Since we worked both in plants undergoing modernization and in new buildings with various levels of sophistication, there were different requirements placed on the intra-logistics solutions.
We installed wireless inductive power supplies in some of the lines to feed the carts without creating barriers for workers or vehicles on the shop floor. Energy transmission is contactless, bridging a small gap to the pick-up system in the vehicle. It is wear-free and low-maintenance and enables high speeds up to 30 m/min. We found a new solution to cut the cable slots and keep the low tolerances of 10 mm to 15 mm distance for the inductive supply all across track lengths of up to 200 m: we fixed the diamond blade cutter onto a frame running on LOXrail® tracks and thus could align the depth of the cable slot with the rail level. We double-checked the tracks for deviations and, if necessary, reworked and re-leveled the floor.
For position detection, we installed coded standards along the entire route instead of positioning via RFID at set positions. Each standard has a different magnetization, which is read out by the magnetic sensors of the linear encoders to determine the absolute position of each transport trolley at any time with millimeter precision. RCoax cables laid under the floor ensure stable, close-range RF data transmission without interference with other nearby Wi-Fi networks. These leakage waveguides have a slotted jacket for near-field data transfer via radio to the transport trolleys' antennas. The data are recorded and evaluated by the process control system.
Our new design solutions for these projects include special pendulum suspensions, which are mounted on the LOXrail® wheelsets to compensate for manufacturing tolerances on the trolleys by means of leveling and buffer plates. Thus, it is ensured that the load is optimally balanced and that all rollers of the wheelsets have permanent rail contact even if the trolley frames sourced externally are not perfectly even. This new design has the added advantage of particularly easy maintenance. To demount individual wheelsets for replacement, it is now enough to slightly lift the platform, loosen three screws and pull the entire wheelset off the stud.
For those factory areas with more dirt, which can impair the system's excellent running characteristics, we have developed larger wheelsets with a 260-mm wheel diameter for load capacities up to 150 kN in addition to the 160-mm standard version. The outdoor segment of the LOXrail® network spans 88 meters with 40-mm rail shafts made of corrosion-free stainless steel.
The wood panel manufacturer chose LOSYCO as an intra-logistics partner, above all, because of plant safety and production line accessibility. Our floor-level LOXrail® system in combination with sub-floor power supply, position detection and data transmission ideally fulfills these requirements. In order to ensure efficient interplay of the trades and various components, we not only successfully installed the LOXrail® system, but also largely coordinated all suppliers involved. The successful cooperation with our client will continue on further current ventures.
