Work handling system is custom-engineered

Gudel UK has been selected by Coventry-based Ultraseal International to produce a custom-engineered work handling system for an impregnation line it is supplying to a major automotive customer.

In the UK, system integration specialist Gudel UK has been selected by Coventry-based Ultraseal International to produce a custom-engineered work handling system for a new impregnation line it is supplying to a major North American automotive customer.

This latest order reflects the accuracy, reliability and in-service performance of earlier Gudel equipment incorporated into Ultraseal impregnation systems for European and US automotive customers during the past eight years.

Ultraseal's impregnation equipment is recognised as an industry standard for solving the problem of micro-porosity in cast components, particularly in the automotive industry.

The technology is based on the precise vacuum control and specially developed sealants, which the company continually refines to meet new applications.

"Our impregnation systems consist of a number of modules, which handle the various process, pre-washing, vacuum impregnation, washing, and hot curing operations", explained Ultraseal's Engineering Director, Mike Priddle.

"One of the keys to our equipment's success is the consistency, repeatability and control we exercise over the workpieces as they progress through each stage of the process.

As a result, we need an effective and reliable method of transferring parts - in some cases weighing several hundred kilograms - from station to station within an controlled automatic cycle".

"This is where we find Gudel equipment really scores", he added.

"In this latest application, the end-user requires a complete, turnkey installation, which will integrate the impregnation of finished machined aluminium castings into existing in-house manufacturing lines".

In order to meet the desired throughput and accommodate the customer's 24 hour a day production operations, Ultraseal has developed a solution based on two parallel processing lines.

These not only use common robot-controlled infeed and outflow stations, but are also capable of independent operation.

"Because our equipment must be able to work round the clock unattended, with only minimal routine maintenance, it's been important for us to partner with a work handling specialist that has a proven track record of success under demanding operating conditions", continued Priddle.

"Just as importantly, it needed to be able to provide first-class product support in North America".

"Through our work with Gudel on previous contracts, we were confident of teaming up with the company again to provide a solution that fully meets our customer's needs".

A key feature of the resulting system is that components are loaded into purpose-designed pallets, which are stacked three high for processing.

Each pallet stack is transferred by conveyor to the appropriate impregnation line, where it is picked up by the Gudel gantry loading system and transferred, sequentially, to each module in the automated process.

"With as little as 3mm clearance between the pallets and the loading aperture at each work station, precise positional accuracy is essential", said Gudel UK's joint Managing Director, Gary Ottley.

"Each pallet stack can weigh as much as 125 kg and is cantilevered to almost 1.5m at some points in the cycle".

"So, rigidity is a further critical issue".

The final design of the twin work handling systems has been developed in conjunction with Ultraseal, using standard Gudel gantry and linear motion components, integrated with a purpose-designed gripper system.

"The specification of corrosion resistant coatings on all slideways combats the handling solution's aggressive operating environment", Ottley added.

"In addition, the overhead gantry configuration provides maximum floor level access to the Ultraseal impregnation modules".

Other equipment supplied by Gudel as part of the overall installation includes the system's inflow and outflow conveyors, software and programming.

Though close cooperation between Gudel and Ultraseal, the jointly-developed controls package delivers maximum operational flexibility.

It not only allows production to be maintained using only one line - while the other is operated manually or receives routine maintenance - but also encompasses all relevant safety issues, such as the avoidance of collisions between the gantry loader and load/unload robots.

"The relationship between our two companies has undoubtedly been strengthened through this contract, which represents one of the largest export orders we have tackled to date", said Priddle.

"I am confident that the complete installation will receive customer sign off within the next few weeks and look forward to working with Gudel again on similar projects in the future".

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