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Case Studies

Fairings

Prior fairings weighed less than 100 pounds and were handled manually, due to a larger fairing size a handling device was needed to complete the operation. The operator must transport the heavy and awkward fairing from the container to the riser, which is more than 50 feet. The riser is also in an open well bay and has a safe zone that operators must remain clear of.

Wood Panels

The material handling solution must be ergonomically correct and of simplistic design. Unit would be handling a variety of payload weights.

Wheel Molds

The part weights and the reach into the press made handling difficult. The customer used special fixtures and a forklift truck to do the transfer. Rotation was accomplished by setting the mold down and rotating it by hand, before picking it up again with the forklift. The transfer back to the press was very time consuming and much of the pre-heating was lost. This resulted in numerous castings being lost while the mold was reheating again during the process.

Wheel Hubs

Operators were lifting hubs out of a crate and holding the heavy part, while trying to align the wheel stud holes and place it on the wheel. This procedure required two operators and still resulted in back injuries.

Wheel & Swing Drives

Operators were using a chain and hoist solution to transfer parts. It was deemed an unsafe environment with several dropped parts. Accurate placement in workstation positioners and pallets could not be achieved. Operators were not meeting cycle times with prior handling method.

Truck Engine Flywheel

Multiple parts to be handled. The dunnage and bell housing create clearance restrictions above, below, and around the part. This leaves the face of the flywheel as the only exposed surface for gripping. The gripper cannot interfere with power tool access for driving in the attachment bolts. The entire process must be completed within a 54 second cycle time.

Torsion Bars

Existing hydraulic manipulator was not as effective at placing bars on the paint line hanger as a pneumatic manipulator would be. The “float” capability of a pneumatic manipulator and ease of maintenance convinced the customer to replace their hydraulic manipulator.

Tires

Increase in injuries during the tire stitching process.

Tire Assemblies

The tire assembly needs to be oriented so that the hub centerline is parallel to the centerline of the axle. there is a close fit between the hub ID and axle OD. The tire assembly must be rotated to align the hub key with the axle keyway. Thus, the tire assembly is lifted, pitched, swiveled, and rotated during installation onto the axle. An overhead hoist with a sling or C-frame lifting device was used for lifting; however, this method lacked control and safety.