HAN-TEK’s Machined-Parts Conveyor System Connects Multiple Machines to Ensure Reliable, Operator-Free Performance

HAN-TEK’s Machined-Parts Conveyor System Allows U.S. Auto-Parts Maker to Remain Competitive

APPLICATION:  

HAN-TEK’s Machined-Parts Conveyor System Allows U.S. Auto-Parts Maker to Remain Competitive

INDUSTRY:

Automotive Parts Manufacturing

KEY COMPONENTS:

  •   Conveyors: twin-strand chain, tabletop chain,
      and gravity
  •   Pick-n-place units
  •   Pushers, pullers and turnover units
  •   Guide rails
  •   Pneumatic stops and escapements
  •   High-limit and part-present controls
  •   Custom electrical control system
  •   Locked reject chutes
  •   Customer machines: lathes, washer,
      induction heat treating, drill, grinders, eddy
      current testing, paint system, stud presses

BUSINESS ISSUE:
To satisfy contract requirements to produce a new component for front-wheel-drive cars, a longstanding HAN-TEK customer needed a customized, labor-efficient system that would reliably move parts to and from machining, inspecting, washing and painting machines. The mandates: Integrate the customer's machines, handle parts efficiently and without damage, and provide for a future expansion.

SITUATION:
The customer, with facilities around the world, designs, engineers and manufactures driveline and chassis systems and forged products for cars and trucks. The customer uses several HAN-TEK solutions to turn out other parts.

HAN-TEK SOLUTION:

HAN-TEK designed, engineered, manufactured and installed a durable, customized parts-handling system that integrates several machines and conveyors with a series of handshakes to move a raw forging through nine operations.

The HAN-TEK solution is designed to ensure the smooth flow of parts between machines that perform operations with varying cycle times. At each machine, a pneumatic stop and escapement system, controlled by photo-eye sensors, allows parts to accumulate until the machine is ready, and then delivers one part at a time.

At the start of the line, an operator loads a raw part, stem down, onto a twin-strand roller chain conveyor that delivers it to one of three lathes, where a gantry moves the part into the machine. When operation #1 is complete, each lathe turns its part stem up, and the gantry moves it to a tabletop chain conveyor for travel to the washing operation (#2).

The part then travels to a Pick-n-Place device that positions it in an induction hardening machine (#3) for localized heat treating. The part is moved by another Pick-n-Place to a conveyor for travel to a drilling machine, where an indexer positions the part for operation #4. After drilling, the indexer places the part onto another conveyor that moves it to one of three grinding machines. After operation #5, the part travels to an eddy current tester (#6) to be examined for cracks.

Next the part is washed, preheated and painted (#7). A HAN-TEK turnover device inverts the part so that it enters the washer stem down. With the painting complete, another turnover device restores the part to its stem-up position and places it on another tabletop chain conveyor for delivery to the stud presses (#8), where a gantry retrieves it. Once studded, the part is moved to a wider conveyor, where parts are placed alternately by two gantries. Finally, the part reaches the rust inhibit operation (#9); when complete, the part is ready for manual removal from the line and packing by an operator.

CUSTOMER VALUE:

  • Labor efficiency. With the HAN-TEK automated solution, the customer was able to satisfy its contract requirements to produce a part that requires a multi-step machining, painting and inspection process. Without automation, taking parts through these steps might require some 12 operators on two shifts.
  • Reliable throughput. The HAN-TEK system is currently set up to produce 180 parts per hour, and a future expansion will boost that throughput to 320 per hour.
  • Safety. Operator protection, guarding and emergency shutoffs built into the system minimize the potential for injury or damage.
  • Product integrity and quality control. HAN-TEK designed the parts-handling solution with guarding, covers and locked access to prevent the incorrect introduction of parts. The solution also features automatic rejection of parts automatically inspected by the system.
  • Turn-key convenience and easy maintenance. HAN-TEK’s solution includes documentation and training, a 20-hour dry run at HAN-TEK’s facility, and monitoring a 25-day production run at rate at the customer’s facility. The system’s maintenance requirements are modest, and lubrication points are easy to access.

To learn more about HAN-TEK crane, hoist, or other solutions, contact HAN-TEK at 800-836-0237 or email  Sales@HAN-TEK.com.

HAN-TEK, Inc., an ISO 9001:2000 registered company, headquartered in Victor, New York
(suburban Rochester), customizes advanced automation technology to optimize
manufacturing-assembly and product-distribution systems. Founded in 1961, HAN-TEK
specializes in overhead cranes, integrated conveyors, and systems automation and controls.