The task
To create a 15-metre gas cylinder transport line that semi-automatically performs cylinder marking and automatically hangs them from the horizontal conveyor line to the vertical conveyor line.
One worker instead of three
Instead of the previous 3 main roles, i.e. 1 person for tapping, 1 person for moving bottles, 1 person for hanging, the number of employees required in this area has been reduced to 1 person. Due to the labour shortage, the freed-up workforce can be used in other areas.
Built-in features
- Tilting into the track
- Semi-automatic gas cylinder marking by dot engraving
- Checking gas cylinder markings remotely on a monitor
- Handling of conveyor belt junctions, horizontal and vertical transfer bridge
- Faulty input rejection branch
- automatic positioning with a hook
Lean
From the outset, we have taken into account that the remaining operator's workload fits within the expected timeframe. We surveyed the operator's tasks at the beginning, and all of this was taken into consideration during the machine's design. The work content, movements, and distances have been coordinated.
Conclusion and results
- Cost reduction naturally, the freed-up staff became usable in other areas.
- Stable output: The employees' work has become scheduled. The bottles are despatched within a given cycle time, the previous fluctuating performance has become balanced.
- Pufferkiegyenlítő szerepe: As our queue is currently faster than the next operation, the queued bottles also act as a buffer, which has given the process further stability.
Gas cylinder conveyor line pictures
Videos
Gas cylinder conveyor line original plans, 3D model
Planning A quick video edit of the original plans. Many things have changed, and many small issues had to be resolved in the meantime, which emerged due to the different bottle shapes.
Gas cylinder handover on the bridge
Gas cylinder transfer bridge An overhead suspended conveyor line passes through our path. Care had to be taken during control to avoid collisions, and the mechanical structure had to be designed so that it could be opened and retracted.
Gas cylinder positioning – rotation: The bottle must be positioned so that it can be hung onto the other conveyor line. We used optical sensors. We also had trouble with the stemmed bottles here.
Automatic gas cylinder suspension
...and finally, hanging the gas cylinder: Instead of manual hanging, the movement of the two conveyors had to be synchronised. Large weights and forces were involved, so great attention had to be paid to damping and workplace safety. A separate system had to be used for hanging long and short gas cylinders due to height restrictions. We had a real struggle with the last 10 cm of the gas cylinder.
Gas cylinder tipping, filling
Tilting a gas cylinder onto a track: Tilting gas cylinders onto a track. Work area protected by a light curtain. When the horizontal position is reached, tilt the cylinder onto the track.
Gas cylinder tap side view, quick setup
Gas cylinder impact from the front
Gas cylinder striking quality check on monitor
Gas cylinder strike When carrying out periodic inspections of gas cylinders, it is necessary to affix markings to the neck of the cylinder to certify the inspection. After a quick adjustment by the operator, lasting approximately 10 seconds, the machine marks the cylinders using dot peening. The operator's work is assisted by rollers, quick clamps, and laser markers. The cylinder is fixed, and the marking is carried out automatically when the door closes. The operator must accept the quality of the marking. This can be done either from beside the cylinder or via a monitor from the dispatch position.
