Solving Movers - For t…
Solving Customer Magaz…
Solving Movers - For the Paper Industry
Solving Movers FOR THE PAPER INDUSTRY
Automated and manual systems Solving AGV Movers on air bearings or wheels Solving AGV Movers are driverless systems for continuous handling of paper reels and cores in paper mills. These are operated from a PC-based control system incorporating the software required to give the AGVs their driving orders. Different navigation methods can be chosen; the three most common are laser, wire and tape guidance. Solving AGV Movers incorporate the latest safety equipment, such as mechanical and laser bumpers, photo cells, audible signals, warning lights as well as the usual emergency stop buttons. Solving AGV Movers are based on air bearings or wheels, or a combination of both. AGVs suitable for continuous use contribute to a more efficient production. For the paper industry Solving is one of the leading manufacturers of customised systems for handling heavy loads, such as reels and cores. Based on almost 30 years experience we provide solutions both on air bearings and wheels. In the paper industry simple Solving Movers are used for manual movement of smaller paper reels, whilst automated systems using Solving AGV Movers are designed for continous handling of paper reels and cores. For printing houses we offer an air film-based handling concept facilitating the supply of paper reels into printing machines. Rapid chargeable batteries are designed for continuous use, 24 hours a day.
Solving Movers: pedestrian and stand-on trucks on wheels Solving has developed simple and cost effective wheeled pedestrian and stand-on trucks for handling loads weighing 4 to 10 tonnes, such as paper and plastic reels, pallets and containers. The trucks are suitable for moves of 20 to 150 meters around production facilities. The hydraulic forks can be adjusted to suit the customer´s requirements. The trucks are robust and able to withstand heavy industrial use whilst still being relatively lightweight. A tight turning circle provides good manoeuvrability. Manually operated Solving Movers Simple U-shaped Solving Movers are used to handle reels, cores, cable drums and similar loads directly from the floor. Air bearings lift the loaded Mover from the floor and a thin film of air is formed on which the Mover floats. The load is thus easy to manoeuvre in all directions and to position accurately. The manually operated Solving Roll Movers are used for handling smaller paper or plastic reels, cable drums and similar cylindrical items. The ”deadman” pedal has to be depressed to maintain movement.
A handling concept for printing houses Solving has developed an air film-based reel handling system that has been installed in printing houses all over the world. The U-shaped Roll Mover is fitted with a lifting system allowing paper reels of various diameters and weights to be collected directly from the floor. Paper reels weighing up to 7 SOLVING CONCEPT The paper reel is collected by a U- shaped air film Mover from the storage area. The reel is rotated and unwrapped easily. Advantages • Multi-directional manoeuvrability; flexible in narrow aisles • Reels can be collected directly from the floor • Rotating device facilitates unwrapping Ab Solving Oy PO Box 98 FI-68601 Jakobstad Finland Tel. +358 6 781 7500 Fax +358 6 781 7510 info@solving.fi www.solving.com The Mover´s forks are fitted with a lifting device to collect the paper reel directly from the floor. The reel is raised by a lift table mounted in the floor. tonnes are positioned in front of the roll changer; the Mover can be equipped with a powered rotator for removing the reel wrappers if required. A lift table mounted in the floor is raised between the Mover´s forks to collect the paper reel. This handling concept can also be automated. • Exact positioning into the roll changer • No fixed installations in the building are required • Competitive price Representative: Integral motorised reel rotators facilitate the unwrapping of reels. The paper reel is positioned accurately in the reel changer.
Solving Customer Magazine 2007
Simplifi ed production and transport by using air bearings. Page 4 SOLVING CUSTOMER MAGAZINE 2007 www.solving.com Automated assembly Prize awarded to Solving by Finland’s President. Page 2. Upgrading AGVs at SCA paper mill. Page 3 Assembly line on air bearings for Wärtsilä’s diesel engines Page 2 Courtesy of Wärtsilä Solving AGVs contribute to an increase in production at Sisu-Diesel Ten AGVs are used in the fi nal assembly of diesel engines at Sisu Diesel, Finland. Page 3. The latest generation of Movers for power transformers ? High voltage power transformers are amongst the largest and heaviest production items found anywhere in the world. When connections are assembled and cooling oil is added prior to test, the transformers become too large and heavy for most cranes. Using Solving’s latest air-fi lm based Mover system these can now be moved aft er fi nal assembly without cranes. Areva T&D in Staff ord, UK, has installed two 230-tonne radio-controlled Movers together with an 80-tonne auxiliary beam. Th ese can be used individually for smaller transformers or combined as a 540-tonne system, controlled from a single radio-control console. Once the air bearings have been activated the transformer can be driven in any direction. Areva has found that the Solving system provides them with maximum effi ciency in the test department and enables all assembly processes to take place in the production areas. Fully-assembled transformers weighing up to 540 tonnes are moved into the test department using an Air Film Mover system. 07
NEW ORDERS Hyundai Heavy Industries, Korea ? An Air Film Mover will be installed at the Hyundai factory to handle large crankshafts placed on racks between assembly stations during production. The total weight of the racks amounts to 160 tonnes. SSAB, Sweden ? The Swedish coil manufacturer has ordered three laser guided AGVs for handling coils from the production lines to the warehouse and vice versa. Two rail mounted coil cars will also be installed for handling coils weighing up to 28 tonnes between various buildings. Teknos, Finland ? One of Scandinavia’s leading suppliers of industrial coatings, Teknos, has ordered three laser-guided AGV systems to move pallets from their production area to storage. Norske Skog, Norway ? Norske Skog, producer of newsprint and magazine paper, has invested in an electric stand-on truck for handling paper reels weighing up to 10 000 kg. The truck is capable of handling reels with diameters varying between 1250 and 1500 mm. Tangshan Locomotive and Rolling Stock Works, China ? Two pairs of Air Film Movers, each with a capacity of 60 tonnes, will be installed to handle railway carriages along an assembly line. In addition to a radio remote control the Movers use an infrared guidance system for improved manoeuvrability in narrow areas. The Movers run on both air bearings and rail-going wheels. Two door assembly carriers will also be installed to handle doors and windows during railcar assembly. 2 • 30 years of creative solutions – an idea that continues to thrive It all started 30 years ago during a business trip to Sweden when I saw a 50-tonne container being moved smoothly on air. My interest in air fi lm technology was born! I brought the idea of air bearings back home to Finland and established ‘Solving’ together with my brothers Paul and Rune. The air fi lm idea developed slowly. Initially the Finnish customers were rather sceptical and hard to convince, but after almost a year of industrious sales work the fi rst order was successfully obtained: an air fi lm transporter to a Finnish printing house, Keskipohjanmaan Kirjapaino, to handle paper rolls from storage to a printing machine. The transporter was paid for by printing brochures for Solving! Our present customers can still be found in the printing and paper industries, but also in heavy electrical, motor, workshop and steel industries, and our products are used to handle a huge variety of loads. During the fi rst ten years in business Solving was active only on the Finnish market. The fi rst international steps were then taken into the other Nordic countries followed by the rest of Europe. Today Solving operates all over the world and about 80 % of our customers come from outside Finland. During the 30 years that have passed since we started our existing products have been continuously developed, new more automated products have been added to our portfolio, subsidiaries have been formed and a network of agents and suppliers created. All this together with an enthusiastic staff has enabled us to run the worldwide business Solving represents today. In many respects our present business diff ers greatly from that of 30 years ago, but the air bearings that started everything continue to thrive. Peter Björk, MD Diesel engine manufacturer Wärtsilä has embarked on a new project, named ‘3000+’, to increase their assembly and testing capacity at their factory in Trieste, Italy. Th ey are investing 18 million EUR in the Trieste Delivery Centre to meet the strong level of market demand and to support the company’s growth target. Th e scope of the 3000+ project is to considerably increase the production capacity Several Solving Air Film Movers are already used in Trieste to handle motor blocks and diesel engines weighing between 2 and 600 tonnes. When deciding to invest in two new parallel fi ve-station production lines within the scope of the 3000+ project Wärtsilä prioritised safety and convenience. Th eir preference was for a fl oor-bound solution and they chose another two Solving Air Film Movers, each having a capacity of 300 tonnes. Th e Movers are designed for handling diesel engines along the two lines and into a test cell located in a separate building. Th e diesel engines are lift ed by crane onto one of several steel pallets; the Mover then drives under the pallet, lift s the load and moves it along the line at a current rate of one station every two days, but with an aim to further reduce this rate. Th e transportation between the stations is assisted by tape guidance and Innofi nland Prize goes to Solving As one of fi ve Finnish companies among 222 candidates Solving was awarded the ‘Innofi nland Prize 2006’. The purpose of this annual prize is to promote creativity, skill, entrepreneurial spirit and co-operation, and President of the Republic of Finland, Tarja Halonen, is the patron of the project. Solving was awarded the prize for its customised handling solutions and related services. We are very proud of the award and see it as an acknowledgement of all the development work we have carried out through the years to be able to provide our customers with the high quality handling systems that best suit their needs. Movers for Wärtsilä’s new project all functions of the Movers are remotecontrolled. Solving has installed two Air Film Movers within the scope of Wärtsilä’s 3000+ project in Trieste. Courtesy of Wärtsilä
Solving AGVs in diesel engine manufacture As part of the AGCO group, Sisu Diesel’s Linnavuori factory in Finland manufactures diesel engines for most of the tractors made by AGCO, such as Valtra and Massey-Ferguson, and also for the external market. Large investments have been made at the Linnavuori engine factory to increase production capacity and Sisu Diesel aims to achieve an annual production of 38 000 diesel engines. As part of this development Sisu Diesel installed two new AGV systems in autumn 2006, one for the fi nal assembly of diesel engines and another for the transport and intermediate storage of engines between the assembly and test run facilities. Th e AGV system for fi nal assembly consists of ten automated vehicles using inductive navigation. Placed on assembly and transport jigs, diesel engines weighing up to 1 200 kg are moved step by step through assembly using fork-lift Solving AGV Movers. Th e AGVs communicate with a PLC-based control system via radio and the indexing takes place by commands given by the operators. Th e AGV system for the test run facility consists of two automated fork-shaped Solving Movers with laser navigation used for stacking completed engines weighing up to 1 500 kg at a height up to 2,4 meters. Manoeuvering of the AGVs is integrated within the data system that follows the stream of manufactured engines through the intermediate storage, test run and other production areas. As a special feature the wagons are fi tted with collecting vessels for liquids from the engines, and these are automatically discharged into a secure fl oor drain. “Solving off ered a complete custommade system that suited us best AGVs at SCA upgraded SCA Hygiene Products AB in Lilla Edet, Sweden manufactures tissue products such as toilet paper and paper towels. A Solving AGV system is used to handle the largest reels at SCA weighing up to 4000kg and this installation consists of new AGVs as well as some renovated units. Solving AGVs collect the 4000 kg reels from the paper plant, transport them to the storage facility and then on to the processing machinery when requested. Th e AGVs are equipped with inductive guidance based on the latest digital technology, radio-communication and laser-based safety devices. Fitted with batteries and automated battery charging at selected home positions the AGVs contribute to automated handling 24 hours a day and provide a high level of reliable service. “One of the most important reasons behind our choice of supplier was Solving’s fl exible timetable enabling a smooth transition during on-going production”, says Johanna Norling of SCA, responsible considering the special requirements that handling of diesel engines set”, says Production Development Engineer Harri Ruponen. “Installation and start-up of the systems took place according to the agreed schedule”. Th e automated assembly wagons also contribute to improved ergonomics and logistics at the fi nal assembly stages. 4 000-kg heavy tissue rolls are handled automatically at SCA. for the project. “Since the upgrading must not interfere with the production, it was impossible to assemble and start up any other system, such as overhead conveyors”. Th e new AGV system is more userfriendly for analysing and fault fi nding functions. Both the system guidance “Using this automated system we have managed to keep the fl oor surfaces in the factory free for other traffi c and pedestrians”, says Project Engineer Petri Ruoho. “Despite all the programming required this automated system is very fl exible for future changes in the layout compared to any competing technology”. Th e production of diesel engines is and the AGVs are equipped with user interfaces providing users and service personnel with the necessary feedback. “Th e Solving project team has been very fl exible and cooperative during the complicated assembly and start-up periods”, concludes Johanna Norling. Laser guided forklift AGVs automatically move engines weighing up to 1 500 kg between assembly and test run facilities. increasing and Sisu Diesel has already ordered another Solving unit to complement their existing AGV system for test run. Floating squash court ? Air fi lm technology from Solving has given an uplift to one of seven new squash courts, installed at the British National Squash Centre, Sportcity, in Manchester, UK. Using 16 Solving modules, the entire squash court complete with glass walls can be lifted and fl oated on a cushion of air into the athletics arena. Here, seating can be arranged around the court to allow spectators to view the game from all sides. Solving’s system will also be used at the 2008 World Squash Championships. • 3
Metso Minerals, USA ? Mobile crushers weighing up to 50 tonnes are moved along a production line using an Air Film Mover from Solving. Barsebäck Kraft AB, Sweden ? At this nuclear power plant lead waste containers weighing up to 10 tonnes are handled using an Air Film Mover with integral steering. ABB, China ? 320-tonne transformers and 10-tonne windings are moved between various assembly stations using two Solving Air Film Movers. 4 • SOLVING GALLERY Floating Rolls-Royce propellers ? Rolls-Royce is a world-leading provider of power systems and services for use on land, at sea and in the air. Propulsion equipment such as Ulstein and Aquamaster, used for driving and controlling ships, is manufactured at their factory in Rauma, Finland. When renovating the Rauma factory, Rolls-Royce aimed for simplifi ed production and easier handling between diff erent production facilities. As a result, Rolls-Royce Propellers weighing up to 40 tonnes are moved smoothly between production facilities using an Air Film Mover. Low-profi le, small and light Mover A standard Mover from Solving can be used to handle a variety of loads. ? Solving has introduced a standard Air Film Mover for general and various industrial applications. Th e new Mover is low-profi le, small and light compared with its load capacity, which can be up to 15 tonnes, and the load can be placed either directly on the transporter or on a load pallet. Using a load pallet the Mover is driven on no-load wheels under the pallet, the air bearings are switched on, and the load is lift ed and moved to the requested destination. No additional lift ing devices are required, because the lift ing height of the air bearings is enough to lift the loaded pallet. Fitted with built-in rotating drive units Aker Kvaerner, Malaysia ? A 60-tonne Air Film Mover is used to handle subsea pumps on load pallets in production facilities. Myresjö Hus AB, Sweden ? A wheeled fourway truck moves modules weighing up to 10 tonnes in the production of prefabricated houses. Salamander, Germany ? A 20-tonne radioguided Air Film Mover assists in handling racks of window profi les in a storage area. installed a Solving Air Film Mover for the movement of azimuth thrusters from the assembly area to the fi nal assembly area and then to a test zone in a diff erent production facility. No cranes or other fi xed installations are required for handling the thrusters. Another advantage of the Mover is the possibility of omnidirectional steering providing fl exible manoeuvring in narrow production areas. Th e thrusters are positioned on a load pallet during assembly and radio-controlled guidance gives the operator full control of the Solving Mover to enter the loaded pallet and pick it up in preparation for a move. the Mover can be driven freely and positioned accurately. Th e Mover is controlled directly from a handle on the control panel. A movable brush guard is fi tted around the Mover to avoid injuries and also to prevent debris from getting under the Mover which might damage the air bearings. Th is type of Air Film Mover has been installed at ATK in Germany to handle tools and at Barsebäck in Sweden to move lead containers in a nuclear power plant. Ab Solving Oy Jakobstad/Pietarsaari, Finland Tel. +358 6 781 7500 info@solving.fi www.solving.com Solving Sweden AB Västerås, Sweden Tel + 46 21 81 10 95 info@solvingsweden.se Solving Transportsystemer A/S Stavern, Norway Tel + 47 33 18 56 00 so-tran@online.no Solving Deutschland GmbH Burgwedel, Germany Tel +49 5139 6443 info@solving-gmbh.de www.solving-gmbh.de Solving Ltd Newbury, United Kingdom Tel: +44 (0)1635 814488 sales@solving.co.uk www.solving.co.uk Solving Italia S.r.l. Lesa (NO), Italy Tel + 39 0322 765 76 solving@solvingitalia.com www.solvingitalia.com Solving Danmark Præstø, Denmark Tel + 45 70 25 01 31 preben-a@petersen.tdcadsl.dk American Solving Inc. Ohio, U S A Tel + 1 440 234 7373 solvinginc@aol.com www.solvinginc.com LKS AG Neuenhof, Switzerland Tel + 41 56 406 65 86 info@lks.ch www.lks.ch I.M.S. Bonneval, France Tel + 33 2 37 47 78 10 imsmanut@wanadoo.fr www.imsmanut.com IDQ, S.A. S.S. de los Reyes (Madrid), Spain Tel +34 911 859 190 idqsa@idqsa.net www.idqsa.net Solving Asia Taipei, Taiwan, R.O.C. Tel +886 2 8751 9667 runhigh@seed.net.tw www.rh-solving.com.tw Solving do Brasil Ltda - ME Sao Paulo, Brasil Tel.: +55 11 4487 1986 vendas@solvingdobrasil.com.br www.solvingdobrasil.com.br Solving Korea Kyunggi, Korea Tel +82 31 492-1691 info@solving-korea.com www.solving-korea.com Editor-in-Chief Peter Björk Editorial Secretary Ullamay Borgmästars Graphic design and layout Wiizart Print Forsberg Rahkola Jakobstad, 2007
PubliCo Oy, Pälkäneentie 19 A, FI-00510 Helsinki, Finland