The existing manufacturing concept required a solution that could be seamlessly integrated into the processes in order to accelerate material flows while ensuring maximum flexibility. SYSTRAPLAN, as a specialist in customized handling systems, developed a tailor-made area storage system that meets precisely these requirements.

Challenge:

Variety of circuit boards and drill holes

The boards used for door frame production varied greatly in their dimensions.

• Length: 500 – 3.000 mm
• Width: 70 – 700 mm
• Thickness: 1 – 2 mm

The special feature was the wide variety of shapes and the numerous holes and cutouts in the sheet metal blanks. Standardized handling was not possible due to these geometries. Conventional vacuum gripping technology reached its limits here, as the cutouts and holes would impair the vacuum tightness. The solution had to be able to pick up each sheet metal blank safely and precisely, regardless of its specific shape.

Solution: Flexible suction frame with individual suction control

SYSTRAPLAN designed a area storage system with a super flexible suction frame at its core. This suction frame is key for handling the different sheet metal blanks. What makes it special is its ability to dynamically adjust to different blank sizes:

• Width adjustment: The rows of suction cups on the frame can be adjusted in width via an axle. This allows the suction cups to be positioned precisely so that even the narrowest circuit boards can be gripped securely.
• Length adjustment: The suction rows can be adjusted in length using multi-position cylinders. This allows the suction frame to be adapted to different board lengths from 500 mm to 3.000 mm.
• Individual suction control: To overcome the challenge of drill holes and cutouts, the suction cups can be controlled individually. A special interface between the machine control system and warehouse management activates the appropriate suction cups, which can be used to securely pick up the sheet metal geometries.

The overall concept:

Integration and flexibility

The SYSTRAPLAN flat storage system was designed as a customized complete solution that can be seamlessly integrated into existing frame production. SYSTRAPLAN’s core strength, its ability to develop tailor-made concepts, was fully exploited here. The system consists not only of the storage system and the suction frame, but also includes the entire connection to production. The storage system’s software communicates with the higher-level production management system to provide the required blanks just-in-time.

• Fast deployment: The automation of the warehouse ensures that the right blanks are available for further processing in the shortest possible time. Manual searching and sorting is no longer necessary.
• Space saving: The compact design of the area storage system makes optimal use of the available space. The blanks are stored efficiently, freeing up valuable production space.
• Reduction of damage: Automated handling with the specially developed suction frame minimizes the risk of scratches, deformations, or other damage to the sensitive sheets.

This solution enables the door manufacturer to significantly increase its efficiency, enhance process reliability, and greatly improve flexibility in its frame production.

Customized solutions

The implementation of this system is a perfect example of how SYSTRAPLAN’s customized solutions can overcome the most complex challenges in material logistics.