Indexed conveyor changeover

Implementation

Overhead shafts keep the sliding mechanism above the reference carton envelope.

Independent plungers locate each support; captive slotted clamps hold the position.

Replaceable wear strips and a written changeover/repeatability procedure.

Reduced-order rail, hanger, post and shaft calculations define a 30 N reference side-load envelope.

Completed 180 synthetic bidirectional changeovers and an exhaustive 243-state indicator exercise; overload, added wear and wrong settings are rejected.

Inputs and assumptions

• 80, 120 and 180 mm cartons, 120 mm long and 60 mm high, on a reference 450 mm frame.
• Two millimeters nominal running clearance per side; declared worst-case tolerances.

Results

Report figures (2)

Open the full report ↗

Verification

14 geometry/tolerance checks pass; regression tests exercise invalid inputs and wear effects. 10 commissioning acceptance checks and 5 additional regression tests pass. The selected 30 N loaded-clearance case leaves 0.744 mm; the 150 N jam case is rejected.

python run.py && python test_project.py && python complete_validation.py && python test_completion.py

Project files

The ZIP contains the source, inputs, results, and instructions. These files are also available individually.

• Parametric CAD sourcemodel.py · 6 KB
• Dimensions and tolerancesinputs.json · 1 KB
• 120 mm assembly STEPoutputs/cad/assembly-120.step · 904 KB
• Three setting dimensionsoutputs/settings.csv · 1 KB
• Tolerance budgetoutputs/tolerance-budget.csv · 1 KB
• Bill of materialsoutputs/bom.csv · 1 KB
• Wear-strip drawingoutputs/wear-strip.svg · 2 KB
• Index-plate drawingoutputs/index-plate.svg · 3 KB
• Design report and procedurereport.html · 7 KB
• 180 synthetic changeover recordscompletion/synthetic-changeovers.csv · 25 KB
• Every four-indicator setting combinationcompletion/indicator-state-table.csv · 6 KB
• Rail load and clearance envelopecompletion/lateral-load-envelope.csv · 1 KB
• Executed commissioning and fault studycompletion/report.html · 9 KB
• Completion acceptance matrix and source hashescompletion.json · 5 KB
• Reproduce the commissioning studycomplete_validation.py · 10 KB
• Declared commissioning inputscompletion-inputs.json · 1 KB

Run locally

Python 3.12 / CadQuery 2.7.0 / NumPy / Matplotlib

Extract the ZIP and open a terminal in the conveyor-changeover folder. The README includes setup and usage details.

python -m pip install -r requirements.txt
python run.py
python test_project.py
python complete_validation.py
python test_completion.py

Limits

• Reference carton, frame and load inputs are declared. No measured changeover-time savings, wear life or factory throughput is claimed.
• Beam calculations omit local joints, nonlinear contact, impact and fatigue; the load envelope is a static screening result, not a conveyor machine rating.
• The checked indicator rule is a written setup gate, not an installed electrical interlock. Independent rails can still be physically set incorrectly.
• Hardware and retention are dimensioned reference envelopes. Supplier approval, physical assembly and machine safety certification are not represented by synthetic evidence.