JC Plant Adapts Briggs Trucks For Handling

JC Plant has manufactured a range of machines using Cat Lift Trucks supplied by Briggs Equipment. The company, which specialises in designing and manufacturing bespoke materials handling solutions, has developed the Skyhook 3.3. It is designed to work in hazardous environments and confined spaces, while providing optimum safety for the operator and bystanders. It reduces the risks associated with using multiple equipment and manpower for certain jobs, by rolling many features into one machine.

'We identified that some of our customers were having difficulty handling smaller loads in restricted areas and in some cases were manually handling items when machinery should have been used,' said Jamie Cooper, managing director at JC Plant. 'We therefore designed and built the Skyhook 3.3 to assist with the handling of such items as motors, pumps and valves - thus reducing the risk of manual-handling injuries. He added: 'As a basis we needed flexible and durable forklift trucks for this operation; ones that could easily adapt to bespoke modifications yet maintain the highest levels of safety and reliability.

Briggs supplied Cat diesel models to JC Plant. Each one had its chassis and hydraulic systems re-engineered to accept a sub-frame and stabiliser structure, onto which JC Plant mounts a compact lifting arm. The Skyhook 3.3 is able to pick and carry over 1,000kg at 1.5m within a 90deg restricted slewing arc over the front of the machine. With the stabilisers in place this can be increased to 520kgs at 6m, while keeping the working head room down to 2.5m.

PI Drives For Automation And Handling

Physik Instrumente (PI) has launched the M-228 and M-229 linear drives, which feature travel ranges of 10mm/25mm and use classic stepper motors as drives, with either compact or cubic configuration.

The drives feature mechanical position display, a non-rotating spindle and safety limit switches. PI said the low-cost drives are ideal for tasks such as setting valves, adjusting components for further processing, and pick-and-place.

Adept Handling Robot Showcased At Food Expo

Adept Technology has announced that its USDA-accepted robot for high-speed food handling will be showcased at the Worldwide Food Expo in Chicago, Illinois on 28-31 October, 2009. The Quattro s650HS is said to be the only USDA-accepted parallel robot available for food processing. It is also available with an optional fixed platform addressing high-payload applications.

The Quattro line is designed for high-speed manufacturing, packaging, material handling and assembly applications. It features a four-arm kinematic, enabling higher speeds and faster accelerations. The Quattro is suitable for flexible packaging, material handling, kitting and assembly applications where performance is of paramount consideration.

Rexroth Offers Devices For Handling Delicate Items

Rexroth offers a number of solutions for handling delicate items during the manufacture and packing of a range of products, including food items and electronic devices. Stuart Cheyne, industry segment manager for automation with the pneumatics division of Rexroth, looks at some of the options now available for handling delicate items. Many conventional product handling systems make use of mechanical grippers that are usually operated pneumatically, although solenoid driven versions are also available, he said.

According to Cheyne, it is often assumed that gripper-based systems are unsuitable for handling delicate products, but this is not necessarily so. Modern gripper products, such as those in the Rexroth GSP Series, are precision engineered, which means that the closing of the gripping fingers is very accurately controlled. Repeat accuracies of 0.05mm or better can be achieved, so, for regularly shaped products, the risk of crushing in a properly designed system is minimal.

In addition, the grippers can be supplied in versions with two, three or four fingers, as required by the application and, if necessary, the gripper fingers can be faced with resilient material to minimise the shock loading when a product is picked up. Cheyne claims that, considering these features, conventional grippers may be suitable for gentle handling, especially as they are available in a variety of shapes and sizes and are very cost effective.

Nevertheless, there are many applications, especially those involving the transport of items that are not only delicate but also irregularly shaped, where no form of gripper system is likely to prove satisfactory. An example is a machine that is being used to transport toothbrushes that were in transparent bubble packs with a card backing. The shape is very irregular, making it difficult to decide on a point where a gripper could be used reliably, and the packs are susceptible to crushing and creasing.

In instances such as this, a different approach is needed and this is often provided by vacuum pick-ups. These devices, which are available in a range of sizes and formats, effectively use suction to pick up and support the product. This does, however, mean that they can usually only be used with non-porous products where a reasonable degree of sealing can be achieved between the product and the pick-up. It might be assumed that the need for a vacuum generator would make these devices expensive and possibly unattractive to use. A solution is available in the form of a Venturi-based vacuum generator, according to Cheyne.

These devices, which have no moving parts, produce a vacuum by passing a fast-moving stream of compressed air over an orifice. In effect, the airflow draws air in from the orifice, creating a vacuum. Since most manufacturing plants of any size have an existing compressed-air supply, this is said to be a very convenient solution. Venturi-based vacuum generators of this type are available in the Rexroth EBS range, for example. Examples of ultra-delicate items that cannot be touched, let alone gripped, are solar cells, which are just a few millimetres thick and are very susceptible to contamination and handling damage.

Another application would be potato snacks or biscuits being placed into small, individual packs - here, the same problems occur, as well as issues with placement accuracy and repeatability. These products can be picked up and transported reliably using a recently developed non-contact lifting and transport device from Rexroth. Designated the NCT (non-contact transfer), Rexroth's lift is based on the so-called Bernoulli principle and, like the vacuum generator, it operates from a compressed-air supply. As a result of the geometry of the Rexroth NCT, airflow under the device generates a differential pressure that creates a lifting force.

With the NCT, the lifting force generated is sufficient to be useful without a seal between the device and the item that is to be transported. This feature means that the lift can transport porous items, such as biscuits, and items with rough surfaces that would prevent a conventional vacuum pick-up from functioning reliably. The Rexroth NCT can even transport items through liquids - a benefit that is being exploited for transporting solar cells through baths of cleaning solutions. Since none of the surfaces of the cell are in contact with the pick-up, all of the surfaces can be cleaned simultaneously and efficiently.

The largest version currently available from Rexroth produces a lifting force of 0.9kg. As the Rexroth NCT devices do not require vacuum generators, they can be easily retrofitted to existing machines in place of conventional mechanical grippers. The company also develops custom lift subassemblies, ready to install as single components, helping machine builders to lower costs, streamline their supply chain and reduce engineering expenses.

Penny Services Lifting And Load Handling Equipment

Richard Short, sales director at Penny Hydraulics, outlines the importance of the thorough examination and testing of load handling equipment. Most companies are aware of the health and safety regulations that require all items of lifting equipment to be inspected regularly. The regulations are a legal requirement and cover all types of lifting equipment, broadly defined as any device used to handle loads in a workplace. This can include, but is not limited to, cranes and tail lifts installed on commercial vehicles as well as similar equipment used in other mobile and static applications.

Goods lifts and hoists are included. The more stringent regulations have been brought in because accidents related to lifting continue to represent one of the biggest causes of deaths, injuries and time off work in the workplace. Official HSE figures show a small but steady decline in these accidents in recent years but there is still much to do. Imposing a more rigorous regime of testing and inspection on lifting and load handling equipment is designed to reduce the risk of mechanical failures that no doubt contribute to workplace accidents.

But this is about more than simply complying with the requirements of the Lifting Operations and Lifting Equipment Regulations (LOLER) and Provision and Use of Work Equipment Regulations (PUWER). Businesses that take health and safety seriously are also more aware of their corporate social responsibilities and duty of care obligations. They understand the need to provide employees with equipment that is properly maintained and fit for purpose. Even without the regulatory pressure there are sound financial reasons to ensure equipment is reliable and well maintained.

Minor problems are sorted out before they lead to something more serious and unscheduled outages are less likely. The consequential costs of accidents and injuries caused by faulty or defective lifting equipment can have obvious and even more severe implications for the business. Good safety and best practice starts with specifying the right load handling equipment and making sure it is installed to the manufacturer's recommendations. The equipment and vehicle manufacturers will normally work together, or with an approved body builder, to ensure this happens. Incorrect installation can be dangerous and make the vehicle and the load handling equipment unsafe.

LOLER proscribes the testing and inspection regime that must be adopted. The main legal requirement is that all equipment should be subjected to what is known as a regular Statutory Thorough Examination (STE). This is similar to an MOT and is designed to ensure that the structural components and mechanical operation of the equipment meet acceptable standards. All equipment must be thoroughly examined before first use. After that, the frequency of an STE varies for different devices but all must be thoroughly examined at least once a year. Lifting accessories (slings, chains, grabs, buckets and so on) and equipment designed to carry people must be thoroughly examined every six months.

Equipment should also have an STE following the repair or replacement of a structural component, when a change of chassis takes place and when the device is removed and refitted to the original chassis. BS7121 Part 2 complements the LOLER recommendations and goes further in some respects, for example, by stipulating additional full tests four and eight years after first use and an annual 'load plus 10 per cent' test. Thorough examinations must be carried out by someone who is competent and impartial, although this can include an employee, the original equipment manufacturer or an independent service engineer as long as they have the relevant accreditation.

The examiner will have appropriate practical and theoretical knowledge as well as experience of the lifting equipment being examined. They should be able to recognise potential defects that might be a safety risk to people if the equipment remains in use. Load testing is no longer required during every STE although it may be a sensible precaution to include this as routine. A competent tester will always consider whether a load test is necessary after they have inspected the equipment and this would then be carried out to complement the STE. Choosing a competent person to carry out the STE can sometimes be a problem for larger as well as smaller companies.

Original equipment manufacturers and their service organisations are likely to offer this as part of their overall service. Those who supply CE-marked equipment will also meet the recommended standards in terms of design and construction. Look for organisations that belong to relevant industry bodies (such as ALLMI or the SMMT for commercial vehicles) because these will probably have a better understanding of the market and work to official codes of practice designed to promote better safety and best practice. One significant area where the current legislation differs from its predecessors is the way in which attachments are treated. In general terms, and there are a few exceptions, an attachment such as a hook or grab is now considered part of the lifting equipment even if it can be easily removed.

Similarly, the mounting or fixing points are also considered part of the equipment and should be covered by any inspection. Of course, any STE can only check the condition of the equipment on the day of the test. Although the STE is a legal requirement, any responsible owner or operator of lifting equipment will want to carry out basic checks more frequently, for their own peace of mind and to instil a safety-first culture among their employees. The objective should be to maintain the equipment so it is always safe to use. Following the manufacturer's maintenance instructions is an absolute minimum requirement. Daily checks need not be onerous and can often be completed in a couple of minutes.

With hydraulic cranes, for example, this might include looking for oil leaks, damage to steel sections or frays on wire ropes. Although potentially serious in themselves they might indicate a bigger underlying problem. There are other maintenance tasks that should be part of a regular routine. These can include, for example, checking the level of hydraulic reservoirs and topping up as necessary, lubricating components in line with manufacturers' recommendations and giving equipment a general clean or simple wipe over from time to time. It is surprising how many companies continue to ignore even the most basic tasks. Load handling equipment operators are also responsible for ensuring proper records are kept for a minimum of two years about a device's test, inspection and maintenance history.

This does not necessarily mean they must keep this information themselves because the records can be held by a third party, such as an inspection agent or service provider, as long as they can be accessed whenever required. The best service providers will offer this facility as part of their overall contract. The penalties for non-compliance can be severe. Companies that do not complete their STE and maintain records properly can be subjected to enforcement action or fined in a court of law. Penny Hydraulics designs, manufactures and services lifting and load handling equipment for use in a wide range of applications.

Products include the Swing Lift range of medium duty cranes for use on pick-ups, drop-sides and flat-beds and the Step Lift, Load Lift and Tail Lift lifting platform ranges for use on pick-ups, drop-sides and vans. The company also manufactures the Mezz Lift for handling loads between ground floor and mezzanines and specialist equipment for handling wheels, tyres and barrels in vehicles and at customers' premises.

Catalog Includes Assembly And Handling Equipment

A catalogue featuring the range of Roemheld assembly and handling equipment is now available. Ergonomically designed, the Roemheld Modulog range enables the safe and efficient handling and movement of heavy loads by operators.

The catalogue, which is in the form of a binder, includes information on the health and safety aspects of this range as well as the production benefits. It also details the modules available within the range, from horizontal and vertical rotating, tilting and lifting of workpieces through to cart and floor modules for easy transporting and installation of the units.

Verlinde Releases Hollow Profile Handling Rails

Verlinde has introduced a hollow profile for its range of handling rails in Eurosystem Alu aluminium. Intended for car manufacturing markets, this fourth profile, AL08, is intended for loads up to 500kg Eurosystem Alu is intended for setting up tailor-made handling systems for loads up to 2000kg. The AL08 profile will be the meeting point between the AL06 and the AL10 (which goes up to 2000kg).

The lightness of the hollow aluminium profiles makes them easy to assemble. They can all be moved and positioned manually without hoisting equipment. The elements are bolted to each other, as are the system and the load-bearing structures, and do not require special tools. This makes the external groves on the profiles compatible with the Item standardised attachment system. The profiles are then manufactured by extrusion which gives them substantial geometric homogeneity.

The profiles can be assembled without mechanical adjustment. The full handling system in hollow aluminium profiles is 50 per cent lighter than a traditional steel structure. In the case of new buildings, renovations or extensions, substantial savings can be achieved on the load-bearing structure, the dimensions of which could be calculated to the minimum according to this equipment.