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Researchers to Develop Solid Lubricant Coatings for Conveyor Systems

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A research and development team led by Min Zou, professor of mechanical engineering and an Arkansas Research Alliance Fellow, has received a $550,000 grant from the National Science Foundation to develop low-friction, durable, graphite-lubricant coatings for industrial conveyor systems.

Belt conveyors comprise about a quarter of the $7.65 billion global conveyor market, which has expanded significantly in recent years because of e-commerce. However, an enormous amount of energy is wasted in these systems. High sliding friction between conveyor belts and slider bed materials is responsible for more than half of the total energy losses in a flat conveyor system.

The researchers will develop novel graphite coatings that will significantly reduce energy consumption and equipment failure in conveyor systems. The research will also deepen a fundamental understanding of the novel coating technology to enable applications in other fields, which could lead to significant savings in many U.S. industries.

The technology is based on a unique, patented bonding approach, developed by Zou’s group, in which graphite coatings adhere tightly to a substrate material.

After developing and optimizing fast-coating deposition processes for conveyor materials, the researchers will build scalable coating processes for full-sized belt conveyors. They will then build a prototype for evaluating the coating performance and demonstrate the feasibility of the coatings for industrial applications.

The new project is a collaboration between university researchers and industry leaders. Zou’s team at the U of A will partner with researchers at Arkansas State University and Hytrol Conveyor Company Inc., the largest conveyor manufacturer in the U.S.

The researchers use a special machine to apply novel graphite coatings that will reduce energy consumption and equipment failure in conveyor systems.

Robert Fleming, assistant professor at Arkansas State; Ty Keller, Hytrol’s manager of product innovation; and Boyce Bonham, Hytrol’s chief engineer, will serve as co-principal investigators.

The project will support a doctoral student at the U of A, who will serve as the entrepreneurial lead, a master’s student at Arkansas State, and undergraduate students from underrepresented groups. They have benefited from site and national NSF I-Corps training and Office of Entrepreneurship and Innovation support and training, as well as mentoring by Cynthia Sides, assistant vice chancellor for research and innovation at the U of A, and Douglas Hutchings, director of the Arkansas Research Alliance Academy.

Zou’s research focuses on nanoscale materials and manufacturing. She is an international expert on surface engineering and tribology — the study of friction, wear and lubrication in the design of bearings and interacting surfaces in motion. Zou has designed, refined and tested solid lubricant coatings for various applications. The coatings are thinner, more durable and environmentally superior to petroleum-based oil lubricants.

Zou holds the Twenty-First Century Chair of Materials, Manufacturing and Integrated Systems.

Genel

Dematic automates warehouse of kitchen manufacturer Schmidt Groupe

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Dematic has automated the picking warehouse of French kitchen manufacturer Schmidt Groupe S.A.S. at its site in Lièpvre in Alsace. The automation technology provider developed a space-saving solution, featuring a multishuttle system for multiple-deep storage in nearly 6,000 locations as well as special tote conveyor technology. Within the multishuttle system, 12 shuttles control order sequencing. The conveyor system z requested items to various workstations. In this way, the Dematic solution provides complete automation of the previously manual storage and retrieval operation as well as picking goods for the entire material flow.

“The Dematic Multishuttle significantly increases speed, storage density, accuracy, and availability within the picking warehouse,” says Boris Herrmann, Process Manager at Schmidt Groupe S.A.S. “In addition, the overall system enables high throughput rates as well as error-free picking, guaranteeing us efficient and reliable order processing.” As one of the international market leaders for furniture manufacturing and distribution, Schmidt Groupe faced several intralogistics challenges. For example, managing the side panels, doors, fittings, and handles of a customized kitchen required more effective processes, so the company decided to automate the material flow at its Alsace site.

Order picking starts at the small parts workstations. There, operators put required parts into cartons using a pick-by-light system. Cartons are then transported to the subsequent stations by conveyor using special roller and belt conveyor technology that support the logistical processes. If larger items are needed for an order, the small parts carton is loaded onto a tray and stored or buffered in the Dematic Multishuttle, which provides space for 5,760 storage locations on 12 levels. Within the multishuttle system, a dozen shuttles handle automatic order sequencing as well as storage, transfer, and retrieval. The conveyor system then transports the filled totes and trays to the other workstations. A continuous scale checks the weight. When an order is complete, the sequenced totes are checked, cartons are closed, and shipping labels applied.

Dematic has also installed a WMS (Warehouse Management System) that optimally manages stocks and orders according to priority, with the most frequently requested items stored in the most accessible locations. A WinCC process visualization system developed by Siemens was also integrated into the solution for monitoring the technical processes. It enables a simple and clear information flow of all accruing data and provides a user interface. As Thomas Meyer-Jander, Director EMEA and Head of Marketing & Communications at Dematic, explains: “In this way, users have access to the current operation status and can use that data to derive optimizations for improved performance.” The Schmidt Groupe’s assessment is correspondingly positive. Herrmann sums it up, “Our throughput and delivery accuracy goals have been more than met. With Dematic, we have the right supplier – due to their intralogistics know-how and expertise, they have been valuable resource, and our relationship has been characterized by cooperation and partnership.”

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Genel

Orion’s Compact RTC Rotary Tower Automatic Wrapper Integrates with Existing Conveyance

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Orion Packaging Systems, a division of ProMach, responded to industry demands by creating a space-saving rotary automatic wrapper that easily integrates with new or existing conveyance.

Orion’s Rotary Tower Automatic (RTC) Stretch Wrapper with Conveyance is the ideal solution for easy integration with 18″ pass-height conveyors due to its compact size, affordability, and the option to expand with additional conveyance.

The RTC is fully automatic and attaches the stretch film at the cycle start, cutting it at the end. The forklift operator simply places the pallet-load on the infeed conveyor and pulls a lanyard switch while moving away to collect the next load. This design increases employee safety by removing them from proximity of the moving rotary arm.

In addition to the compact size, expandability and increased employee safety, the RTC has:

  • 20″ Insta-Thread™ Film Carriage standard with 260% pre-stretch
  • Revo-Logic technology with photo-eye sensor carriage ensuring precise application of programmed wraps and maximizing load containment and film yield
  • Separate up and down film carriage speed control and top and bottom adjustable wrap counts, customizing wrapping for each load
  • Long lasting AC motors and Variable Frequency Drive (VFD) controllers, providing low maintenance
  • Labor saving film tail clamp with cut & wipe that automatically secures film, allowing faster output by reducing per-load wrapping

Orion’s RTC Stretch Wrapper delivers performance and cost-savings to new or existing wrapping systems, providing increased production and output.

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Genel

Orion S-Carriage Wrapping Technology Saves Money While Increasing Customer Efficiency

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The patented “S” design on the newly redesigned S-Carriage InstaThread Pre-stretch Film Carriage from Orion Packaging Systems, a division of ProMach, can save up to 15% on film per load – a substantial savings to help offset the rising cost of film seen over the past year.

The S-Carriage really improves upon what many consider to be the most important component of a stretch wrapper – the carriage. The performance of the carriage and the efficiency of how it applies film to a load are two factors that determine its overall level of effectiveness. Here’s how the S-Carriage proves its worth by reducing film and saving customers money.

At heart of the design are two pre-stretched rollers. Film travels in an S pattern around the rollers, providing over 180° of film contact to reduce slippage and neckdown. The result is a consistent pre-stretch of 260% at different tensions and 1″ less neckdown. In other words, achieving this consistent level of pre-stretch means the customer can wrap faster while receiving better film yield; it reduces film acquisition costs for shippers and improves end-user sustainability through less waste.

Changing film is safer and easier with Orion’s S-Carriage’s InstaThread design. When loading a new roll of film customers don’t have to weave film through the rollers. Rather, the InstaThread design has streamlined this process by simply opening the dual lock carriage door, pulling the film right through the middle of the rollers and closing the carriage doors.

Other features and benefits of the redesigned S-Carriage InstaThread Pre-stretch Film Carriage include:

  • Dual chain drive that won’t wear and stretch like belt driven carriages
  • Dancer bar comes with multiple holes for easy adjustment of springs

The S-Carriage is designed to bring consistency to Orion’s product line. Currently, Orion has different carriages for its flex and fully automatic product lines. The goal is for the S-Carriage to become the one carriage that works best for Orion’s entire product line. It also brings a unified experience to customers in using the same carriage for all of Orion’s stretch wrapping machines. On average, the S-Carriage enables customers to increase their loads per roll of film from 135 to 154 – with rising film cost that’s a reduction in more than $100 per month. The S-Carriage allows customers to wrap faster, while reducing film and saving money.

For more information on the redesigned S-Carriage InstaThread Pre-stretch Film Carriage from Orion, visit: www.orionpackaging.com

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