Vacuum lifting device rationalises your material flow

18.06.2009

The processes of loading machine tools and removing finished workpieces still represent time during which the machine is not working productively. By using vacuum handling systems, you can reduce unproductive downtime to a minimum.

Topics such as “increased productivity” and “efficiency and profitability” are recurrent themes today in all production, assembly and other business operations. Especially in the trade of semi-finished products and raw materials, profound changes have been observed as the industry has moved away from pure logistics (that is, delivering semi-finished products) and toward combined services comprising materials, logistics and provision of pre-cut parts. Suddenly, material costs are no longer the sole value creation factor; storage, handling and cutting are also creating value due to the many small orders and pre-cut parts. Since competitive pressure is also rising, it is essential to be consistent and mechanise and/or automate all conceivable operations. The following case from the field of wholesale acrylic glass and plastic semi-finished products is an impressive example of how you can realise quantifiable productivity and profitability advantages using relatively simple material flow solutions. The König GmbH Acrylglas company in Cologne, Germany, operates as a wholesaler for acrylic glass and plastic products and has also provided its customers with cutting services for years. For this purpose, two upright sawing systems are used to realise all cutting orders in single-shift operation. The raw sheets are first taken from the warehouse, placed in an upright position, and positioned or fastened to the saw. After sawing, the pre-cut parts and any leftover sheet pieces must be removed and stacked (e.g. on a pallet) or the leftover pieces must be transported back to the warehouse. A fork lift is used to remove the stock from high-rack storage and deliver it to the picking area. Depending on the size and weight of the plates, two to four employees are then needed to carry the raw sheets to the sawing system and rotate them by 90°.

Economic vacuum-based material flow solution

As if that still weren’t enough, personnel are also needed for the removal and stacking of the pre-cut parts and the removal and return transport of the leftover sheets. For this reason, the people in charge at the König company were interested in an appropriate rationalisation solution and got in touch with the specialists at vacuum technology manufacturer J. Schmalz GmbH in Glatten, Germany. König already had limited experience with vacuum, but only to the extent of using simple manual suction devices to support plate handling. Because their employees found this method of plate handling to be rather tedious, they were now looking for a more comprehensive solution. After analysing their needs, Schmalz created a complete material flow concept that consisted of a small aluminium crane system and a vacuum lifting device from the VacuMaster Comfort series. A complete vacuum handling system was thus provided by a single source, which convinced the König company to place an order. A number of requirements had to be taken into account when designing the material flow and vacuum handling system: the ability to reliably handle acrylic glass and plastic sheets up to a weight of 280 kg; consideration of the high quality requirements of the sensitive surfaces, which can be smooth or slightly rough; various plate formats up to a maximum of 3,000 x 2,000 mm, where the plate thickness can amount to 60 mm in the small format and 40 mm in the large format; and easy adjustability of the suction pads and crossbeams to the different plate and cutting formats. For the time being, they started by using a vacuum handling system to load an upright saw. The crane system is designed so that later, the second sawing station will also be able to be loaded and unloaded with an additional vacuum lifting device.

Vacuum handling system from standard modular components

The optimum material flow solution now turns out to be a single-beam overhead crane system with a working area of 16 x 6.8 metres and a vacuum lifting device from the VacuMaster Comfort series. The single-beam overhead crane system has a proven, lightweight design, is based on a sturdy aluminium profile, and is designed to hold loads of up to 375 kg. The VM Comfort 250-90-8-2400 is intended for handling and continuous 90° rotation of plates and workpieces and can hold loads of up to 250 kg. The VacuMaster has an adjustable beam system (one main/longitudinal beam and four crossbeams), to which eight SPU series suction pads are attached. Each of these suction pads has a diameter of 210 mm and consists of sturdy, wear-resistant Perbunan, which adjusts perfectly to the smooth surfaces of the transport materials. The four crossbeams carry the eight suction pads and are individually adjusted to the longitudinal beam and quickly adjusted to the plate/cutting formats. Especially noteworthy are the practical operating options found directly on the VacuMaster Comfort vacuum lifting device, for which there is a centrally and ergonomically located operating unit. With the push of a button, the employee can move the electrical chain hoist up or down, switch the vacuum on or off, and rotate the transport materials 90° from the horizontal to the vertical, or vice versa. In addition, an electromagnetic valve (two-hand-vacuum-off function) is installed for safe operation. The vacuum is generated by means of a pump. The pump has automatic energy conservation. It automatically switches off when the required vacuum level has been reached, and automatically switches on when more vacuum is required. The vacuum handling system has now been in operation at König for some time, and employees and management alike appear content with this universal and flexible material flow solution. Not only does it save time, but now it only takes one person to load the sawing system. By contrast, this used to require two to four employees (depending on the size and weight of the plates to be sawed), which works out to a personnel and cost savings of 50% or 75%, respectively. In addition, the output of cut materials has increased, since the downtimes of the sawing system have been reduced.

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Questions regarding public relations:
J. Schmalz GmbH Marketing Communications Aacher Strasse 29 D-72293 Glatten	Tel.: +49 (0)7443 2403-506 Fax: +49 (0)7443 2403-9506 presse@schmalz.de

Questions regarding usage:
J. Schmalz GmbH Customer Centre Aacher Strasse 29 D-72293 Glatten	Tel.: +49 (0)7443 2403-105 Fax: +49 (0)7443 2403-9105 kundencenter@schmalz.de

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