01
Application context
At the core of this system were ERT250 conveyors. Each individual ERT250 conveyor for this application is 32 inches wide and 84 inches long, and includes two gear motors to support the 300 lb load. The only non-standard feature of these conveyors were the stands, which needed to support a lower return conveyor below the ERT. The ERT250 conveyors were connected along the line for a total of 125 feet.
While the ERT250 conveyors remained fairly standard, the pallets were entirely customized to fit the application. These pallets were engineered to fit 20 different part sizes, including some part sizes that are wider than the size of the conveyor.
02
Design considerations
The system begins with the large appliance part loaded on to a custom pallet which is then scissor lifted on to the main ERT250 line. The pallet then enters an automated assembly area which is off the main line. Within this area is a three-way Lift and Transfer module that is custom engineered to be low profile so it does not interfere with the lower return conveyor. Once the part has completed the automated assembly Lift and Transfer station, it then moves back to the main line.
Once the pallet returns to the main line it meets a series of Lift and Manual Rotate modules, and In-Conveyor Lift manual assembly stations. Both of these modules were engineered with the goal of improving operator ergonomics. The Lift and Manual stations pneumatically lift the pallets, then operators can turn the pallet 360 degrees for better access to the part. This serves as a cost-effective method for easier assembly. The In-Conveyor Lift is directly integrated with the ERT250 conveyor and is able to lift the pallet 18 inches higher for improved ergonomics during assembly. Additionally, the In-Conveyor Lift was surrounded with a covering for improved operator safety.