Automation of repetitive lifting tasks can offer significant benefits for Canadian industries, especially in regions facing tight labor markets. Automating processes not only improves worker safety but also optimizes material flow within facilities, enhancing throughput and operational efficiency. As the Canadian job market becomes more competitive, businesses may find it challenging to hire and retain skilled workers. In such cases, automating lifting processes is a practical solution to keep operations running smoothly.
Types of Lifting Automation
Automation for overhead cranes or monorails typically involves several stages: grabbing or securing a part, lifting, horizontal travel, lowering, and releasing or placing the part. The process can be either fully automated, requiring no operator input, or semi-automated, where some steps are performed by an operator. Automated systems allow operators to focus on higher-value tasks while repetitive functions are handled by the machines.
Semi-Automated vs Fully Automated Lifting
When considering automation for your Canadian facility, it's important to understand the differences between semi-automated and fully automated systems. Both can be tailored to meet your specific operational needs.
Semi-Automation: In this scenario, an operator performs part of the process, such as attaching a part to the hook. Once this initial step is completed, the automated system takes over, transporting the part to its destination without further input. This approach saves time and resources, as operators are not required to monitor the process closely.
Full Automation: A fully automated system operates without any human intervention, completing tasks like lifting, transporting, and placing parts autonomously. While this option offers significant labor savings, it comes with additional costs for equipment such as automated grippers and advanced control systems.
Starting Your Automation Journey
To begin automating your lifting processes, the first step is to outline the sequence of operations. This sequence details each stage of the process, such as lifting, moving, and placing materials. For example, you might start with "lower 3 feet," "pick up from pallet," and "travel 20 feet to the conveyor centerline," followed by lowering and releasing the part. Make sure to account for the timing of each step and consider potential future requirements.
Once the basic sequence is outlined, you can add further details like operator input (e.g., pressing buttons or using a control screen) and speed and accuracy specifications. For Canadian industries that require precise or rapid operations, these additional requirements can influence the overall cost. Gathering accurate and detailed information early on will lead to a more precise project quote.
Key Components of a Lifting Automation System
Automating a lifting process involves several components working together. The automation control system integrates sensors, communication devices, motion controllers, and PLCs to manage the entire operation. For loads up to 5 tons, electric chain hoists are a common choice, while heavier loads may require electric wire rope hoists.
Horizontal Travel: For rectangular work areas, freestanding workstation cranes or ceiling-mounted cranes provide flexibility in picking and placing items. Linear paths, either straight or curved, can be served by monorail systems. Electric tractor motors enable powered horizontal travel.
Control Systems: Automated crane and monorail systems may include variable speed lifting and lowering, load measurement, and travel limit switches. The PLC system can also interface with other facility equipment, either wirelessly or through wired connections.
Safety in Automation
In any automated system, safety is paramount. Automated processes should begin with both visual and audible warnings to alert personnel. Areas where automation is in place must be secured with fences, gates, or sensors to prevent unauthorized access or stop the process if someone enters. In cases where loads are transported above workers, safety screens can be installed for full protection.
Additionally, by reducing repetitive tasks, automation can keep your workforce healthier and safer, minimizing the risk of injuries in Canadian workplaces.
Conclusion
Automation offers Canadian businesses a practical way to overcome labor challenges and improve operational efficiency. Whether you choose semi-automated or fully automated systems, automating overhead crane or monorail processes can significantly enhance productivity while maintaining high safety standards.