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There are conveyors that just move items from A to B. And then there are conveyors that are actually part of a production process or machine; they actually directly manipulate a product as part of the production process.
Half way up the stairs, in the middle, are the assembly line conveyors. These present a partially-assembled product to the human operators, who complete one or more assembly steps, and then pass the product down the conveyor to a colleague, who undertakes other assembly tasks, and so on.
No matter how short or long your assembly line, Central Conveyors can manufacture a bespoke conveyor system for your business, including integrating it into your existing operation.
Once work has been completed in the fifth zone, the crane removes the completed engine from the jig. At this point, the jig is driven onto an elevating conveyor (inside the yellow cage), is lowered to (almost) floor level, and then driven onto an underslung conveyor which takes it back to the beginning of the line, where it is raised back up, and pushed onto zone1, and the sequence repeats.
There where extensive Zone Sensors controled by a PLC (programmable logic controler) to ensure that jigs don't attempt to collide. For example - a jig isn't driven from the elvator to zone1 until zone1 is empty and available. Similarly, an operator presses a button when they have finished their assembly work. However, their jig may NOT move.. unless the NEXT zone is empty and ready to receive it.
QFC Furniture in Grantham had a problem with injuries arising from staff lifting heavy furniture components on and off their workbenches. CCL's solution; replace the workbenches with gravity roller conveyors !
The roller conveyors where formed into lines of six. The first conveyor would have a jumble of wooden sticks, which would be nailed into a frame, and rolled onto the next conveyor in the line, where the frame had fabric nailed on, and rolled onto the third conveyor where springs where inserted.. and so on.. until a completed sofa or armchair slid off the last conveyor and into a bagging machine.
As a refinement, the conveyor featured a roller brake that froze the rollers in the centre of each unit. This gave the operator a stable platform to work on. Once finished, he or she would release the brake, and roll the item towards their right, into a 'buffer zone'. This allows them to receive their NEXT item from the left, and made the original item they where working on available to the operator on their right. In this way there was a smooth succession of items down the line, with the buffer zones smoothing over any discrepancies in operator speed.
The brakes where initially a manual handle, but this was then upgraded to a pneumatic actuator.
In certain parts of the production line the operator needed to be able to access the back (and sides) of the item. To effectuate this, we arranged for some of the gravity roller tables to be mounted on a turntable. Pressing a button released the turntable to rotate 90 degrees in either direction, at which point it would lock in place until the button is pressed again.
We have a little video snippet of the system in its early test days..
CCL offer a range of conveyors that will allow you to manufacture or build a product on the actual conveyor – not just for small assemblies, but for large and heavy products such as automobile components and vehicle production. We can guarantee that there is a conveyor which will allow you to create an assembly line that will make your production process quicker and easier. The chances are that Central Conveyors have already created an assembly line conveyor system which can be beneficial to your business.If you would like more information on these conveyor case studies, or any other CCL conveyors or conveyor systems, call us on 01509 974215 today for an informal, no obligation chat. We’re here to listen to your conveyor enquiry and help provide you with complete conveying solutions.