The automation of lifting processes encompasses a spectrum of operations, which could involve an overhead crane or monorail system. These operations typically entail tasks such as part retrieval, lifting, horizontal movement, lowering, and the release or placement of the item. A process can be fully automated without any operator assistance or semi-automated with portions of the operation performed by an operator. An automated process can complete repetitive tasks, allowing an operator to complete other, more valuable tasks.

There are two main types of lifting automation: semi-automated and fully automated. Semi-automated systems require some operator involvement, while fully automated systems do not. The best type of automation for a particular business will depend on its specific needs and budget.

As you delve into the realm of automation for your lifting and production processes, it's vital to understand the distinctions between semi-automation and full automation. Both approaches offer unique advantages that can be tailored to suit your specific requirements.

Semi-Automated Lifting

Semi automation is a process that has an automated component but requires some operator input at certain points, for instance to begin or end the process. A simple automation example could be an operator connecting a part to the hook or manipulator. Then, once certain criteria have been met and confirmed by the control system, the automation process is enabled. An automated portion of the process can save time and resources, for example when the operator does not have to accompany the part during transport. 

Fully Automated Lifting

Fully automated processes run autonomously without operator intervention, allowing manpower to be saved or redeployed as needed. Using the same example, full automation could be achieved by using an automated gripper or end effector to secure and release the part at the beginning or end of the process. It’s important to note the higher initial investment in full automation.

Planning for Automating Overhead Lifting

To determine the best way to automate a lifting process, businesses should first consider the sequence of operations involved. This is the process of constructing the narrative of how the process unfolds from start to finish. The sequence can include specifics like lowering distances, part retrieval, lift height, travel distances, and the point of placement or release.

As this narrative is being put together, it’s important to factor in the timing of each operation and potential future requirements. Look at how operators are involved to determine their role in the process and how they will interface with the equipment with control screens or buttons. Consider the speed and accuracy required and whether external signals from offboard equipment will be integrated. Offboard equipment like conveyors will need to be meticulously integrated to ensure seamless functionality. Be sure to collect comprehensive and precise information during this phase.

Components of Automation for Lifting

In all automation systems, there is an array of components that work in unison to bring automation to life. The automation control system includes sensors, communication devices, motion control mechanisms, PLCs (programmable logic controllers) and other elements to orchestrate the automated process.

For automating lifting processes, electric chain hoists are a suitable choice for loads up to 5 Tons while wire rope hoists can handle heavier loads. When horizontal motion is necessary, options range from freestanding workstation to ceiling mounted cranes to accommodate the diverse requirements of pick-and-place processes.

Linear paths can be serviced by a monorail system with straight or curved track and driven by electric tractor motors. These systems can be equipped with variable speed lifting and lowering, encoders, and load measurement devices to enhance precision. PLCs and onboard control systems can integrate offboard equipment wired or wirelessly.

Prioritizing Safety

Safety is always a priority, especially in any automated process. Initiating an automated sequence typically involves both a visual and audible warning to alert operators and others the process has begun. Access to areas with automation is restructured by physical barriers like fences, gates, or sensors to prevent unauthorized personnel from entering. When loads are transported above personnel, protective screens can be installed beneath a crane or monorail for full protection of those under the path.

Automation controls can be interconnected with other plant equipment to ensure the secure execution of the automated process. Moreover, eliminating repetitive tasks from the responsibility of operators contributes significantly to a safer work environment. In addition, automation can eliminate manual lifting processes to further improve ergonomics in your operations.

Partnering with the Right Manufacturer and Dealer

Choosing a knowledgeable partner is critical when investing in automation. Manufacturers with a board spectrum of product offering allow for the customization of projects to align with your precise needs, leveraging standard solutions.

Demag light lifting solutions excel in automating processes up to 2 Tons, offering versatile options with KBK light crane and monorail systems along with DC electric chain hoists. These modular systems can incorporate automated components like curves, track switches, turntables, and interlocks. KBK rail can include an internal busbar system for reliable power distribution and seamless operation.

Demag DC chain hoists are available in configurations to meet your needs, from single hoists to synchronous two and four point lifting. These hoists offer two-speed or variable speed options and can be equipped with precise positioning switches and encoders.

Design, installation, maintenance, and troubleshooting of your automation system is critical. Demag's network of expert dealers stands ready to collaborate with you, from the initial concept to the seamless installation of a tailored solution. They also provide ongoing maintenance and troubleshooting support, ensuring the longevity and efficiency of your automated lifting system.

Incorporating automated lifting processes into your operations can be a transformative step that not only streamlines material flow but also empowers your workforce to focus on value-added tasks. Whether your facility requires fully automated or semi-automated lifting solutions, it is essential to conduct a comprehensive evaluation of your processes and needs. Collaborating with an expert material handling dealer and a reputable lifting products manufacturer ensures that the system is finely tuned to meet your unique requirements.

If you seek guidance or have inquiries, don't hesitate to reach out to us for expert assistance on your lifting automation journey.