Factory Equipment Case Studies
A fully automated production line in the automotive industry necessitates the use of protective machine guards.
40 Series profiles were utilised to construct bespoke individual segments, forming a customized on-site solution. In this arrangement, the posts are seamlessly integrated with the panelling material to create a cohesive unit. The segments are assembled adjacent to each other, securely connected using plates or adjustable angle brackets, and anchored to the floor with retaining brackets. This design allows for the protective fence to be adaptably configured based on the specific on-site conditions.
Black, powder coated 40×40 welded mesh panels are used for the panelling material. Access to the machines is provided by swing doors, secured with mechanical solenoid latches.
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Testing and storage frame for fuel tanks
An automotive supplier needs frames to conduct extensive pressure, heat, and emission tests on fuel tanks and to provide storage for these tanks.
The frames are intended for the installation of tanks to replicate the conditions found in an actual vehicle. The objective is to simulate the installation scenario with as much realism as possible. These frames need to be adjustable to accommodate various tank geometries and equipped with rating plates for individual projects. Additionally, frames for different tank types should share identical external dimensions to facilitate stacking and prevent tipping or falling when stacked. They must also possess fuel resistance and the ability to endure temperatures ranging from -40 to +100°C, as well as vibrations generated during testing.
In response to these specifications, we engineered durable and versatile frames crafted from 40 Series aluminium profiles, featuring precisely positioned mountings for the fuel tanks.
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Sturdy gantry structures for a beverage sorting system
To establish a beverage sorting system, a mechanical engineer required robust gantry frames that will support X-Z-axis handling systems. Utilising linear handling, the objective is to sort full and empty beverage crates onto the respective lines of the system in a pick & place application.
The linear units accelerate at approx. 4 m/s². It should be possible to hang a load of up to 200 kg on the Z-axes. With an unsupported length of 4 m, the beams must not deflect by more than 2 mm. The customer requires a repeat accuracy of less than 0.5 mm to ensure the gripper can grip the products cleanly.
To fulfil these unique specifications, a gantry frame was crafted using 60 Series aluminium profiles. To be able to absorb the maximum load and the forces from the dynamics, profiles from the 60 Series were used with M12 screws. Transverse beams were connected to large angle brackets and supported with truss struts.
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Mobile Assembly Platform for Helicopters
A European helicopter and aircraft component manufacturer requires various mobile assembly platforms and work platforms for the assembly of the helicopters.
These platforms have to be adapted to the height and contours of the helicopters and fitted with different levels and in some cases multiple stairways. They should be capable of standing independently or rotating to connect with each other. Moreover, free span widths of up to eight meters are necessary to guarantee unimpeded access to the helicopter beneath the platform. The different platforms should receive electrical supply in accordance with the customer’s requirements and include compressed air connections. Some platforms may also require features such as height adjustment, foldable guardrails, and flaps in the platform floor.
The assembly platform, along with its guardrails and stairs, were designed using profiles from the 40 series range. Sections that encounter notably heavy loads are constructed using profiles from the 60 series.
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Ergonomic workbenches with ESD protection
Workstations are needed to assemble wireless mobile phone charging cradles for vehicles. Every stage of the assembly process, including the final inspection, takes place on these workstations. Hence, the workstations need to be customized for each specific assembly step. Additionally, an efficient feeding and removal system is necessary to minimize conveying times. Given that the products being assembled are highly sensitive to electrostatic discharge (ESD), the workbenches must incorporate complete ESD protection.
Diverse workstations, constructed using mk 40 Series profiles, featured integrated roller conveyors for feeding and removal. The workbenches, along with the roller conveyors, incorporate hydraulic height adjustment, enabling workers to customize the benches to an ergonomically suitable height. Tabletops, roller conveyors, extensions, and frames are all meticulously designed to meet the ESD protection requirements specified by the customer. These workstations were individually planned and executed in collaboration with the customer to align with the specific assembly steps.
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