Batch reciprocating lifts create severe throughput bottlenecks on high-speed sortation and assembly lines. This continuous vertical fork conveyor utilizes a continuous circulating loop of intermeshing cantilevered fork carriages to elevate or lower totes, cartons, and packaged bins continuously, delivering uninterrupted vertical throughput up to 1,200 units per hour within an ultra-compact floor footprint.
Continuous Circulation: Multi-fork arm carriages provide continuous, non-stop vertical conveyance without reciprocating delay.
Intermeshing Comb Infeed: Precision-aligned fork fingers mesh seamlessly with powered roller conveyors for zero-impact load transfer.
High-Throughput Speed: Variable-frequency drive achieves continuous vertical transfer rates from 600 to 1,200 units/hour.
| Technical Parameter | Standard Specification | Engineering Customization Range |
| Payload Capacity Per Carrier | 50 kg – 100 kg per fork-arm carriage | Fully Customizable to Client Specifications (20 kg – 250 kg) |
| Throughput Capacity | 600 – 1,200 units/hour (Continuous flow) | Fully Customizable to Client Specifications (Up to 1,800 units/hr) |
| Lifting Height / Travel | 6,000 mm (Standard multi-tier configuration) | Fully Customizable to Client Specifications (2.5m – 20m) |
| Max Workpiece Dimensions | 600 mm (L) × 400 mm (W) × 350 mm (H) | Fully Customizable to Client Specifications (Totes / Cartons / Bins) |
| Carrier Configuration | Intermeshing Multi-Finger Cantilevered Fork Arms | Solid comb trays / Telescopic fork options |
| Drive Mechanism | Heavy-Pitch Precision Roller Chain + UHMW-PE Guides | High-strength steel cable / Timing belt drive systems |
| Vertical Linear Speed | 15 – 30 m/min (VFD variable speed control) | Fully Customizable to Client Specifications (Up to 45 m/min) |
| Infeed / Outfeed Interface | Intermeshing Powered Roller / Belt Conveyor Combs | 90° transverse transfer / Multi-infeed, multi-discharge |
| Drive Geared Motor | 3.0 kW – 7.5 kW SEW/Nord Helical-Bevel Brake Motor | Sized per total circulating payload and line velocity |
| Tower Frame Construction | Laser-Cut Structural Steel Channels with Cross Bracing | Stainless steel SUS304 / Aluminum extrusion options |
| Control Architecture | Siemens S7-1200 / Mitsubishi PLC + Touchscreen HMI | Seamless WMS, WCS, and Profinet/EtherCAT integration |
| Power Supply Rating | 380V / 50Hz / 3-Phase | Fully Customizable to Client Specifications (208V–480V, 60Hz) |
| Operating Noise Level | ≤ 68 dB(A) at maximum operational speed | Ultra-quiet precision guide bearings |
| Safety Sensor System | Dual Photoelectric Overhang Sensors + Jam Detection | Light curtains / Interlocked acrylic or mesh perimeter guards |
The central vertical tower is precision-machined from heavy-gauge structural laser-cut steel channels, reinforced with internal anti-torsion cross members to maintain strict mast parallelism along travel heights up to 15 meters. Dual heavy-pitch ANSI precision roller chains operate along continuous high-density UHMW-PE low-friction guide tracks (green polymer strips), eliminating metallic wear and chain slacking during continuous multi-shift production cycles. Cantilevered fork arms are fabricated from high-strength structural rectangular hollow tubing, load-tested to eliminate deflection under dynamic cantilever loads up to 100 kg per fork carrier.
Integrated automatic chain tensioning units and central oil drip lubrication systems maintain optimal chain elongation control without manual intervention. Modular bolted access windows along the mast casing permit rapid inspection of chain links, guide rollers, and drive sprockets from floor level. GRADIN provides a 12-month complete mechanical and electrical warranty, standard replacement chain links, spare carrier arm assemblies, and comprehensive engineering support for fast commissioning.
The infeed and outfeed stations utilize motorized roller conveyors with intermeshing comb fingers that transition totes smoothly onto moving fork platforms without pneumatic pusher stops. Variable-frequency drive (VFD) controls enable seamless synchronization with upstream sorting systems and downstream packaging lines. To connect ground-level container staging with higher payload material stations, facilities can integrate complementary continuous vertical lifts across multi-tier mezzanine layouts.
Optical photo-eye curtains at infeed and outfeed portals instantly shut down the drive motor if tote misorientation, item overhang, or operator intrusion is detected. A redundant electromechanical motor brake holds the entire circulating chain assembly static during emergency stops, preventing backward drive slip. The unit fully conforms to international industrial handling and machinery standards:
ASME B20.1 Safety Standard for Conveyors and Related Equipment
OSHA 1910 Material Handling and Machine Guarding
ISO 13849-1 Safety of Machinery – Performance Level d (PLd) Architecture
CE Machinery Directive 2006/42/EC compliance for continuous vertical conveying systems
Automated E-Commerce Order Fulfillment: Continuous high-speed vertical routing of plastic storage totes and shipping cartons between multi-tier pick towers.
Automotive Parts Kitting Lines: Continuous vertical staging of small-parts bins and hardware trays to elevated assembly workstations.
Electronics & PCB Manufacturing: Smooth, non-jarring vertical elevation of delicate component trays between surface-mount technology (SMT) clean rooms.
Pharmaceutical & Medical Packaging: Uninterrupted vertical transfer of sealed carton batches from primary packaging to elevated case-packing mezzanines.
Food & Beverage Carton Packaging: Moving packaged food cartons, beverage cases, and tin cans from basement packaging lines to ground-level palletizers.
3PL Multi-Level Sortation Hubs: Connecting multi-level sortation loops with continuous tote induction to maximize system sorting capacity.
For this heavy-duty series, we can engineer load capacities up to [300] tons, with platform dimensions and lifting heights customized to your operational envelope. Requirements exceeding our standard engineering matrix will undergo a Finite Element Analysis (FEA) by our engineering team to ensure structural viability before proposing a solution.
To initiate the engineering proposal, please provide the following baseline data:
Rated Load Capacity
Maximum Lifting Height & Closed Height
Platform Dimensions (L x W)
Duty Cycle (e.g., operational cycles per hour/day)
Environmental Conditions (e.g., indoor/outdoor, washdown, explosion-proof)
Pit depth or overhead clearance constraints
Yes. The control systems can be equipped with standard communication protocols (e.g., Profinet, Modbus, Ethernet/IP) utilizing [Siemens / Allen-Bradley / Omron] PLCs. This ensures seamless I/O signal synchronization with upstream/downstream conveyors, AGV/AMR units, and your central control room.
Every custom unit undergoes a mandatory Factory Acceptance Test (FAT) prior to dispatch. This includes continuous operational testing at 100% rated load, static overload testing at [120% / 125%] capacity, and the physical triggering of all mechanical anti-fall and hydraulic safety interlocks. FAT documentation and video proof are included in your engineering package.
Upon final approval of the General Arrangement (GA) drawings, the manufacturing lead time is typically 4 to 8 weeks. Oversized structural components are engineered with a modular design to fit into standard shipping containers (20FT/40HQ). On-site assembly utilizes pre-engineered bolted flange connections and heavy-duty aviation plugs, strictly eliminating the need for field welding.
We provide a standard [12/24]-month warranty covering the structural frame and primary hydraulic/electrical components. To minimize operational downtime, a comprehensive set of standard consumables (e.g., cylinder seal kits, travel switches, relays) is shipped alongside your equipment. During the warranty period, replacement parts for non-human-induced failures are dispatched via priority air freight (DHL/FedEx) within 48 hours.
Beyond the warranty, we guarantee lifetime engineering support. Your custom equipment's CAD drawings, electrical schematics, and BOM (Bill of Materials) are permanently archived in our system. This ensures you receive uninterrupted remote troubleshooting, maintenance guidance, and exact spare parts matching for the entire lifecycle of the equipment.
Gradin Machinery is a leading manufacturer specializing in aerial work platforms and hydraulic lifting solutions. With ISO & CE certifications, we provide safe, reliable, and customized equipment for global industrial needs
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