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Counterweight Confusion

This case study was presented by Baltimore Key Account Manager Lorne Rickert.

Challenge

A counterweight was attached to a turntable before the Hydraulic Motor which “keys” the turntable to the frame, located underneath.  The counterweight caused the turntable to rotate until it was so far off balance that the Turntable with Counterweight fell off the Frame, coming to a rest about 2’ from a Team Member!  This posed a significant safety hazard, as well as, assembly frustration to the onsite engineering team.

Air Power Solution

Air Power utilized an Ingersoll Rand QX Power Tool and Sturtevant Richmont Digital Wrench to positively confirm that all of the tightening’s have been completed before the Counterweight can be installed.

Results

Air Power’s Engineering Team, Michael John and Jesse Bryant, designed a “Lifting Sling Lock” device that will not release the lifting sling for the counterweight until the Tightening’s are complete – a Poke Yoke control to insure safety.  This “Lifting Sling Lock” is utilized in conjunction with the I/O output of the Ingersoll Rand QX and the STR Digital Wrench, thus eliminating the safety hazard of a dropped counterweight.  The Lifting Sling Lock will only unlock once all tightening have been positively confirmed, removing a safety hazard and improving overall production quality.

Counterweight Confusion

 

 

Ingersoll Rand – Makes it Easy

One of the main causes of injury in a manufacturing facility is due to lifting heavy objects. In this case study, Air Power helps a customer eliminate the risk of injury with an Ingersoll Rand custom monorail lifting system.

 

Challenge

 

A local machinery manufacturer has had issues finding a suitable solution to include as part of their OEM machinery builds. They had a history of using electrical hoists and I beam trolleys which have not been well received by their end-users. The previous offerings by others were hard to maneuver and difficult to position the load for final placement.

 

Air Power Solution

 

Air Power proposed an Ingersoll Rand Zimmerman rail system, which are easily adaptable, cost-effective and easy to use. We designed a system for them that included 4 individual monorails with rigid mount hanger kits to increase clearance and ZAW air balancers with pendant controls for load lifting and proper part positioning.  The solution allows each of the 4 sides of their machine to be covered from end to end.

 

Results

 

The proposed solution provided the necessary benefits including:

  1. The ZRA1 monorails utilized minimum push/pull forces, allowing ergonomics on the operator and ease of use.
  2. For future integrations, the individual monorails provide an easily adaptable solution, should the OEM design change over time.
  3. The aluminum profile ZRA1 provided a reduction in solution weight.
  4. The ZAW air balancers allow the end-user to position the load close to its final destination then use the “float” of the balancer for final (and exact) placement of the part; further enhancing the user experience.

Ergonomics Meets Dispense

 

Assembly solutions often require an array of different equipment to get the desired result. In this case study, Air Power was able to design a fully ergonomic dispense solution for this customer.

 

Customer

 

Manufacturer of HVAC Equipment

 

Challenge

 

This customer was planning an expansion that included adding 2 additional assembly lines for panel foaming. They wanted to have a more robust Gantry System, contrary to solutions discussed previously with other distributors. Air Power’s ability to integrate the Material Handling portion of this project along with the Dispense/Fluid Management system allowed us to be the sole solution provider the customer was able to find through the initial quoting phase. After digging into the project, the customer realized our potential and requested the Mix, Meter, and Dispense System to supply two separate assembly lines, thus adding more complexity to both portions of the MOVE project. Factors like pressure loss, high-pressure piping, distance, ergonomics were key when bringing this project from theory to paper to real life.

 

Air Power Solution

Our team was able to design a custom solution that utilizes a Unified Dual Cantilever Overhead Rail System, paired with a Hennecke High-Pressure Metering Machine designed to dispense the full range of rigid foams and flexible foams. This dispense system controls 2 mix heads to fill panels with a Polyurethane Foam on 2 assembly lines. This system pumps the foam through high-pressure hoses mounted overhead with an Ingersoll Rand Suspension Balancer and Z-Servo Balance Control.

 

Ergonomics Meet Dispense

Results

This system has the ability to have cross-lateral movement spanning the entire workstation, pump foam throughout the 1000+ feet of piping/hoses, ergonomically sufficient enough to navigate the 100lbs mix heads North, South, East, West with minimal effort, and produce foam with the touch of a button. We were able to deliver all of the key factors with a combination of our vendor support, customer communication/guidance, and our internal resources to deliver a unique one-of-a-kind turnkey solution!

 

Ergonomics

 

Ergonomics_HVAC_ASSEMBLY

Ergonmics Dispense Assembly Solution

 

New Brand Offerings

 

With the acquisition of Zenmar Power Tool & Hoist Systems, Air Power Manufacturing Solutions has expanded the brands that we offer our customers. We are now an authorized distributor for 6 new product brands, including Ajax Tools, Enerpac, Gorbel, Harrington Hoists, Michigan Pneumatic, and Southworth Products. We are excited to offer these products throughout our entire Southeastern territory.

 

Ajax Tools

 

ajax tools incRanking among America’s finest quality manufacturers of industrial and construction tools, Ajax is a highly regarded brand name for forged specialty tools and accessories. Ajax is ISO 9001 certified and all products are engineered to meet or exceed OEM specifications.

Founded in 1946, Ajax Tools built on its expertise in heat-treating, forging, and machining; earning an image of uncompromising dedication to quality. Ajax is a full-service American manufacturer, and offers a modern manufacturing facility and advanced production equipment, to support our quality products and our focus on customer’s needs.

Ajax Tools is your Global Resource for:

  • Chisels (Pneumatic, Electric, and Hydraulic)
  • Pry Bars (Lining bars, Connecting bars, Pinch bars)
  • Wedges (Stock, Flange, Banana)
  • Drift Pins (Broad Head pins, Barrel Drift pins, Pull pins)
  • Drill Steel (Speed Bits, Drill Rod, Rock Bits)
  • Retainers (Chipping Hammer, Rivet Buster)

 


Enerpac

enerpac 1Enerpac is a global leader in the engineering and manufacturing of high-pressure hydraulic tools, controlled force products, and solutions for precise positioning of heavy loads that help customers safely and reliably tackle some of the toughest jobs in the most demanding environments without compromise.

For mission-critical applications, Enerpac provides tools and solutions that make your work safer and easier to perform.

 

 

 


Gorbel

 

GorbelGorbel offers a comprehensive line of overhead material handling, crane technology, ergonomic lifting products, and fall prevention systems. You can count on Gorbel to be on the cutting edge of manufacturing; constantly seeking out new ways to innovate and elevate their products and processes.

Gorbel’s mission is simple: They improve people’s lives. That mission guides everything they do, from the products and services they provide to their outside customers to the tools they create for their sales force and the work environment they foster for their employees.

They have a comprehensive line of Crane Technology products, Ergonomic Lifting products and, a line of Tether Track Fall Arrest Safety Systems.

 

 


 

Harrington Hoists

harrington hoists 1Located in Manheim, PA, Elizabethtown, PA, South Holland, IL, and Corona, CA, Harrington Hoists, Inc. is a leading manufacturer of revolutionary manual, electric and air chain hoists as well as wire rope hoists, crane products, and below-the-hook devices. Known in the industry for world-class products, a driven sales focus, and outstanding customer services that are unmatched in today’s market, Harrington is committed to doing whatever it takes to satisfy customer needs.

 

 

 

 


 

Michigan Pneumatic

MichiganMichigan Pneumatic Tool is a full-service air tool company celebrating 75 years as a leader in the design, distribution, manufacture, repair and rebuilding of industrial air tools. At MPT we service construction, industrial, demolition, bolting, and foundry tools. Michigan Pneumatic Tool also has an unrivaled parts inventory that includes brand name, hard to find, obsolete, and discontinued parts. We have the parts you need when you need them.

 

 

 

 


 

Southworth Products

southworth liftSouthworth Products Corp is a world leader in the manufacture and distribution of vertical lifting and positioning products including lift tables, container tilters, pallet level loaders, manual lifter transporters, and many more. The company headquarters are in Falmouth, Maine with manufacturing located in Manila, Arkansas.

They are a supplier of innovative products designed to improve worker productivity and safety through the practical application of ergonomics in work positioning applications; including scissor lift tables (hydraulic, pneumatic, mechanical), portable lift tables, low height lift tables, container/basket tilters, pallet loaders, turntables, roll and coil cars. These products are sold under some of the industry’s most recognized brand names; including Dandy Lift & Leveler, PalletPal, EZ Reach, and Floor Height Lifts.

 

 

 

Ingersoll Rand Ergonomics Reduce Injury Risks

 

One of the most common workplace injuries reported is muscle strain due to repetitive motion.  Manufacturers are seeking ergonomic material handling solutions to reduce the risk of injury for operators. In this case study, Air Power proposed a solution that successfully eliminated the risk of injury for these robotic machining cell operators.

Challenge

 

This customer had dealt with various injuries due to the operators handling parts of various sizes/weights while loading and unloading parts onto automated infeed/outfeed conveyors on robot machining cells. Hand and finger injuries were commonly reported, as well as various back injuries. The customer required a solution that was safe and easy for operators to use. The solution needed to be located out of the way of forklift traffic and out of the work area of the cell so as not to impede on the operator’s workspace. They needed a device with the ability to grasp multiple sized parts without hassle. This solution also required a system that was low maintenance, durable, with low compressed air usage.

Air Power Solution

 

Ergonomics

Air Power proposed an Ingersoll Rand column mounted with a 10ft reach and articulating arm. This system mounts out of the work cell yet reaches into the work cell to reach the work area for loading and unloading. It includes an integrated 500lb air balancer for lifting/lowering with the ability to adjust both the lifting and lowering speed to dial in the exact application. This device features low rotational inertia for ease of use and improved ergonomics for the operator, low maintenance, low CFM usage per cycle.

This Custom Air Power/Ingersoll Rand Manipulator is made of heavy steel for durability with pistol grip controls and a dummy handle for ease of use and maneuverability. It includes single-hand controls for lifting/lowering of the device & clamping/unclamping of parts, safety interlock that is load sensing to prevent parts from being dropped once elevated off the work surface, V-shaped movable jaws to allow clamping of various sized parts, padded jaws to prevent damage to machined surfaces, and requires little to no maintenance.

 

 

 

ErgonomicsErgonomics

 

Schmalz Makes Lifting Easy

Manufacturing commonly requires operators to lift and move heavy materials, which can lead to injury and fatigue. This material handling solution makes lifting a breeze.

Customer

A leading US Electronics Recycling Company.

 

Challenge

This customer wanted to reduce the possibility of injuries from the amount of lifting their operators were exposed to. This problem was leading to higher turnover in specific areas due to common complaints of lifting parts that were upwards of 120 lbs! Thus reducing the rate of production and declining morale throughout the production floor due to manual lifting.

 

Air Power Solution

The Schmalz JumboFlex 50 was able to lift the customers’ desired weights of 40-120 lbs and capturing their desired throughput goal of 60-70%. This piece of equipment utilizes a vacuum suction pump that relieves the weight of the piece you’re picking up and relieving the amount of strain on the operator’s backs. Pairing the JumboFlex with Schmalz’ Column Mounted Jib Crane, we are able to reach out 10ft and have 270 degrees of full motion!

 

Results

This material handling solution completely eliminated the customers’ problem. The Schmalz JumboFlex 50 eliminated the risk of injury for operators. This allows them to work faster, increases the rate of production, and reduces fatigue from constantly lifting heavy materials. The Section Manager stated, ” It’s not about the speed we’re able to go at, what this piece of equipment has done for us is, improve employee morale and reduce turnover now that they don’t have to lift heavy stuff all day long.”