Safe & Efficient Solution to handle large & heavy tractor tyres by Dalmec Manipulators

October 12, 2021 11:52 am

The case study highlights an application where a Dalmec manipulator is deployed to handle large & heavy tractor tyres with enhanced safety by achieving optimum operational flexibility at the work zone. 

A leading indigenous farm equipment manufacturing company was planning to expand its footprint into the International Arena. After extensive research, the company realised the growing demand for tractors in the US market and started chalking out a plan to capitalise on the opportunity. Sensing the growth potential, a ‘Greenfield Project’ with a dedicated product portfolio made sense over importing child parts from Japan, South Korea, and India and assembling them at the plant. 

The company planned to manufacture a complete range of existing models, plus new large-size and high-horsepower tractors specifically developed to cater to large farms. The company’s central purchase team located in India was in charge of overseas procurement and project initiation. Considering the technical and geographic challenges, they have been looking for a reliable local partner with a global existence and experience with a large client base in the farm equipment sector. 

Project requirement and challenges 

The manipulator had to handle 14 tyre variants ranging from 26 kg to 350 kg with different widths and diameters. Incoming tyres were horizontally stacked on a wooden pallet. The Lowest Tyre Gripping Point was at 300 mm & the topmost Tyre Gripping Point was at 2000 mm from the Ground level. This created a blind grip zone for the operator while standing on the ground floor. 

Each time the input position varied, making the lowest gripping point at 300 mm and the highest at 2000 mm from the ground level while gripping this topmost surface of the Tyre, the operator lacked visibility & hence the operation was in a blind zone. 

Layout study 

Before conceptualising the solution, Dalmec requested the client for a plant layout study, available space for a manipulator concerning the distance between input tyre pallet and assembly line, location of nearby equipment & their orientation, and arrangement of overhead facilities. 

The layout study by Dalmec technical team revealed the presence of the EOT in the area defined for the installation of the manipulator. The initial thought process of suggesting the rail-mounted system was thwarted by the EOTs presence as it caused an obstruction & we needed a clear space to install the Manipulator. 

Since the client had invested in the EOT earlier and was planning to retain it for handling other components within a larger area of EOT’s Operation, it couldn’t be removed. Hence, Dalmec had to think of a Modular “one of its kind” System, which can be collaborated with existing EOT. 

Dalmec Solution 

Considering the existing EOT and the client’s requisites, Dalmec decided to utilise the EOT arrangement to fit the manipulator. Going by our new concept the operational flexibility of the manipulator enhanced, the manipulator would cover a larger working area making it a unique proposition that facilitated easy assembling of left & right side-tyres of the Tractor. 

Dalmec’s design team was focused on conceptualising a “single pneumatically operated jaw-type gripper” to handle 14 Variants of tyres, having different ODs and widths instead of an inter-changeable gripper. This single but highly flexible gripper concept reduced the operation time by completely eliminating the time required for gripper changeover. 

The jaw-type gripper was a self-centring mechanism to accommodate the smallest to largest tyre variants in a single unit. There was a need to tilt (Horizontal to Vertical) the tyre while fitting it on the Tractor Axle by the manipulator. Dalmec Team has achieved the smallest tilt radius with a special leverage mechanism. A manual handwheel was provided to match tyre ‘Hub Holes with Tractor Axle Bolts’. 

As a general plant standard for the EOT fitment, the client’s EOT was too fitted at 8000 mm from the ground floor; this made the height of attachment of flange 7000mm from the ground floor. As a standard of installation, Dalmec Manipulators are ideally fitted at 5000mm to 5500 mm from the ground floor. Dalmec also resolved the mounting height issue by providing an extended column on the main vertical inverted column of the manipulator. The Reactions & Load acting on this inverted column were also safely calculated & designed, and the system was made as a single unit to achieve its optimised working by our team. 

Special features 

• A Specially Designed System that is capable of being fitted on Overhead EOT Crane. This is the first of its kind solution by Dalmec India. 
• An extended column is developed to fit on the EOT Trolley which is at a higher position than the normal fitting height of the manipulator. 
• Customised unique gripper to handle all the 14 tyre variants weighing from 26 kg to 350 kg. 
• The Gripper is provided with a mounting bracket to accommodate the EOT operation pendant. 
• The Operator has all the controls near his hands. 

Benefits for the client 

• Best Utilisation of available System of EOT. No need for the installation of a new structure & rail system. Obviously, a time and cost-saving solution. 
• As the Manipulator is fitted on the EOT, it can be moved & parked to any corner of the floor zone to give a clear working space. 
• A higher degree of flexibility throughout the assembly area. Theoretically covered a rectangular work zone under the EOT Hook/ Hoist Zone by Manipulator. 
• The manipulator can serve all tractor variants as they are coming online making it a continuous operation in a true sense. • Shorter assembly (Cycle) time per tyre loading as compared to conventional Jib Crane Unit. 
• Safety Features of Anti Release, Grip Interlock, Rigorous movement, etc. are included to make the operation absolutely secure. 
• The manipulator is designed as per UL Safety & Ergonomic standards, so the operator is not subjected to undue stress and fatigue. 

Customer Verdict 

• Highly satisfied procurement & project team, as this solution met their requirement of “Variants of tyre” and “Operator Visibility Issue” etc. 
• Effective use of available plant facilities made the project successful within the shortest possible time. 
• Single Operator use with safety features is a big plus in productivity. 
• Dalmec’s Global Support made it an easy walk for I & C and handover with Dalmec India’s expertise for such projects. 
• Quickest Production Handover as Dalmec left no stone unturned during the Initial Engineering Study. No Rejection/Rework made the client happy.