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Crane with advanced automation features for a heat treatment plant enhances process accuracy, reduces cycle time and assures safety.

About Randack Fasteners India Pvt. Ltd.

Randack specialises in manufacturing high tensile fasteners for diverse markets. In India, the company is promoted by Randack Spezialschrauben, Germany, a pioneer in the field of specialised fasteners. Randack’s product range includes bolts, nuts, machined parts and fasteners, which are mainly used by energy, aviation, construction, oil & gas, transportation and heavy engineering sectors.

Besides the usual low alloy steels, Randack uses a variety of high alloy steels, special steels and other materials to produce high quality tensile fasteners.

Fasteners play an important role in the safety of a structure, machinery or equipment and fasteners from Randack are known for their high reliability.


Handling challenges

Heat treatment is an important process in fastener manufacturing which ultimately decides the quality and reliability of fasteners. Randack, Pune plant has an in-house Heat Treatment Facility with SCADA control and is qualified as per AMS 2750 standard.

During the heat treatment, heating temperature, time and the quench process vary depending on the fastener material and require meticulous control on process parameters. In a heat treatment process, first, the materials are heated to between 800°C and 900°C. The second step is the quenching process where the materials are soaked in water, oil or air to obtain certain material properties. The process reliability is governed by precise control on temperature as well as the soaking time.

Considering these aspects, Randack intended to automate the process of handling baskets of fasteners during quenching. An automated system would minimise the manual intervention that is risky considering the high temperature even in the surrounding areas of process tanks. Moreover, an automated system was required to strictly adhere to the quenching duration, which is about 40 to 60 seconds depending on the material.

The challenge was to configure a crane to achieve automation for long traverse, halting at precise locations, lowering the load and lifting it back from the soaking tank after the predetermined time duration.

Solution from ElectroMech

This was a unique requirement where automation was to play a key role. Our design experts conducted an in-depth study of the entire work cycle and interacted with different stakeholders to understand their problems and expectations from a new system. The insight helped us to design a crane solution with the highest possible level of automation, which could lead to safe operations and improve process accuracy.

We have designed and installed a Double Girder Gantry Crane having 5t load capacity, 13m span and 7m height of lift with the following features:

  • PLC system – The entire process of handling, halting, soaking and retrieving material to the unloading station is controlled using a sophisticated PLC system
  • Encoders for hoist and long traverse (LT) motion ensure position accuracy
  • Wireless push button for auto command actuation (start button) is located near the operator’s console
  • Cross traverse (CT) and long traverse (LT) limit switches for position feedback are mounted in accordance to the tank position
  • The hooter and the visual signal indicator denote that the system is healthy, safe and ready for use

Operational cycle with automated crane

  • Based on the tank positions and layouts, visual markings are made on the gantry and crane girder for LT and hook movement to –
    - Indicate the start position
    - Indicate the tank position for LT movement stop
    - Indicate the hook position
  • A hooter is triggered indicating that all the sensors and limit switches are in healthy condition and the system is ready for operation
  • On hearing the hooter sound, the operator attaches the load to the hook
  • The operator activates the process via the wireless start button provided on the operator console
  • The crane automatically travels along the LT rails and halts at its pre-determined location
  • The crane lowers the load as per the preset time limit
  • The crane automatically lifts the load for drying as per the pre-defined time limit
  • This completes the quenching cycle and the process is repeated for the next jobs

The crane being operational in the above-normal temperature zone, special components are used which could withstand higher temperatures


How Randack Fasteners India benefits from ElectroMech solution

Advanced level of automation helps in reducing manual intervention

Higher precision can be exercised on process duration

Reduction in the wastage that occurred earlier as a result of lack of precision control on process duration

Enhanced safety of operator and material

Reduced cycle time resulting in higher productivity. From earlier 55–60 seconds, the cycle time is reduced to 30–40 seconds.

Energy saving as the tank idling time is reduced as a result of faster cycle completion


Total number of crane: 1

Type SWL Span Height Of Lift
DG EOT 5t 13.00m 7.00m


Challenges

  • Automation of crane operation in order to minimise manual intervention
  • Automatic halting at precise location above the dipping tank
  • Automatic lowering and hoisting of load after predetermined soaking duration
  • Advanced safety features to ensure safe operation
  • Crane components to withstand above-normal temperature

Solution

  • Double Girder Gantry Crane having 5t load capacity, 13m span and 7m height of lift with PLC
  • Use of limit switches and sensors to ensure that the crane stops exactly above the dipping tank
  • Wireless control for critical processes to avoid manual intervention and ensure safety
  • Special components and electrical control panel that can withstand high temperatures

Disclaimer

© Copyright 2020 | All the names and logos used here are the registered trademarks of respective companies. For private circulation only. Certain data mentioned here is based on assumptions and theoretical calculations, hence may not be accurate in practice and can’t be considered as a claim by the company.