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Cylindrical

The core shafts are long and weigh 200 lbs. each. Two operators were required to handle the part. Finished drum surface couldn’t be marred or scratched by the shaft. There were many work cell obstructions and limited floor space.
Workers had to lean over the chassis to install the cylinders resulting in several back injuries.
The cylinders weigh between 50 to 100 lbs., 8″ – 10″ diameter and 48″ – 52″ long. 120″ of radial reach is required for three pick up and place points. The cylinders are up to 350° in temperature when the are brought to the work cell. Plant safety procedures require maintenance personnel must be able to service the electrical and hydraulic components from floor level.
Cylinders are stacked on top of each other in a crate with no access for a gripper end-effector. Additionally, wash racks do not have access for an end-effector to grip around the parts.
Limited work space, multiple obstacles, and heavy parts lead to ergonomic problems. Restricted power sources and underground environmental conditions limited the available equipment to perform the tasks. The end-user was looking for a solution to improve operator ergonomics as well as the overall efficiency of this maintenance process.