The rolls are very heavy and expensive to manufacture. The largest roll is 63″ in length, 30″ in diameter and weighs 1,450 lbs. While core diameter remains constant at 6″, the length, width, and weigh vary. Vertical travel is a concern in order to be able to retract the material handling device in the vertical orientation. Operator safety is top priority when considering the weight of the rolls to be handled.

The vertical up and down dimensions of the manipulator end-effector was critical due to the large variation in roll heights and part orientations. The end-effector must prevent the rolls from telescoping when pitched down.

Minimal floor space is available with pallets placed over a wide work area. Slit rolls on the pallet are placed over a cardboard core poke for shipping. Rolls are dropped to the pallet until a stack is formed. Inner core of the slit rolls cannot be deformed. Operators need to work from both sides of the end-effector.

The spools have an inner and outer wall between them, which an end-effector could be inserted. However, the opening between the spool walls is curved and has spokes that create four quadrants and only a 3/4″ height into which an end-effector can be inserted. In addition to supporting the weight of the spool, the end-effector must slider the spool off the spindle.

How to safely pitch heavy rolls, varying in size from vertical to horizontal beneath a hoist.