The production facility at Bergrohr in Germany, one of the world’s leading manufacturers of large diameter steel tubes, is exceptionally quiet for a steel processing company – an achievement due mainly to the firm’s internal product transfer logistics system. Up to 30 000 kilograms of heavyweight tubes glide effortlessly through the production halls producing nothing more than a faint buzzing noise thanks to a rail-mounted, automated transportation system that uses contactless energy transfer. The system has been in operation at Bergrohr for around two years.
The company had originally wanted to switch its workshop logistics systems over to this type of rail-mounted system 10 years ago, but at that time, the necessary drive technology was not yet available in the market. It was only when contactless energy transfer systems were developed around two years ago that Bergrohr was finally able to put its plans into action. The Movitrans system from SEW-Eurodrive made the changeover possible, providing the technology that turned this long anticipated project into reality.
Solution enhancement
Yet another innovation from SEW-Eurodrive is being used in combination with the Movitrans solution. The Movidrive inverter controls the travel velocity of up to 30 metres per minute, as well as acceleration and braking for the 40 compact transportation vehicles that convey up to 30 tons of heavy steel tubes to the individual processing stations. Movement and braking processes need to be fluent and harmonious at all times as some work pieces project several metres ahead, or behind, of the vehicle. They are also sometimes processed directly on the transportation unit and must not tip over when brakes are fully applied. Movidrive provides an optimum solution for this delicate task.
Waste from the production of steel tubes, such as slag and cuttings, is kept away from the rails, ie, the electrical conductors of the Movitrans system, by a high-performance sweeping machine that clears the hall floor at regular intervals. Employees were also trained in how to use the new transportation system and were instructed not to place any tools or similar objects on the tracks or cover the conductors during hot-wire welding or grinding work.
The Movitrans system is based on the principle of inductive energy transfer: energy is transferred without contact from a fixed conductor (for example a rail) to the vehicles. The electromagnetic connection takes place across an air gap and is not subject to wear making it virtually maintenance-free. Contactless energy transfer does not produce dirt and is not sensitive to external contamination, moisture and temperature fluctuations. The system at Bergrohr has run without a hitch and boosted tube throughput by some 20% since its inception. A Movitrans system will be on display at Electra Mining from 10-14 September at the SEW-Eurodrive stand.
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