Steel Sheet Handling Made Easy

15.01.2010

The Schmalz VacuMaster Vario crane-operated vacuum lifting device helps mid-sized steel work company Haist, based in Baiersbronn-Mitteltal, to achieve more safety and efficiency in steel sheet handling.

Streamlining concerns mid-sized businesses too! It is not enough for companies to invest in powerful, modern production machines; they must also streamline the logistics environment. This process includes the storage of raw materials, the loading of machining tools and the removal and storage of finished parts.

Metal construction companies recognised long ago that vacuum handling devices can assist employees in handling and transporting sheet metal of all sizes and thicknesses quickly, easily and safely. When it comes to handling steel sheets (heavy plates) weighing up to 1,800 kg, companies do not, however, think of vacuum systems immediately but instead tend to use conventional handling methods such as crane-operated gripper jaws or magnetic grippers. The disadvantage of these methods is that sheet metal that does not retain its shape, is uneven or is non-ferromagnetic cannot be moved at all or only in a manner that is not process-safe.

Looking to optimise your material flow?

Vacuum handling presents a technically simple and, most of all, process-safe solution, as shown in the following real-world example: The steel work company Egon Haist, based in Baiersbronn-Mitteltal in Germany’s Black Forest region, was able to streamline its material flow for loading their CNC plasma flame cutting machine to such an extent that today all large, heavy steel sheets are transported by a single employee.

Before, at least two employees were required to perform this task. The process of transporting the steel sheets from the storage area to the machine took far too long and was not completely safe. Previously, loads were handled using a crane and chain suspensions. This always resulted in safety problems, as plates were constantly in danger of slipping through the suspensions. The steel sheets produced by Haist are medium-sized at 1,500 mm x 3,000 mm (L x W) and weigh between 540 kg and 1,800 kg depending on thickness (15 mm or 50 mm). However, they are particularly difficult to position and handle, especially because the chain suspensions are difficult to position on the plates and remove after transport while placing the plates onto the machining tool.

Streamlined, more efficient, safer

Today, this process looks completely different. Thanks to the vacuum technology specialists at J. Schmalz GmbH, it was not only possible to make basic improvements to the handling process, it was possible to make it considerably safer as well. After conducting an analysis of the operational processes, Schmalz technicians recommended the VacuMaster Vario 2000, a crane-operated vacuum lifting device. This device is designed for a maximum load of 2,000 kg and is extremely flexible to use.

The vacuum lifting device is composed of a steel longitudinal beam with an ergonomic operator handle, integrated vacuum reservoir and vacuum generator. The entire unit is suspended on the crane. After connecting the power supply and switching on the vacuum pump, work can begin immediately. Fourteen single suction plates are installed for lifting, gripping and transporting items. These suction plates are attached to spring elements. This way, the lifting device can compensate for uneven or bent areas, supporting safe handling.

Safety is taken into account in multiple ways for handling heavy steel sheets. In the case of a power failure, the large integrated vacuum reservoir and non-return valve ensure that steel sheets are held securely. An electronic warning system issues an acoustic signal if the vacuum level is too low. The manual slide valve with its clamp-safe catch lever prevents incorrect operation and the unintentional release of the load.

Expectations met

Haist’s management has stated that the Schmalz vacuum handling system more than met their expectations for the handling of heavy and unwieldy loads.

Now, only a single employee is required for plate handling and much less time is needed for the task. The vacuum handling device is in working order and has not exhibited any faults or required maintenance to date. It has found wide acceptance among the employees as the device makes difficult work much easier. Lifting loads using a vacuum system requires less strength, prevents the employees from overstraining themselves and is much safer. Unproductive down-time can be dramatically reduced. This leads to better use of machine operating times in the form of “real” production times, which leads to an increase in productivity. Add in the drop in personnel costs and it becomes clear that this investment will amortise quickly and that the use of the VacuMaster Vario vacuum lifting device for steel plate processing streamlined more than just the material flow.

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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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