Heavy Load Process Automation

Task

Ultraseal International, manufacture Impregnation Process lines to ensure minimal scrap of cast products due to porosity problems. They needed to automate the handling of large baskets of metal components through one of its Impregnation Process lines, comprising various process tanks. The end user site was very limited in floor space and the roof height was low, therefore limiting the type of automation that could be used. The Impregnation process involved the use of Nitric acid in some tanks and special engineering was required on the system to ensure high availability of the system was achieved working in this environment. At the same time, Ultraseal wanted GUDEL to use as much of its proven standard modular equipment as possible. The total weight of the basket and components is 550KG. To get the throughput required, the system needed to operate at 1 metre/second velocity.

Solution

GUDEL based its design around a standard trackmotion module of 22 metres length, fitted with a vertical column of 2.5 metres to which an offset arm was fixed. At the end of the offset arm was fitted a Stainless Steel gripper system to interface with the component baskets. This design enabled the baskets to be handled through the top of each tank without the need for a traditional overhead system and ensuring that it fitted within the low roof.

Scope of supply

The main base axis was a standard GUDEL TM-90 Trackmotion Module fitted with additional levelling and securing feet. The vertical column was manufactured from a 350 x 350mm steel section and fitted with size 62 heavy duty guideways. All guideways drive racks and pinions were specially coated to prevent corrosion. All fasteners were stainless steel. GUDEL provided all control system and software required for the system to operate with the Ultraseal Impregnation Process.

Result

Easy and speedy site installation due to the GUDEL equipment modularity ensured minimal site time. GUDEL designed the equipment to be installed at site using only a fork lift truck as this was the only handling equipment available due to the restrictive roof height. All production criteria were met.