Transport and alignment of rails for vehicle seats
Task
To convey steel rails and align them to millimetre precision
An automotive supplier manufactures steel rails for the adjustment of vehicle seats. The degree of automation in the production processes is high. Automatic conveyor systems that transport the rails from one processing step to the next – from the punching to welding, for instance – are therefore important. The manufacturer sought a solution for this step that would be able to fulfil several requirements: the system should eject faulty items and convey the remaining rails gently, while simultaneously aligning them with millimetre precision for the next process, the automated welding.
The automotive manufacturer discovered that the experts at mk offered the solution they were looking for. The mk team visited the production facility, analysed the specific conditions and developed an individualised conveyor solution within a short period of time.
The solution from mk
Customised roller conveyor with positioning function
The mk solution consists of several components: an accumulating roller chain conveyor SRF-P 2045 is responsible for transporting the rails from the punching machine. The contact between the rollers and the rails is designed in such a way that only exceptionally low frictional forces are effective, and no back pressure is created. This means that the products aren’t damaged when they reach the retainer at the end of the conveying path and come to a standstill. An earth terminal also provides protection against electrostatic charging.
In the next step, an articulated arm robot grabs the rails, turns them in the air and places them on a second conveyor system: a tangential chain roller conveyor RBT-P 2255, which mk designed as a specialist product for this task. Its special feature: an additional roller made from polyoxymethylene (POM) was mounted on each roller of the conveyor, the geometrics of which correspond to the negative characteristic of the U-shaped rail structure. This means that the rail is already securely positioned for the next process, the automated welding, when it is put into place. At the same time, the rollers only generate very little frictional force, so that when the rails are at a standstill – due to the different cycle times of the machines, for example – no back pressure occurs at this point either.
Another advantage: as the tangential chain roller conveyor is very compact, mk was able to install a second conveying path that the articulated arm robot is also able to load with rails during high throughput periods. This solution allowed the customer to significantly improve the efficiency of its automated production processes.
Since the conveying path blocks one of the passages between the processing stations, an additional transition was constructed from Series 40 aluminium profiles and installed at the corresponding location.
Benefits for the customer
- Gentle conveying: Gentle transport of the rails with minimal friction and no back pressure
- Precise and reliable alignment: Secure positioning of the rails for the automated welding process
- Increased system efficiency: The compact design of the conveying path allows double the usual throughput in busy periods
- On-site project planning: The direct collaboration with customers enables a smooth and rapid implementation
Products used
> Accumulating roller chain conveyor SRF-P 2045
> Tangential chain roller conveyor RBT-P 2255
> Stairs and platforms
