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Scanclimber’s major role in the automation of NGK Ceramics in Poland

Takenaka Corp. Japan constructed a modern ceramics factory for NGK in Poland. An automated material handling system was implemented at the factory for higher productivity. Scanclimber played a part in this successful automation project.

Background

Takenaka Corporation is one of Japan's oldest construction companies. Its history dates back to the 16th century. The company operates worldwide, mainly working on infrastructure projects. In 2012 Takenaka was building a ceramics factory for NGK in Gliwice, Poland. The factory's layout and infrastructure were also designed by the Takenaka Corporation. Automated production and material handling were key points of this project. The target was to design a factory where labor costs and manual processes would be minimized.

A specialized machine supplier was required to achieve this goal. Takenaka needed a supplier that had flexible industrial elevators and had the capability of customizing them according to their automation needs.

Scanclimber made a joint project with a conveyor line supplier and a door supplier to provide a solution. NGK ceramics' plant's three floor transport line was successfully automated with light weight Scanclimber hoists integrated with horizontal conveyer belts and doors with sensors. One of the key reasons for Takenaka to choose Scanclimber products was based on their philosophy to only use high quality products.

Challenges

The design of the NGK Ceramic factory included a high level of automation. The amount of manual work was to be minimized. This meant that the full transport line in three floors should operate nearly unattended. The main difficulty for Scanclimber in providing a solution was the need to integrate a vertical material transportation module (hoist/elevator) with horizontal conveyors.

ngk ceramics pl 2nd level
There were certain challenges in implementing such a ystem:
  • The search for adequate suppliers for the project
  • The seamless operation of vertically and horizontally moving modules.

The seamless operation of all transport line components was important for Takenaka. Other proposed solutions were not seen as adaptable or flexible enough. The biggest challenge was to find a horizontal conveyor line which could be seamlessly integrated with a vertical lifting machine on three floors

Objectives achieved

Scanclimber was chosen considering the challenging aspects of the project and the various properties of our products. Takenaka appreciated product quality, safety, adaptability, durability and the applicability to different industries.

A station for the hoist was established on each floor of the building during the installation phase. The hoist included a small roller table at the height of the conveyer rollers outside of the hoist for material transportation. The gates of the hoist had automated sensors which would open the doors when the hoist reached the right floor so it could move the materials out to the conveyers directing them to their production units. The hoist’s vertical movement was along two mast sections on the sides in order to ensure stability. The manual handling of materials was successfully minimized after the implementation of Scanclimber's hoists in the NGK Ceramics factory.

ngk ceramics pl 3rd level
Project Facts 
Hoist used SC1120MF & SC1120MFL
Max height achieved
14.65 meters (3 floor factory)
Max lifting capacity
1100 kg
Project negotiations started
November, 2011
Order shipment
February, 2012
Main benefit of Scanclimber
Automatic line for horizontal and vertical goods transport
Special features of project
  • Hoist used with conveyer rollers
  • Scanclimber supported complete process from design  to realization and certifications
  • Scanclimber teamed up with its partners from rollers and gates to develop the automation handling.

SC1500K Technical Data Overview

  • Technical Data
  • Electrical Data
Technical DataSC1500K
Payload 1500 kg or 15 persons
Speed 36 m/min
52 m/min
Lifting height >200 m
Max. free mast after topmost anchoring 5 m
Max. distance between anchors 12 m
Weight of the mast section 134 kg
Weight of the lift car 1100 kg
Operation temperature -25°C – +45 °C
Noise level to the surroundings [dB (A)] Max. 80 dB
Electrical DataSC1500K
Number of lifting motors 2
Motor rating 9,2 kW
Starting current 63 A
Power consumption 10 kW
Supply voltage 230/400 V  AC 50 Hz
Lift control voltage
  • safety
  • control circuits
  • 48 V AC
  • 24 V DC
Lighting circuit voltage 230 V AC 50 Hz
Signal circuit voltage
  • lamps
  • buzzer 
    • 48 V AC
    • 12 V AC
    Permissible voltage variation ±5 %
    Fault mode current protection residual current device
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