, as track routing During the implementation phase: • System integrators As an intelligent conveyor with integrated can be extended at any time with other • Fast delivery accumulating conveyor technology, Interroll products. • System manufacturers the Interroll Intelliveyor simplifies unit-load • Quick and easy installation Roller conveyor modules, curves, divert- • OEMs handling. Its internal control, the Z-Card, • Ready for installation and use thanks ers, merge modules, transfers and trans • Consulting and planning offices converts a roller track into a single space positioning modules for material handling to pre-fabricated modules (“plug and • Operators of distribution centres conveyor which allocates each material play”) of light to heavy cardboard boxes, crates to be conveyed in its own zone along the and packages are available, depending • Users During operation: material flow. on the drive, for loads of up to 175 lbs • Approx. 50 % energy saving (depending (80 kg per zone). Unit loads can be buffered without con- on operating mode up to 70%) com - (see page 12-15) tact and transported further as required pared with conventional accumulating to achieve an overall continual material conveyors flow. With its well developed, economic • Extremely quiet operation (< 60 dBA concept, the ready to connect roller without conveyor belt) track modules offer a complete range of customer advantages. • Maximum safety thanks to 24 Volt low voltage During the planning phase: • High availability • Individual and flexible routing based • Low maintenance on a complete modular system from straights to 45° high performance • Extendable and adaptable to future diverters growth • Simple planning of conveyor lines from the modular system ® MEX (55) 53 63 23 31 MTY (81) 83 54 10 18 4 DIST. AUTORIZADO QRO (442) 1 95 72 60 [email protected] 5 Visualization of the functional principle of an Intelliveyor conveyor line exemplifying one single zone. Buildup of one zone: • 1 RollerDrive • 8 slave rolls • 1 photo cell

INTERROLL INTELLIVEYOR – INTELLIGENT CONVEYING EXPLAINED IN AN UNCOMPLICATED WAY

Intelliveyor – this name stands for a com- Up to four of these zones or alternatively To keep the system simple, the Z-Card low noise and significantly reduced wear plete conveyor system which enables unit a whole range of complex conveying has a program switch to select 32 differ- compared with conventional 480 Volt loads to be conveyed and accumulated functions are managed by one Z-Card. ent standard functions of the control systems. with zero pressure, i.e. without ever This includes, for example, a merge and card. touching each other. diverter element with a 45° and 90° angle. The programs stored cover all standard The fact that this is so easy to achieve lies The Intelliveyor system is designed as conveyor technology applications. in the Z-Card, a proven 24 Volt control a decentralised, intelligent control in such For example, the same Z-card is used in PCB. It handles the control of the con- a way that with the modular principle all modules and the required program veyor line divided into individual zones and a complete system can be constructed is only selected during actual installation. communication along the material flow. and also simply extended later if required. Given the large number of different varia- During the operation of the system each No higher order control is required for tions, stocking of spare parts is therefore Z-Card controls its assigned zones this thanks to the self sufficient Z-Card. simplified and reduced. according to control signals sent out by The great advantage in terms of economy Connection with photo cell adjacent zones. is provided by its drive. Conveying really 4-wire data cable does only take place when a conveying Connection with RollerDrive movement is actually necessary. If there are no materials to be conveyed in Zone 1 Zone 2 Zone 3 Zone 4 the zone, the system switches off until the next pulse. Our customers notice this by the energy saving of up to 70 %,

® MEX (55) 53 63 23 31 MTY (81) 83 54 10 18 Z-Card 6 DIST. AUTORIZADO QRO (442) 1 95 72 60 [email protected] 7 Singulation release: In the “Singulation release mode”, a zone In this operating mode, a jam is converted communicates with the upstream or into a marshalled material flow which downstream zone via a control PCB. enables, for example, simple removal or additional loading of the conveyor track.

Z-CARD AND ROLLERDRIVE – THE HEART OF THE INTELLIVEYOR

Each conveyor line of the Interroll Intel- Because less really can be more, the liveyor is divided into zones, which are Interroll Intelliveyor does not use conven- adapted to the maximum length of the tional external drive components but material to be conveyed. at the same time increases the safety of the operator thanks to a low power Each zone has: supply of 24 Volts. • 1 x RollerDrive • Rollers driven by belts (O-rings or At the beginning of a roller track section Poly-Vee belts) there is an additional photo cell to start the conveyor track. • 1 x Intelliveyor control PCB Z-Card controls up to 4 zones simultaneously The Intelliveyor has two operating modes: • 1 x Photo cell singulation release and train release (see photo below). A pre-assembled conveyor unit (module) consists of 1-4 zones with complete wiring. This enables an easy plug and play connectivity with other modules.

Train Release: In the “Train release” mode, a Start/Jam started, the intelligent control of the Z-Card signal can be passed through the whole delays the start up of the RollerDrive from chain of the Z-Card control PCBs and zone to zone. The power peaks which this enables the quasi simultaneous start otherwise occur temporarily can thus be or stop of all inter connected zones. significantly reduced. The resulting lower level of power to be installed means lower As the power requirement of an electric investment costs and further energy motor is increased temporarily when Slave rollers can be connected to Poly-Vee belts are another variant and are savings. the RollerDrive by different methods, used especially for conveying higher for example with O-rings. loads on straight and curved modules. ® MEX (55) 53 63 23 31 MTY (81) 83 54 10 18 8 DIST. AUTORIZADO QRO (442) 1 95 72 60 [email protected] 9 COMMUNICATION WITHIN THE INTE LLIVEYOR. PLUG AND PLAY.

GATEWAY

CAN-BUS

ETHERNET

PLC

PC

Standard communication Communication variant with EASY-Bus with Easy-Bus and CAN-Bus All Z-Cards exchange information Alternative to the possibility shown within the Intelliveyor via a pre-installed on the left higher order controls can data cable. be connected to the CAN-Bus.

Every Z-Card communicates with its This connection is a real plug and play Among others these are used for the In addition to the digital inputs and out- status etc.). It is also possible to influence All functions available on the CAN-Bus adjacent zones via a 4-wire data cable. connection and therefore insures following requirements: puts, a CAN-Bus connection is available the functions of the control here can therefore also be implemented immediate function without specific for connection to a higher order control. (e.g. merging and diverting behaviour). via today’s standard network protocol This cable transmits signals to start, • Transfer of materials to be conveyed addressing. TCP/IP. stop, detect errors or conduct certain to third-party systems A unique ID number is set on every To fulfil current requirements of the control procedures along the conveying For connection to external systems, • Influencing the merging and diverting Z-Card via a selection switch, which can higher order control even better, Interroll system. every Z-Card has four connections for behaviour of the modules be individually accessed via CAN-Bus. provides the gateway AnaGate CAN, incoming and outgoing signals. which implements the CAN-Bus on Eth- • Issue of an error signal Up to date information of a Z-Card can ernet with TCP/IP. then be obtained (motor status, sensor

® MEX (55) 53 63 23 31 MTY (81) 83 54 10 18 10 DIST. AUTORIZADO QRO (442) 1 95 72 60 [email protected] 11 ZERO PRESSURE FROM A TO B TO C: CASES, BOXES, CARTONS AND TRAYS

Technical specifications General properties standard module of all modules Zone length (ZL): 11.75" to 59" Whether in the automotive industry, • Zero pressure (contactless) transport; (300 to 1500 mm) postal logistics, mail order business or the arriving unit load always switches Module length (ML): 1 x ZL to 4 x ZL, internal distribution – where cases, the downstream zone when the photo ML ZL max. 118" (3000 mm) boxes, cartons and trays are conveyed, cell is reached Between Frame (BF): 12.2" to 39.75" the Interroll Intelliveyor provides a solu- • Flexible combination from the module, (310 to 1010 mm) tion. without programming Roller pitch (P): 2.2", 3", 4", 5", 6" All modules are well engineered with • Quiet operation (55 mm, 75 mm, P low energy consumption, flexible combi- • Plug and Play 125 mm, 100 mm, nations and particularly low-noise. 150 mm) • Energy savings Total Width (TW): BF+4.3" (110 mm) The following outlines which characteris- • The functions of the Z-Card can be tics are assigned to the various modules. influenced with inputs and outputs Between Frames Sidestream (BFS): 12.2" to 39.75" • Modules can be combined in any order (310 to 1010 mm)

BF Velocity (v): 20 ft/min to 240 ft/min (0.1 m/s to 1.2 m/s)

TW Load range: max 175 lbs/zone (max 80 kg/Zone) (depending on drive) Drive: 24 Volt Interroll RollerDrive Power transmission: O-Ring round belt or Poly-Vee belt

® MEX (55) 53 63 23 31 MTY (81) 83 54 10 18 12 DIST. AUTORIZADO QRO (442) 1 95 72 60 [email protected] 13 OVERVIEW OF THE INTELLIVEYOR MODULES

BF BF P P ZL ZL ML

P BF

P/2 90°

R825 ZL P P P ML ML ML = 2 x ZL BFS

Straight roller track Roller track curve 45° merge 45° diverter 90° transfer module Task: Transport of unit loads (cardboard Task: Whilst maintaining the alignment Task: Merging of 2 conveyor lines. Task: Division of one conveyor line into Task: Merging or diverting perpendicular boxes, packages, containers). of the materials to be transported, two conveyor lines. to direction of transport. Operating principle: Gaps in the the curve enables a change in direction Operating principle: Due to integrated material flow are used for merging via an Operating principle: Unit loads are Operating principle: Toothed belts of a conveyor line. controls goods are transported with zero angular roller track attached to the side. diverted via rotating bearing rollers. installed between the conveyor rollers pressure. Operating principle: With the aid of transport the materials to be conveyed Special advantage: Simple prioritisa- Special advantage: The material flow tapered rollers, the alignment of the into or out of the conveyor track installed tion of the merging behaviour via control is not interrupted, so that throughput materials to be transported within the on the side at an angle of 90°. input or bus. remains constant. Simple transmission of side walls is maintained. the divert command – via 24 Volt control Special advantage: Simple transmis- Special advantage: The division into line or the bus. sion of the merge/divert command via individual conveyor zones is also main - a 24 Volt control line or bus. tained in curves. Pure 24 Volt operation, no pneumatic system required. Low overall height from upper edge of roller to lower edge of transfer module (5.5", 140 mm). ® MEX (55) 53 63 23 31 MTY (81) 83 54 10 18 14 DIST. AUTORIZADO QRO (442) 1 95 72 60 [email protected] 15 MARKETS ARE PACEMAKERS FOR THE FLOW OF GOODS. WE MAKE THEM MOVE.

Interroll Intelliveyor – • Expert support • Long-term solid partnership Interroll Automation – Products ranging from the Interroll total flexibility Interroll offers support for questions As a financially sound company with best-in-class engineering and Crossbelt Sorter, the Interroll Intelliveyor, production worldwide: the Interroll Belt Conveyor and Pallet Flexibility is the yardstick of our products. regarding projecting and engineering a long-term growth strategy, Interroll is Conveyor to the Interroll Belt Curves are It must therefore be possible to extend thanks to a wide range of user at its customer’s disposal at all times The Interroll centre of excellence for produced at the 3 manufacturing units and freely configure each module as the know-how from numerous applications as a long-term partner. conveyor modules and sub-systems, in Sinsheim (Germany), Jeffersonville conveying task requires. For this reason worldwide. based in Sinsheim (D) is responsible for: • Worldwide availability (USA) and Suzhou (China). we develop unlimited solutions with global product management, research • Fast commissioning you which take the available space into Top quality products, solutions, and development, production and consideration and ensure simple coordi- Precise pre assembly of Intelliveyor support and consulting are always production technology, strategic pur- Centre of excellence for conveyor nation of material flows, in line with the modules in the factory allows fast, close to the customer – thanks chasing, logistics and technical support modules and sub-systems motto: everything is possible, without fully functional plug-and-play installa- to the global network of Interroll. of local production and assembly com- disregarding economy. tion on site. panies of the worldwide Interroll network. Untere Au 4 • Outsourcing frees up resources D-74889 Sinsheim • Tailor-made installation support This is the way flexibility To concentrate on their own core Germany is expressed for our customers: Interroll supports and supervises competencies, systems integrators Tel. +49 72 61/9 38-0 correct installation or handles order a comprehensive package solu- • The customer’s own value added complete installation – according to tion for fully functional sub-systems [email protected] takes priority precise customer requirements. from Interroll. The system’s integrator determines the scope of the customer’s own work (installation of switch cabinets, electrics, control, terminals, assembly etc.) ® MEX (55) 53 63 23 31 MTY (81) 83 54 10 18 16 DIST. AUTORIZADO QRO (442) 1 95 72 60 [email protected]