More and more companies are realising that it is necessary to optimise their material flow and handling in production, trading and distribution by means of both specific and wide-ranging rationalisation measures. This is true for the continuous loading and unloading of machine tools, safe handling of the workpieces and the damage-free movement of the products. After all, more throughput and better productivity play a major role in the efficient handling of parts. Depending on the tasks and products, this handling may differ greatly. Nevertheless, the rationalisation needs to be implemented without large investments. The solution to this is a comprehensive modular system of standard components to meet individual handling and material-flow requirements. For this, the vacuum specialist J. Schmalz GmbH in 72293 Glatten (Germany) not only offers a complete range of vacuum tube lifters and vacuum lifting devices for many different material-flow solutions but, as a logical continuation of this concept, their new range of aluminium cranes. Schmalz can thus now offer complete manual handling solutions from a single source, extending from the initial analysis of needs through consulting, planning, manufacture and commissioning to the after-sales service.

Experience gained from uncounted
material-flow solutions

On the basis of experience gained from the many different material-flow solutions they have already installed, the engineers at Schmalz developed a crane system made from aluminium designed specifically for the optional combination with vacuum tube lifters of the Jumbo series, with vacuum lifting devices of the VacuMaster series or even with mechanical, pneumatic or electric grippers developed and built by customers. Just like all other standard Schmalz systems, the new crane system is fully modular and is based on four different aluminium beams. This makes it possible to quickly implement crane systems which are optimised for weight, load and costs and are perfectly matched to the planned applications. The aluminium crane beams have a maximum length of eight metres and can be connected together as desired to form longer beams and runways for covering larger working areas. The system is optionally available with one or two beams or in a monorail version. The maximum load is 660 kg. The proven ease of movement of the crane system permits fast, safe and effortless movement of all types of goods. Depending on the planned application, the aluminium crane systems can be combined with a directly mounted vacuum tube lifter or with a chain hoist, which means that they are suitable for universal use. The modular concept, together with the Schmalz planning program, permits fast and easy configuration and design of the systems. Since all components are available ex stock, such complete vacuum handling systems can be designed and installed very quickly and are immediately ready for use.

Standardised single-beam aluminium crane system
can be equipped with individual grippers and holders

The responsible persons at L`Orange GmbH in Stuttgart-Zuffenhausen (Germany), manufacturers of high-pressure injection systems for marine diesel engines, special vehicle drive systems and power-station technology, were quickly convinced of the above benefits. They planned to equip a phosphating plant at their production facility in Glatten in the Black Forest and were looking for a suitable crane system to move metal baskets full of small parts quickly and safely between the various stations of the plant. For each treatment phase (cleaning with hot water, surface treatment and rust-protection by immersion in tanks containing various chemicals), the metal baskets containing valve housings have to be lifted, traversed, lowered and, after the appropriate treatment period, lifted again. Each basket of parts can weigh up to 150 kg. It must be easy to move the baskets between the stations and to position them precisely over the treatment tanks. After consideration of the subject and the performance of the aluminium crane systems from Schmalz, the company decided to purchase a single-beam overhead crane made of aluminium, equipped with a chain hoist and the company's own gripper for holding the metal baskets. The very compact and light aluminium crane system was mounted directly on the existing ceiling in the factory with the aid of the standard runway suspension elements. It covers a working area of 14.5 x 2.5 metres and can lift a maximum load of 250 kg, providing a good safety margin. The working area was also deliberately made rather large so that the treatment tanks can be repositioned or additional tanks can, if necessary, be installed at any time. The installation of the crane system on the ceiling means that there are no supports or columns within the working area which could interfere with normal work. This was important because the phosphating plant operates in three shifts and the crane system has to lift, move and lower about 1000 baskets of parts per day. It is thus important that the crane system is easy to traverse and that it runs quietly. Thanks to its smooth surface (the aluminium beams are anodised), the crane system is easy to clean, a further benefit in view of the large amounts of steam and the generally rough environment in which it is used. The single-beam crane system from Schmalz is thus a very flexible and economic material-flow solution with which the surface-treatment process can be carried out more productively and with less risks for the health of the persons involved.