Weld Cell Conveyor System: A Productivity Boost
When a leading automotive supplier of suspension systems sought to boost throughput at their robotic weld cell, they chose LEWCO to develop the best solution. The primary challenge was to accumulate and convey steel rails and fabricated sub-assemblies, which get welded to the rails. The rails measured approximately 8” wide, 8” high, and 8.5ft. long, with a weight of up to 115 lbs. The fabricated sub-assemblies varied in size and weighed up to 33 lbs.
Engineering
LEWCO Applications Engineer, Tom Cook, collaborated closely with the customer to understand their specific requirements and determine the best solution. The outcome was a two-level conveyor system. The top level featured a 2-strand drag chain conveyor (model MSCC) with chains positioned on 49” centers and an overall conveyor length of 23.5ft. Two zones on the top-level enabled product accumulation. The bottom level included a combination of gravity conveyor (model 1916), chain-driven roller conveyor (model CDLR19), additional drag chain conveyors, and a pop-up chain transfer (model T02C19). Additionally, a 9-foot section of CDLR was mounted to a scissor lift table on the bottom level.
Controls
LEWCO designed and built the system controls in-house, incorporating both a main control panel and two remote operator pushbutton stations. In addition, worker safety and ergonomics were prioritized in the design, with a Keyence safety laser scanner preventing the upper chain conveyor from starting if an operator is detected in the unload area.
Customer Satisfaction
Before shipping, the customer came to LEWCO for a Factory Acceptance Test. After implementing a few minor improvements, the system was disassembled and safely packaged for delivery. Following installation, the customer reported positive feedback, stating, “Operators are very happy with the system…” and “I hope we will be purchasing more systems from [LEWCO] in the future.”
We’d love the opportunity to turn your material handling challenges into a LEWCO engineering triumph! Contact us today to get started.
