This month, we are looking at our newest conveyor project, designed to allow forklift operators and line workers to maintain a constant workflow without relying on being in sync with each other. Specialized features make it a completely automated conveyor with advanced safety and productivity customizations, such as:
- Providing a densely packed automated interface between the forklift operators and the assembly line, where forklift operators are dropping off the rear axle housings.
- Each of the 3 main assembly lines at the assembly plant have one conveyor system to deliver unassembled parts to the line and a second conveyor system to take away finished parts to be brought to final assembly. Each of the 6 conveyors is independently monitored and controlled by its own operator station and control cabinet.
- The conveyors act as an automated queue for parts at the line to maintain a constant flow of pallets and parts.
- Up to 4 pallets of parts can be queued at a time for the operator, as well as another 4 pallets that are being sent back to the forklift.
- By creating a buffer for parts at the line, the line operator does not need to rely on the forklift operator so heavily to deliver parts just-in-time to the line. By queuing up to 4 pallets at the line, we’ve created up to 20 minutes of buffer time if the forklift deliveries are delayed.
- Light curtains on both ends protect operators from entering the cell when it is in motion and unsafe. When a forklift operator wants to drop off a set of pallets, they use their remote pendant as a request to enter with no need to get off the forklift. The PLC will receive the request and notify the forklift operator through an orange or green indicator on a stack light when motion has stopped, and it is okay to enter with the pallets. Similarly, the forklift driver uses the pendant to indicate that the drop-off is complete to activate the light curtain and resume motion.
- An interesting addition to this cell is the use of a 3rd pair of light curtains that cuts the conveyor into 2 separate safety zones, each with its own separate safety circuits. This allows the line operator to safely advance pallets on their end of the conveyor if the forklift side enters a faulted condition. The same works in the reverse direction if the line side enters a fault condition, the forklift can still drop off a pair of pallets and advance them while a team member works on addressing the fault.
- With 2 distinct safety zones, this further reduces the likelihood of a fault in the system impacting the steady rate at which parts are delivered to the line.
Contact us to learn more about our customized conveyors and how we can help your company with your next project!
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sales@giveng.com
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(519) 453 – 9008
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327 Sovereign Road
London, ON, Canada
N6M 1A6
