Vacuum Handling Systems Optimise Material Flow

21.08.2009

Maximising the usage of machine running times while minimising unproductive downtime is the key to greater efficiency, economy and competitive strength.

By purchasing new and more powerful machines for tasks such as cutting sheet metal, the user has the potential for more opportunities, better performance and higher production efficiency. However, the material flow must first be optimised before these new and powerful machines are able to reach their full potential. For this reason, Dietrich Aldinger GmbH Metall- und Lasertechnik, based in 72202 Nagold, Germany, went one crucial step further when investing in a new laser-cutting machine. The company invested at the same time in a loading system and removal system. Prior to this purchase, the process required two employees to manually load and remove raw sheet metal and pre-cut parts from a specialised machine. With the new system, this task can be handled by a single employee.

The vacuum specialist J. Schmalz GmbH based in 72293 Glatten, Germany was selected to supply the system. Schmalz has supplied and installed hundreds of vacuum handling systems and draws upon extensive experience in the area of loading and removal systems as well as sheet metal processing machines.

The vacuum handling system is used to handle raw sheet metal and leftover pieces as well as pre-cut and semi-finished parts flexibly. It can handle different workpieces with different dimensions – sheet metal in large, medium-sized and small formats as well as special formats up to 25 mm thick with parts weighing up to 70 kg and maximum weights of up to 400 kg. Some workpieces are coated and protected from rust using oil.

Schmalz technicians planned a complete solution consisting of the VacuMaster Basic vacuum lifting unit with a multiple suction pad system and aluminium slewing column crane. The lifting device is designed to handle a load of 500 kg. The workpiece is handled horizontally using eight suction plates of type SPU with a diameter of 210 mm. Longitudinal cross arms with a length of 2,400 mm allow for quick and, most importantly, individual adjustment of suction plates to the appropriate plate format and the contours of the pre-cut parts. The vacuum is generated using an electrically operated vacuum pump.

When planning the project, we concentrate on developing the most energy efficient solution possible. This way, individual suction plates can be switched off when they are not in use. This is especially helpful for handling of different formats and pre-cut parts flexibly. The suspension of the suction plates is spring-loaded and articulated so that the suction pad system can be adjusted to all different working conditions while ensuring a secure grip and safe transportation. The vacuum lifting device can be used for all different types of materials without going through the complicated process of changing the grippers.

The complete vacuum handling system is mounted on an aluminium slewing column crane with a chain hoist. The slewing column crane is attached to the foundation using heavy duty anchors. The maximum load is 650 kg. A swivel angle of 270° and a jib length of 6,000 mm provide the user with a large working area. The height of the lower edge of the jib is 2,600 mm. The raw sheet metal and semi-finished products can be placed onto and removed from the laser-cutting machine and positioned from there without any spacial limitations.

Managing Director Achim Aldinger has the following to say about the new material flow solution using the vacuum handling system. “All steps can now be completed by a single operator. The employee no longer has to cope with any physical strain, because the handling system supports the weight of the workpiece. We have been able to increase the laser-cutting process flow by many times that which we had with manual loading and removal. The machine runs almost continuously, so we have been able to reduce idle times to an absolute minimum.”

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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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