By Clint Yonkers
Ergonomic Automation Engineer
Thomas Conveyor & Equipment Co
Recently, Thomas Conveyor & Equipment Company was approached by a Manager of Production Operations who works for a large pharmaceutical manufacturer located in the state with the motto "The Bay State."
They required an ergonomic device which could grasp, lift, transport, rotate and then position 20” diameter x 4-1/4” wide PETG plastic rolls weighing up to 60 lbs. each. This material is used in a final packing operation.
These rolls are initially moved into the processing area and staged on a cart positioned close to a series of packaging machines. The maximum pickup height was 50” above the floor. The rolls are arranged on the cart with the core vertical. They could be stacked as high as 5-6 layers.
The past practice was for a company associate to manually lift these rolls from the cart, rotate and set them on the floor. Placing them on the floor meant risk to the outer wraps and possible scrapes, not to mention the possibility of injuries from back strains. When the roll is on the floor then an air bladder type machine spindle was inserted in the roll core.
Finally, two associates would have to manually pick up the roll and shaft together and place the assembly onto the machine spindle saddles without pinching their fingers. The term we use for this type of operation is a cross shaft handling application.
This entire old handling method was eliminated with the use of our ergonomic equipment. We recommended a custom ergonomic lifter, which now grasps, lifts, transports, rotates and then positions a roll in the machine without any operation intervention except for placing the air bladder type machine spindle inserted in the core.
Since our ergonomic lifters are light weight and extremely maneuverable, capable of turning inside its own footprint, the increased flexibility allow use at several different machine positions negating any reason to purchase multiple units.
There were many special requirements that had to be met to satisfy their needs. The most challenging or unique was the low clearance between the roll and the floor once it was placed in the machine. This gap or space amounted to one inch. We accomplished our goal by providing a custom made end effector tool with a very slender but strong flat handling arm. More challenges arose and but were solved since this process is highly proprietary and certain security clearances had to be obtained before proceeding forward.
Several pictures and an instructional videos accompanies this blog and demonstrates the use in a controlled setting.
Thomas Conveyor & Equipment Company is an authorized and factory trained distributor of Lift-O-Flex ergonomic lifters. As described above, these lifters are specifically designed and manufactured to suit each application no matter how stringent.
They are light weight and precision built featuring a manual transverse and battery operated lift/rotate features. Each lifter can be supplied with customized tooling allowing a host of different methods for grasping, lifting, turning and rotating.
A manual foot operated three position central brake system allows for the rear casters to be set at either freewheeling swivel or locked for single directional travel. These lifters are available in the standard powder coated/aluminum anodized construction or is stainless steel wipe or washdown versions.
The next time you encounter an impossible product handling application contact Thomas Conveyor & Equipment Company at 844-220-0086 for the right solution. Our systems integrators have the expertise to help you with your ergonomic lifting application.