Our manipulators and turntable were the perfect answer to their install solution, needed to improve worker safety and productivity in the workplace.

Read more about this unique, workspace solution at the following link:

https://www.linkedin.com/feed/update/urn:li:activity:6911721679912099840/

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The video below shows a 2,500-lb capacity manipulator system handling diesel engines from the production conveyor to the shipping dunnage. We worked closely with our dealer/partner who supplied the runway system and provided the end user with the ideal turn-key installation.

Other manipulator manufacturers limit the maximum capacity they will work with – some as low as 300 pounds. Cynergy Egronomics will design manipulators to meet any capacity/reach requirement needed.

Check out a video of the custom Diesel Engine Transfer Manipulator in action.

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Check out our latest force sensing handle control tools:

Pallets – Rigid Mast Manipulator

Bar Handling Vacuum Lifter

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Metal service centers and fabricators utilize gas, plasma and water jet cutting tables to create various size plates weighing up to several hundred pounds. Operators remove these plates by hand or use an overhead bridge crane when the weights are heavy. This is a slow, labor intensive process that exposes operators to significant risk of stress/strain injuries.

Solution

A high speed servo drive, PLC controlled lifter incorporated with magnet based, pneumatically controlled end tooling is utilized to quickly and safely “sweep” the table – allowing the operators to lift and stack plates effortlessly. The tooling is mounted to an extended shaft providing waist-high control (shown) or from an extended arm for tableside operation. The magnet geometry is field-adjustable in order to accommodate various plate geometries; the system can be used on parts weighing over 500 lbs.

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Companies that handle large heavy rolls need a quick, safe way to lift, rotate and place the rolls into machines or onto pallets. Often, the rolls are stacked tightly so access with on OD gripper is not available and often, the tooling needs to “reach-in” and under obstructions to access the rolls.

Solution

Cynergy Ergonomics provides roll handling systems designed to pick the roll via the core in either the horizontal or vertical orientation and rotate 90 degrees. With the telescopic mast, the operator can travel over other palletized rolls or other obstructions. The cantilevered tooling arm design allows the roll to be pulled from inside or from under machinery obstructions. And the all-electric system keeps the power requirement economical, simple and gives the operators precise positioning control as well as safety holding features in the event of power loss.

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Manufacturer of refrigeration units utilizes a wood shop work cell to manufacture the custom pallets required for their specific product. A new model of refrigeration unit required pallets that were over 7 ft. long, weighing in excess of 100 lbs. – they had no way of moving and stacking the pallet without introducing additional operators.

Solution

A vacuum lifter was installed into the work cell with adjustable cup end-tooling. This system provides for quick adjustment of cup spacing, allowing the operator to lift and stack the full range of pallets that are manufactured. Through a post-installation study, the customer found that productivity increased, work-related injury incidents decreased while improving overall safety.

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Illinois based heavy earth moving machinery manufacturer utilizes welded fabrications of various shapes, sizes and weights in their equipment. After the welding process, these parts require stress relief. The stress relief oven has shelves located on a carousel; the parts (which can weigh in excess of 250 lbs.) require loading on the shelves, reaching into the oven by 3 ft. They needed a way to perform this process quickly and safely.

Solution

Cynergy designed a free standing work cell crane system utilizing a rigid mast manipulator with gripper end tooling designed to pitch 90°. The gripper is offset from the mast so as to allow the operator to reach into the oven while standing in front of the door, outside the oven. This system is all-electric, eliminating the various problems associated with pneumatic manipulator systems.

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Operators were loading chassis cross frame members manually into robotic weld fixtures. The 35 pound – 45 pound cross frames were lifted from the dunnage, carried to the weld fixture and set into position (requiring the operators to lean over and position the load in front of them). This work cell was a chronic source of back strains and shoulder related injuries.

Solution

A high speed servo drive, PLC controlled lifter incorporated with magnet-based, pneumatically controlled end tooling was installed into the work cell. The design enables the operators to pick from all layers of all dunnage racks and set into the weld fixture without bending, reaching or lifting the load. After initial training, tact times were maintained. Additionally, the system is designed to handle multiple cross frames simultaneously when new dunnage designs are completed.

The post Cross Frame Handling Chassis Assembly appeared first on Cynergy Ergonomics.

Due to the design of blister packaging machines, operators at a pharmaceutical manufacturer were required to hand-scoop caplets from drums while standing on an elevated platform. This required repeated trips onto the platform during the packaging process and ultimately lead to operator injuries from handling the drums and scooping the caplets from an awkward, elevated position.

Solution

Mobile, battery operated drum handling devices were provided designed to grasp individual drums, raise above hopper height and rotate, dispensing caplets as required into the individual hoppers. These operations are performed by the operator while standing on the ground; this system also facilitates transportation of the drums in/out of the clean room environments. The units at this facility are lifting 400# drums to a pour height of 10 feet.

The post Pharmaceutical Drum Dispensing, Lifting, Handling appeared first on Cynergy Ergonomics.

An international controls and drive manufacturer assembles large control panels at their Texas facility. These panels can exceed eight feet in height and weigh over 1,000 lbs. Assembly of the back plates and doors requires lifting from the horizontal orientation, pitching to vertical and maneuvering into position. These functions were performed by hand or with the assistance of an overhead crane and had a long history of operator injury. Additionally, there was a high incidence of product damage by attempting complex moves with the conventional overhead crane system. A single solution was sought to alleviate both areas of concern.

Solution

Cynergy designed a lightweight, vacuum-based end tool coupled with a servo-drive lifter to lift and manipulate the various components. The servo-drive lifter provides high-speed maneuvering when desired as well as very slow, precise speed control when needed. In addition, “float mode” zero-gravity control was added to allow the operator to align the large, awkward load into position.

In addition to addressing the injury and product damage issues, the new system provided for an additional benefit by allowing the customer to reduce their manpower requirements. Job descriptions requiring 2-3 operators were rewritten for one operator offering substantial savings. Return on investment occurred within a short 5-months. The below video shows the system being used to lift, pitch and place one of the large control enclosure doors onto the cabinet.

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