Thursday, January 18, 2007
New innovations of MHEs - Carts for a Forklift-free environment
Carts can be used to replace forklifts when using with conveyors.
Side-by-side conveyors offer many desirable options in line-feed presentation. Size, shape and function depend on the part, the container, the operation, and the operator.The container or rack that the part is delivered in is usually loaded onto the conveyor with a forktruck. As assembly plants work to restrict the use of forklifts, delivery is often with transfer conveyor carts (roll-on/roll-off) or AGVs. With
the proper rolling surface under the container or rack, all of these options are easily achieved.Part presentation to the operator is adjusted to the
ergonomic window using lift tables, rotate tables, and tilt tables. Draw bridges can be used to give the necessary clearance for the circumference of the rotating corners. Topper?s draw bridge is powered up but gravity down as a safety feature, should anything get in the travel area.Cross transfers vary with the type of container or rack. They can vary from skate rollers to Super-Rail to ball transfer depending on the rolling surface. Pneumatic cross transfers with skate rollers is the most common.
The size of the side-by-side conveyor depends on the size of the container or rack, the type of part presentation, the number of parts needed in the staging area, and the number of parts per container or rack.
Transfer conveyor carts were designed to eliminate the use of the forktruck. In Forktruck-Free environments the Transfer Conveyor Cart with a container is tugged to line side. There the container is usually manually pushed onto a roller container. Then by power or gravity the container is moved into position.The transfer conveyor cart typically holds one to two 
containers that most have a smooth bottom for easy rolling. The space between the cart and the conveyor will determine the ease of the transfer. When positioning the cart by hand a caster system with low push/pull forces is highly recommended and is 
often necessary to stay with ergonomic limits.
containers that most have a smooth bottom for easy rolling. The space between the cart and the conveyor will determine the ease of the transfer. When positioning the cart by hand a caster system with low push/pull forces is highly recommended and is 
often necessary to stay with ergonomic limits.When the cart is tugged to the unload position and space is determine by a straight entry to the area and the accuracy of the driver. A side shift is designed on its Transfer Conveyor Cart which allows a 6-inch movement in either direction to reduce the space between the cart and conveyor. This is accomplished by a minimum number of strokes on a foot pump incorporated into the cart. For Forktruck-Free environments where the container weight is over one ton, this is one of the best options available.
Cradle carts eliminates the need for forktrucks in the assembly area as well as presents the material in an ergonomically correct position. There is also a major space savings at the assembly line which is one of the most valuable pieces of real estate in the factory. By inverting the material vertically and nesting the carts inside one another, the space requirement is much less than the material lying on a pallet or in a container.
Rotation carts are designed to keep the commodity within ergonomic limits for both reach and weight (leverage). By rotating the container or rack the distance of reach can be cut at least in half. This is very important with heavy parts in large containers.
Rotation is usually controlled with detents which are spring-loaded pins that are depressed with a foot pedal. Normally the detents are
located at every 90 or 180 degrees. The rotation is important to prevent any movement during unloading, loading, or moving to or from a location.
The turning mechanism can vary greatly in ease of operation. A precision thrust bearing that was designed for the turret on a crane which
has a very high cantilever load rating. Although a rotation cart will never have this kind of load, the bearing is rated at 188,000 pounds thrust and 24,000 pounds cantilevered at 24 inches. The cantilevered rating is important when the rack or container is half unloaded and the weight is all on one side. More economically priced bearings are available but, of course, there would be a loss in ease of operation.
The E-Cart is the answer to a completely fork-truck-free environment. It is a flexible system that lends itself to other fork-truck environments as well.
The E-Cart holds two dollies for tugging purposes. However, the E-Cart actually lifts the dollies off the ground which makes many options and configurations available. These options include the types of casters, the weight capacity of the dolly, and roll-on/roll-off capabilities.
The E-Cart will always be tugged rather than manually moved so the casters can be a soft, pliable wheels that will be quiet, will shed debris, and will not skid around corners. The dollies will never be tugged so they can have hard wheels that are easy to push and maneuver. The dollies can be 4-wheel or 6-wheel configurations and the E-Cart can be 4-wheel standard or quad-steer designs.
Since the dollies will never be tugged there is no need for tow bars or rear couplers which means they will fit over lift, tilt, and/or turn tables easier and the fixtures will not be in the way for operator part presentation or packing in semi-trailers for transport. The E-Cart will always be tugged so there is no hitching or unhitching which will also help with ergonomic issues of trying to align heavy dollies.
Dollies are lifted hydraulically approximately one inch in the E-Cart with a minimal number of foot pumps. They are then lowered by simply turn a relief valve.
This is the animation video of how the ecart is used:
Cradle carts eliminates the need for forktrucks in the assembly area as well as presents the material in an ergonomically correct position. There is also a major space savings at the assembly line which is one of the most valuable pieces of real estate in the factory. By inverting the material vertically and nesting the carts inside one another, the space requirement is much less than the material lying on a pallet or in a container.
Tilt carts are used extensively in the industry because of the unique features that set them apart from anything else available. The closed-loop hydraulic dampening cylinder which is adjustable and absorbs the energy of the load as it tilts. This provides for a safe, controlled, tilt movement in an full-to-empty application. (For an empty-to-full application, please reference our pump-up tilt cart.)
Tilt carts are available in 15-, 30-, 45, and 60-degree tilts or as an adjustable tilt that can stop at any angle by merely releasing the squeeze handle. Options are also available for the type of caster, the type of floor lock, the type of hitch (if tugged), and the working height of the tilted container.
Each cart is built to order and is custom tailored to fit the specific need.
Tilt carts are available in 15-, 30-, 45, and 60-degree tilts or as an adjustable tilt that can stop at any angle by merely releasing the squeeze handle. Options are also available for the type of caster, the type of floor lock, the type of hitch (if tugged), and the working height of the tilted container.Each cart is built to order and is custom tailored to fit the specific need.
Rotation carts are designed to keep the commodity within ergonomic limits for both reach and weight (leverage). By rotating the container or rack the distance of reach can be cut at least in half. This is very important with heavy parts in large containers.Rotation is usually controlled with detents which are spring-loaded pins that are depressed with a foot pedal. Normally the detents are
located at every 90 or 180 degrees. The rotation is important to prevent any movement during unloading, loading, or moving to or from a location.The turning mechanism can vary greatly in ease of operation. A precision thrust bearing that was designed for the turret on a crane which
has a very high cantilever load rating. Although a rotation cart will never have this kind of load, the bearing is rated at 188,000 pounds thrust and 24,000 pounds cantilevered at 24 inches. The cantilevered rating is important when the rack or container is half unloaded and the weight is all on one side. More economically priced bearings are available but, of course, there would be a loss in ease of operation.
The E-Cart is the answer to a completely fork-truck-free environment. It is a flexible system that lends itself to other fork-truck environments as well.The E-Cart holds two dollies for tugging purposes. However, the E-Cart actually lifts the dollies off the ground which makes many options and configurations available. These options include the types of casters, the weight capacity of the dolly, and roll-on/roll-off capabilities.
The E-Cart will always be tugged rather than manually moved so the casters can be a soft, pliable wheels that will be quiet, will shed debris, and will not skid around corners. The dollies will never be tugged so they can have hard wheels that are easy to push and maneuver. The dollies can be 4-wheel or 6-wheel configurations and the E-Cart can be 4-wheel standard or quad-steer designs.
Since the dollies will never be tugged there is no need for tow bars or rear couplers which means they will fit over lift, tilt, and/or turn tables easier and the fixtures will not be in the way for operator part presentation or packing in semi-trailers for transport. The E-Cart will always be tugged so there is no hitching or unhitching which will also help with ergonomic issues of trying to align heavy dollies.
Dollies are lifted hydraulically approximately one inch in the E-Cart with a minimal number of foot pumps. They are then lowered by simply turn a relief valve.
This is the animation video of how the ecart is used:
