Product category:
Robotics, Handling and Storage
News Release from: Gudel UK | Subject: Trackmotion
Edited by the Engineeringtalk Editorial
Team on 20 April 2006
Handling system brings home the bread
Handling system at Allied Bakeries' West Bromwich plant services three storage areas and feeds two automated bread baking lines with a fresh pan every 2.5s, 24 hours a day, 6.5 days a week.
Ever needed to transfer a couple of tonnes of parts with pin-point accuracy? What about handle high temperature components in a continuous foundry operation? Or maybe position components precisely in a radio-active or toxic environment? Not everyday component handling problems perhaps, but whatever the complexity of the application, the chances are that precision handling firm Gudel UK will have tackled something similar before During its 50 year history, the company has built a strong reputation for problem solving, which is reflected in its continuously expanding range of multi-axis modules and individual drive components
This article was originally published on Engineeringtalk on 7 Dec 2001 at 8.00am (UK)
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At the heart of the Gudel range are its single, twin and three-axis gantry handling systems.
With the ability to position components weighing up to 15tonne with accuracy, speed and repeatability, these multi-axis units are designed as standard modules that can be easily integrated with automatic machining, welding or robot assembly equipment.
Units are normally built to order, using modular assembly principles.
The company's ability to mix and match existing parts to create customised installations is important, both to keep initial installation and subsequent operating costs down.
Gudel can also act in a consultancy or systems integrator role to help meet customer requirements.
Further reading
New design booklets on component handling systems
New versions of five design and selection data booklets from Gudel UK provide in-depth specification data on the company's extensive range of multi-axis handling modules and more
Rapindex press transfer machinery now from Gudel
The acquisition of Michigan-based Rapindex Inc by Gudel AG has extended the comapny's range of advanced multi-axis gantry loading systems, automation equipment and press transfer machinery
Roboloop tackles heavy-duty transfers
The Roboloop system combines the benefits of a precision tracked guideway with high accuracy rack and pinion drive and high load carrying capabilities.
"It's about tailoring the solution to the problem, rather than the other way round", said Gudel Joint Managing Director Gary Ottley.
"Our range of standard modules and equipment is the foundation of our business".
The range includes all types of drive components, including precision linear drive pinions, racks, vee rollers, guide rails, bevel gears, carriages and accessories.
These are available in various materials and load carrying capabilities, making them suitable for machine tool, automation and special purpose assembly applications.
Everything is manufactured in-house to internationally recognised quality standards and every product is designed as a building block for use within tailored systems.
To aid specification, the company publishes five design and selection guides.
These provide more than 750 pages of in-depth equipment data and application recommendations - including precise load carrying capabilities and installation details - and are available for free.
Full equipment specifications can also be found on the company's web site (www.gudel.com), along with dimensioned drawings that can be downloaded in standard DXF, Step and PDF formats directly to engineers' desktops.
"Our range is constantly evolving to meet new customer requirements", said Ottley.
"But the fastest growing area of our business during the past two years has been in heavy-duty custom-engineered handling products".
A cross-section of recent Gudel contracts includes several repeat orders for systems to transfer batches of parts to a series of process stations within an automatic component impregnation line.
"Not only did we need to develop installations to meet specific operational demands - including high positional accuracy and repeatability of components over each system's length - but ones that would withstand the corrosive action of the applications' warm, moist operating environment", said Ottley.
"This was achieved by manufacturing the drive rack and guideways in stainless steel".
"For other operating conditions, the use of aluminium, high performance alloys or special purpose coatings would have been more appropriate".
The company's attention to detail is underlined by the specification of special purpose seals and oils for equipment destined to be used in low ambient temperatures.
Equally, various automatic lubrication options are offered to ensure high performance, low maintenance installations under the most arduous operating conditions.
The need to combat aggressive working environments is typified by the specification of four Gudel systems to transfer mould packs at an automated foundry specialising in complex automotive components.
The gantry handling units not only transport the packs from a feed conveyor to an automatic roll-over casting module, but subsequently transfer them to a thermal sand reclaim unit.
Here, temperatures in excess of 500C burn off the resin used to bind the mould sand together, enabling it to drop away for re-use, while leaving the solidified casting behind.
"As well as the heat, our systems are subjected to a working environment of highly abrasive zircon sand", said Ottley.
"Gudel units form an integral part of the plant's continuous process and have performed without a single failure since installation".
"Indeed, when we recently checked the original machine's guideways, rollers and other mechanical components as part of an upgrade project to renew the drives and control package, everything was still found to be within original manufacturing tolerances, despite the demanding operating environment".
A further recent contract, this time for the food industry, highlights another equally demanding set of operational and environmental requirements.
The task was to devise a handling system at Allied Bakeries' West Bromwich plant that would service three storage areas and feed two automated bread baking lines with a fresh pan every 2.5s, 24 hours a day, 6.5 days a week.
"Not only did this have to meet stringent hygiene regulations, but also to perform with total reliability", said Ottley.
"In particular, it needed to overcome the effects of airborne flour dust, which can be surprisingly abrasive to mechanical components".
Other considerations included an overall height constraint within the bakery building and restricted access to the conveyor lines themselves.
To achieve the desired stability of the grippers, which can accommodate up to 18 baking tins at a time, the firm equipped the gantry modules with double vertical beams, each having a common motor drive.
To meet the height restriction, it substituted a standard z-axis transfer module with a custom-engineered telescopic unit.
This allowed the overall height of the space to be reduced by more than 1.2m, so it cleared the roof of the building by just 20mm.
"This may not seem very much", said Ottley, "until you realise that Gudel workhandling systems will routinely position loads of up to several tonnes repeatably to within a fraction of a millimetre over linear runs of more than 100m".
Following detailed discussions with the prime contractor and the user, it was also decided to opt for a manual, rather than a fully automated, lubrication system to deliver food grade grease to the equipment's moving parts.
At the other end of the load carrying spectrum is an application involving the transfer and positioning of mould tools - each measuring 2 by 6m and weighing 15tonne - used in the production of pre-formed food trays.
In operation, the custom-designed equipment provides precise location of the multi-impression moulds at a fraction of the cost of a special purpose press or machine tool.
Furthermore, such heavy duty gantry systems have higher load carrying capabilities and larger operational space than most industrial robots.
Likewise, they provide levels of precision and repeatability that are unattainable by traversing cranes, while simultaneously avoiding the health and safety issues associated with human operators.
Versatility is a further attribute, which can be demonstrated by one of its Trackmotion units in the automated production of de-icing systems on GKN Westland helicopter rotor blades.
The positioning equipment at the heart of the installation has helped transform a previously labour-intensive series of operations into a fully automated process.
The elimination of human variables has, in turn, increased productivity and quality through the system's overall repeatability of better than 0.03mm at any point on the surface of the 7.5m long blades.
Manufacturing and automation applications engineering experience is accessed through the company's technical support service, which includes detailed equipment selection and application engineering advice, as well as special-purpose gripper and component manipulator design and manufacturing capabilities.
It is also mirrored by the company's in-house controls engineering expertise, which covers everything from motors, drives, PLC and CNC to motion controller technology.
"It enables us to back our products with a complete range of support services, including control system development, installation and commissioning", said Ottley.
"In practical terms, it means there are few problems we have not come across, and solved, before".
"As a result, we have established something of a reputation for taking on applications that other handling system suppliers seem to steer well clear of".
"Whatever the reason, one thing is clear.
Gudel is a company that relishes a challenge".
"So the next time you find yourself facing a particularly demanding component handling problem, at least you'll know who to approach for some help".
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