Better working conditions are always an interesting subject, particularly when they result in better motivation of staff and thus in more productivity. In many cases, it is the workers or the persons responsible for work planning who, with simple devices, help to improve the efficiency, quality and safety of operations in a factory.

For many years, this was so at Messrs. UCON AG Containersysteme KG in D-77756 Hausach, where a practical lifting device for sheets of stainless steel was designed, built and used for rational loading of a welding station. So far, so good. One day, however, safety inspectors visited the factory and immediately forbade the further use of this lifting device, which meant that the production manager had to look for a suitable device to replace it. This new device would have to offer all of the benefits provided by the "home-made" unit and, at the same time, comply with the requirements of the safety authorities.

Efficiency and safety are the keywords

The company found a perfect and efficient solution which was approved by the safety authorities in the form of a vacuum lifting device of the type VacuMaster Light, made by the vacuum-technology specialists J. Schmalz GmbH in D-72293 Glatten. The VacuMaster Light is the smallest unit in the series of vacuum lifting devices and is designed to handle loads of up to 100 kg. It is simply suspended from an existing overhead crane in the workshop. The VacuMaster Light can handle loads only in the horizontal position, bit this is sufficient for loading the welding station with the stainless-steel container bases, which weigh between 20 and 30 kg. The overhead crane which was installed for the home-made device is suitable for use with the VacuMaster Light, which meant that the investment costs for the new solution were limited to the price of new lifting device.

From a single-purpose home-made unit
to a flexible vacuum lifting device

The VacuMaster Light is available ex stock in two different versions, with either one or four suction pads. In the case of product changes, or for other applications, the suction pads can be adjusted quickly and easily to other positions, complete with the integrated vacuum generators. This means, for example, that a single VacuMaster Light can be used for handling small parts or larger assemblies, narrow workpieces and profiles, sheet-metal parts or cases or even barrels, packing cases and parcels weighing up to 100 kg.

The suction pads are mounted on flexible joints, which means that they can compensate for angled surfaces and can pick up and position parts on slopes of up to 12°. The very compact VacuMaster units of the types VM LI 100-1 and VM LI 100-4, with overall heights of only 250 and 310 mm, respectively, weigh only 13 and 15 kg, which makes it easy to move and position loads of all types. The small size and low weight also simplifies the flexible use of the devices wherever an overhead crane or similar lifting tackle is available.

Low-cost complete solutions with
the modular VacuMaster system

The vacuum lifting device is delivered fully assembled, complete with vacuum generator and operating controls, and are ready for immediate use. The customer only needs to suspend it from a crane and connect the compressed-air supply. The VacuMaster Light can grip and transport air-tight and slightly porous materials safely. An optical warning device with a red/green indicator and a compressed-air and vacuum manometer clearly show the operating status of the device.

Messrs UCON is very satisfied with the vacuum lifting device from Schmalz – and a welcome side-effect is that the low investment costs will pay for themselves in a very short time.