Moving and Precisely Positioning 1500-lb Rolls Safely and Easily

About The Company

For 75 years, United Envelope has led the way in envelope printing and manufacturing, providing unmatched quality and service nationwide. Their unwavering commitment to excellence is reflected in state-of-the-art facilities and experienced personnel catering to diverse clientele, from agencies to non-profits.

United Envelope prides itself on consistently delivering top-quality envelopes within tight timeframes, thanks to a focus on precision and efficiency. With dedicated account and production managers, they exceed customer expectations by tackling challenges with a solutions-oriented approach.

What sets United Envelope apart is their steadfast dedication to unparalleled quality, meeting the highest standards of functionality and reliability. Leveraging cutting-edge technologies, they ensure efficiency and cost-effectiveness without compromising on quality, providing clients with an exceptional value proposition.

Load Specifications

  • Load Type: Paper Rolls
  • Weight- 1,500-LBS Each
  • Diameter- 60”
  • Width- 14”

Application Analysis

Paper rolls have to be manually moved, aligned, and loaded into production machines multiple times a day.

Handling Issues

Moving the 1,500 LBS paper rolls several times a day requires a significant amount of effort and manual labor to accomplish the handling task. United Envelope needed an easier way to move and properly align their rolls into the production machines.

The Solution

ASE specified one of our air caster roll movers to easily move the client’s paper rolls. Air Caster technology allows the load to literally float on a film of compressed air which provides the highest ergonomic value in the market today. Each air caster roll mover is built to the client’s roll specifications and makes it possible to not only move all kinds of heavy rolls but also coils, reels and other round loads regardless of the size. Air caster systems require a smooth non-porous surface like trawled concrete that is sealed to operate at optimal efficiency. The air caster roll mover can be equipped with power drive systems, guide wheel assemblies, remote controls, adjustable forks all designed to increase productivity and enhance the ergonomic value. Standard unit capacities range from 500-lbs to 12,000-lbs with custom builds available for higher capacities.

Want To See How ASE Can Help You?

Send Us A Message And We Will Contact You Soon!

query form
Read More

Maneuvering 23,000 LBS Aluminum Fixtures Safely & Easily

About The Company

For decades, D-J Engineering has been a trusted name in the aerospace industry, renowned for its expertise in manufacturing large assemblies and complex aerospace parts. From legacy aircraft components, emergent technologies, or challenging development projects, their high-caliber engineering and reliable manufacturing, deliver solutions for clients worldwide.

With a focus on speed, expertise, and innovation, they stand as a strategic asset for clients needing to develop new manufacturing processes, especially for low production runs. D-J Engineerings seasoned management and collaborative teams of passionate, curious, and skilled professionals work together to tackle the toughest engineering and manufacturing challenges head-on.

Over the past 30 years, D-J Engineering has evolved from a small aerospace manufacturing company with six employees in a single building to a thriving enterprise with over 300 employees across three campuses.

Load Specifications

  • Aluminum fixture
  • Weight- 23,000-lbs each
  • Size: 141 x 288
  • Clearance to the floor: 1.875

Application Analysis and Handling Issue

Large aluminum fixtures weighing 23,000 lbs each need to be maneuvered within a limited area. This task was difficult to perform in the space that was available on standard wheel and caster assemblies, then pushed by fork truck. D-J Engineering needed a system that could slip under the beams of the fixture and be easily removed when not in use.

The Solution

ASE specified one of our air caster load module systems #TS-32-21N rated at 32,000-lb capacity. The system includes four 21 air casters load modules, four interconnect hoses with quick connect couplings and one air regulation control console. The air regulators contained in the control console ensure that the incoming air is properly distributed to each load module even if the load weight is unevenly distributed. The air caster load module system enables precise positioning, side-shifting and omni directional movement of the load. With this technology one pound of force exerted by the operator will move a 1,000-lb load.

Key Technologies

Air Casters

https://asesystems.comair-casters/load-module-rigging-systems/selection-guide/

Want To See How ASE Can Help You?

Send Us A Message And We Will Contact You Soon!

query form

Read More

Lifting and Rotating Large Plastic Rolls With Ease

About The Company

Established in 1882 in Brownsburg, IN, Weston Foods boasts a rich legacy as a pioneer in the milling industry, specializing in rice and gluten-free flours. The company was founded by a group of highly skilled individuals with extensive experience in crafting top-notch gluten-free ingredients. Guided by principles of service, quality, and value, Weston Foods has flourished over the years to emerge as one of the foremost millers of gluten-free ingredients. Positioned as a leader in allergen-free food security, the company has consistently prioritized delivering excellence to its customers.

The company operates 16 facilities spread across 13 states, producing a diverse range of fresh and frozen baked goods. From doughnuts, cakes, and pies to cupcakes, cookies, crackers, cones, ice cream novelty products, and artisan bread, Weston Foods’ extensive product line graces the shelves of North American grocery retailers, supermarket chains, and various food service outlets.

Weston Foods commitment to quality extends beyond mere products; it’s a dedication to providing allergen-free food solutions that meet the highest standards. With a focus on freshness, innovation, and customer satisfaction, they continue to lead the way in delivering delicious, safe, and top-quality baked goods to households and businesses across North America.

Load Specifications

  • Load Type: Plastic Rolls
  • Weight: 145 lbs
  • Size: Diameter – 18” Width- 22” ID- 3”

Application Analysis

Lifting plastic roll weighing 145-lb from a pallet while roll is standing vertical. Once the roll is lifted it needs to be rotated 90-degrees and placed on a dolly for transport to the production area.

Key Points:

  • Pick up point- from a pallet, roll in vertical orientation standing 48” high
  • Rotate – 90°
  • Place point- horizontal onto a dolly at 5”
  • Area of coverage- 6-8’
  • Cycle time- 5/hr.

Handling Issues

The handling procedure was being completed by hand manually which was causing safety issues. Additionally, heavier rolls would require 2 workers to accomplish the task, decreasing productivity.

The Solution

When considering the load weight and cycle time, ASE specified an ERH-200 portable, semi-powered floor-based Roll handler. The unit is designed to be manually pushed and included powered lift & manual turn functions. This light-weight unit is easy to move and grips the roll by the core, by way of an expanding mandrel with fail-safe spring force grippers. Once the expanding mandrel is inserted into the roll, the operator is then able to lift and turn it °90 so the roll can be placed eye to the horizon onto a portable dolly (designed for roll handling) which we also specified for the size and weight of their rolls. We included a handle bar and floor locks for functionality & safety. Weston Foods was able to eliminate the use of multiple workers by implementing the ERH-200 roll handling device which allowed them to achieve their goals and add ergonomics and safety to their roll handling process.

Key Technologies

Some of the standard features on the ERH-200 include:

• Quiet 2-Speed Drive

• Lightweight Construction

• Micro-movement Control

• Quick-Change Battery Box

• Quick-Change Tooling Mount

• Battery-Charge Meter

• Manual Grip Tooling.

Want To See How ASE Can Help You?

Send Us A Message And We Will Reach Out To You Soon!

query form
Read More

Repetitive Lifting of Boxed Batteries for Palletizing

About The Company

Eaton Corporation, headquartered in Fontana, CA, stands as a prominent leader in power management technologies and energy-efficient solutions, operating across more than 175 countries.. Their primary focus is to empower customers worldwide by effectively managing electrical, hydraulic, and mechanical power in a reliable, efficient, safe, and sustainable manner.

In a world reliant on critical infrastructure and technology, Eaton plays a pivotal role in ensuring the smooth operation of essential services such as planes, hospitals, factories, data centers, vehicles, and the electrical grid. Their mission is to tackle the toughest power management challenges, contributing to a more reliable, efficient, safe, and sustainable future for everyone.

Their comprehensive range of industry-leading electrical, aerospace, hydraulic, and vehicle products and services enables them to assist customers in overcoming their most significant power management hurdles.

Load Specifications

  • Batteries in corrugated boxes
  • Weight: Up to 170-lbs.
  • Size: (LWH) 37.5” X 23.5” X 20”

Application Analysis

Key Points

  • Pick up point: From a pallet, stacked to 42”
  • Travel: 12’-14’
  • Rotation: None
  • Ceiling Height: 30’ clear
  • Cycle Time: 24 per hour

Handling Issues

The job was being performed manually using two workers causing work related fatigue and back strain issues, especially when reaching down to pick up boxes on the lower rows of the pallets. The customer’s goal was to double the number of boxes currently being handled and to reduce the number of workers on this task to 1 so the other could be reassigned to another task in the facility.

The Solution

ASE Systems recommended a lift assist solution consisting of a Workstation Jib Crane which delivers a high ergonomic value when moving loads from point A to point B in combination with a Vacuum Tube Lifter designed to grip and lift the corrugated boxes. The Jib crane allowed for the coverage needed to access all of the pallets in the operating area. The vacuum tube lifter consists of a high-volume vacuum pump which typically sits near the base of the jib crane, a vacuum lift tube and the control head w/ vacuum cup assembly. Vacuum Tube (VT systems) are ideally suited for lifting corrugated boxes or any materials that are semi-porous or porous. VT systems are well suited for high-speed pick and place applications such as palletizing, sorting and production operations. Eaton was able to increase their productivity by not only doubling their lifts per hour but they were also able to accomplish this handling task with only one operator. In addition, the vacuum tube system eliminated the possibility of repetitive worker injuries associated with the handling task.

Want To See How ASE Can Help You?

Send Us A Message And We Wil Reach Out To You Soon!

query form
Read More

Repetitive lifting of fiberglass enclosures out of a molding machine

About The Company

Vynckier Enclosure Systems, Inc., headquartered in Houston, TX, stands as a premier provider of electronic enclosures, renowned for delivering a comprehensive range of high-quality products coupled with exceptional service capabilities. Specializing in the design, manufacturing, and distribution of electronic enclosures, the company caters to diverse industries, including telecommunications, industrial automation, renewable energy, and more.

The product portfolio of Vynckier Enclosure Systems encompasses electronic enclosures, fiberglass enclosures, and NEMA enclosures. Vynckier’s enclosures offer protection against harsh environmental conditions and customized features like thermal management or cutouts.

Vynckier enclosures are designed to safeguard electrical components from water, dust, wind, chemicals, and other environmental factors. Available in a wide range of sizes and configurations, from handheld pushbutton enclosures to large free-standing cabinets. The non-metallic enclosure solutions provide high-performing protection in challenging environments such as petroleum, chemical processing, water and wastewater treatment, and more.

Load Specifications

  • Load Type: Fiberglass Enclosures
  • Weight: 20 to 30-lbs
  • Size: 18” x 16” x 10.5” to 24” x 36” x 11” to 24” x 24” x 11”

Application Analysis

The fiberglass enclosures are formed in an hydraulic press and then removed by the operator from inside the molding machine at approximately 38” above floor level. Operator has to travel up to 10’ to place the enclosure on a table for deburring and then on to a pallet stacked up to 72” above floor level. A tilt range of 90° is needed in a workspace with a 22’ ceiling height and air availability of 120-psi. This cycle is repeated approximately every 3 minutes.

Key Points:

  • Pick up point- inside of molding machine at approximately 38” above floor level
  • Travel- up to 10’
  • Place point- table for deburring then to pallet stacked up to 72” above floor level.
  • Tilt- 90°
  • Ceiling height- 22’
  • Cycle time- 1 every 3 minutes
  • Air available- 120-psi in operating area

Handling Issues

Operator has to reach into the forming cell and unstick the enclosure from the mold and lift it out of the press. All the while the operator’s arms are extended out and his back is bent 60 to 80 degrees. Repeating this action every three minutes was causing shoulder rotator cuff & lower back injuries.

The Solution

Based on the limited floor space around the press ASE specified a Mirus industrial manipulator with vacuum grip tooling that was underhung from a pair of aluminum overhead rails. The Mirus manipulator includes a power drive system for easier traversing back & forth along the dual rail system. The tooling was also able to rotate the load 90° for inspection and deburring activities. ideally suited for reaching into enclosed machines and servicing all types of low headroom handling applications. The overhead rails were fastened to support beams that were attached directly to the top of the press. The manipulator is attached to an offset load platform which includes a power drive system for easier traversing back & forth along which includes a power drive system for easier traversing back & forth along the dual rail system. The tooling was also able to rotate the load 90° for inspection and deburring activities

Have Question/Query? Fill this Form to send us a message, we will get back to you shortly!

query form
Read More