Innovative Handling Systems for the Coating Industry

In one of our most recent projects, we designed and implemented three handling systems for a leading supplier in the coating industry that specializes in small parts. These systems had to be able to cope with the extreme conditions of the coating environment.

Despite the limited space available in the production facility, maximum freedom of movement was required. In addition, the new systems had to integrate seamlessly into existing production processes and synchronize with other machines.

Dynamics meets precision: the manipulator

Lifting – up and down and back and forth – and turning at the same time. Sounds like too much to ask? We have created just such a solution for our customers. To accomplish this task, it was clear that strength, precision, and multitasking were required.

Maximum flexibility: simultaneous movement on three axes

By integrating the Y-axis into the lifting axis along with the rotation unit, we were able to design the manipulator in a way that perfectly meets the customer’s specific requirements. Thanks to its rotation speed of 72° per second, the manipulator can quickly switch between different working positions, reducing cycle times and increasing overall productivity. This flexibility is especially beneficial in complex production environments, where efficient use of space and rapid responsiveness to changing production demands are essential.

Design for durability and reliability

The lifting and moving system is characterized by a robust design that withstands harsh industrial conditions. The lifting carriage with an integrated linear axis ensures smooth and precise parallel movements. The use of ALFATEC guide rollers and profiles ensures these movements occur without unwanted vibrations, improving the machine’s precision and longevity. The chain drive for the vertical axis and rack-and-pinion system for the horizontal and turning axis provide effective power transmission and motion control, even under heavy loads.

Efficiency through advanced drive systems

Servomotors for lifting, turning and moving systems ensure precise control over movements, which is crucial for production processes. These motors allow loads to be positioned quickly and precisely, and guarantee optimum synchronization with other machine components. The control panel, which is mounted on the side of the lifting and moving system, houses the control unit, which ensures smooth communication between the system components. All cabling for the actuators and sensors is also strategically placed to optimized maintenance accessibility and minimize potential malfunctions.

Speed at the highest level: the lifting and moving system

After the small parts have been coated, they need to be heated in an oven unit. In order to carry out this process and the subsequent steps—transport to the cooling units and removal—fully automatically, a lifting and driving unit is required that is precisely adapted to the production environment.

Minimal space, maximum efficiency

To meet all these specific requirements efficiently, it was necessary to precisely adjust the sizes of the technical components to the available space and required parameters: shrinking them without compromising power, speed, and dynamics. For this purpose, we designed a custom chain conveyor that ensures the baskets are efficiently, quickly and dynamically transported through the various processes.

Precise control and maneuverability

The advanced control technology and high positioning accuracy are crucial for automation processes in the coating industry, where even minor deviations can lead to inefficiencies. To ensure consistent movement of the baskets along predefined paths—as well as straight-line motion and reliability—the system is also equipped with a rack-and-pinion drive system.

Integrated safety features

Of course, we also made sure to ensure safety. The lifting and moving system is equipped with slack chain and chain breakage monitoring, which helps prevent failures and increase operational safety. These monitoring systems are crucial for early detection of issues, allowing proactive maintenance before unexpected downtimes can affect production.

Optimization through tailored design elements

A key element of the customized special solution is the use of single-column lift masts and lift carriages, ensuring effective load handling. These components are designed to minimize space requirements while maximizing accessibility and ease of maintenance. Additionally, the hoist moving unit placed above contributes to a clear movement area, improving the overall efficiency of the system.

Harmonized systems: the portal

After the cooling phase, which was precisely maintained by the lifting and traveling unit, the 2-axis gantry of the lifting and traveling unit removes the coated and hardened components. Equipped with an advanced rotary axis, the gantry is perfectly designed to securely grip the baskets and transport them to their final destination.

Robust construction for industrial requirements

The construction of the portal is based on a solid steel design, specifically developed to meet the challenges of industrial manufacturing environments. The welded portal supports and the base plates fixed with dowels provide a stable foundation for operation. The precise control, enabled by synchronized rack-and-pinion drive, highlights the efficiency and reliability of the system. With its advanced technology and well-thought-out design, the portal ensures that the final phase of the automated handling process is completed successfully with the highest precision.

Crossing boundaries: export to the US

Special attention was given to adapting both systems to the strict UL standards for the American market. Through our careful planning and customization, we were able to not only meet international safety standards but also ensure seamless integration into the production environment of our customer. For the customer, this means not only the assurance that the system operates reliably and safely, but also the flexibility to operate in international markets and unlock new business opportunities.

Special solutions that drive things forward

By working closely with our customers and suppliers, we have been able to achieve significant improvements in production efficiency and flexibility. By integrating highly developed moving systems, robust design principles and compliance with internationally recognized safety standards, ALFATEC has not only optimized the customer’s production capacities, but also strengthened its competitiveness on the global market.