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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.

SC2000K Technical Data Overview

  • Main Components
  • Details
  • Technical Data
  • Electrical Data
  • Technical Data Lift Car and Lifting Mechanism
Description of THE SC2000K  main components
  • SC2000K Lift
    SC2000K Lift
    The lift is a functional complex and consists of the following main components:
    - ground sation
    - lift car
    - lifting mechanism
    - mast and landings
  • SC2000K Mast section
    SC2000K Mast section
    The mast section is completely hot-dip galvanised. Its height is 1.5 meters and it weighs 84 kg.
  • SC2000K Landings
    SC2000K Landings
    On the landings, there are landing sliding double doors made of sections and covered with sheeting and equipped with a safety lock. The landing door is opened manually and below the threshold it has an apron.
  • SC2000K Car
    SC2000K Car
    The car and the landings are designed such that it is possible to enter and leave the cage from the front side of the car. The car door is made as a vertical sliding door. The door is coated with a solid steel sheet. A safety lock is used for locking the door. Below the threshold the cabin is equipped with an apron 750 mm high.
  • SC200K Drive Unit
    SC200K Drive Unit
    The lift drive is provided by one unit installed above the car roof, equipped with two electric motors with helical-bevel gears. In case of emergency, it is possible to lower the car and to stop the car precisely at the nearest landing.
  • Elastomer Buffers
    Elastomer Buffers
    The buffers are used for emergency braking of the car.
  • Safety Brake
    Safety Brake
    The car is equipped with a safety brake and overload control system.
Description of SC2000K  main components
  • SC2000K Mechanical parts of lift base and lift
    SC2000K Mechanical parts of lift base and lift
    The bottom station is the lower part of the lift well with the landing door (landing 0). The hoist pit is composed of the lower part of the bottom station with the depth of 1.20 m. The mast base (1) with elastometer buffers (2) is mounted on the lift pit support base. The buffers are used for emergency braking of the car. In the bottom station there is sliding double door (3) equipped with a safety lock Schmersal AV20. 
  • SC2000K Mechanical part of mast section
    SC2000K Mechanical part of mast section
    For mast construction, mast sections 1508 mm high are used, with load bearing tubes spacing of 650 mm. The mast is anchored to the supporting structure at distances of 4.5 m by means of a special plate anchoring with a radius adjusted in the range of 450 to 500 mm by means of M20 bolts. Upper buffers are mounted on the last mast section.
  • SC2000K Mechanical part of landings
    SC2000K Mechanical part of landings
    On the landings, there are landing sliding double doors (1) made of sections and covered with sheeting and equipped with a safety lock Schmersal AV 20. The landing door with inside dimensions of 1000 x 2000 mm is opened manually. Below the threshold, the landing door has an apron (2) 750 mm high.
  • SC2000K Mechanical parts of car
    SC2000K Mechanical parts of car
    The car with a lifting capacity of Q = 2000 kg moves with a speed of v = 0.60 m/min. The car's dead weight is 1400 kg. The car and the landings are designed such that it is possible to enter and leave the cage from the front side of the car. The car door (1) is made as a vertical sliding door. The door is coated with a solid steel sheet. A safety lock Schmersal AV20 (2) is used for locking the door. Below the threshold, the cabin is equipped with an apron (3) 750 mm high.
    In case of emergency, it is possible to evacuate people from the cage through a trapdoor (4) in the roof sized 800 x 800 m, therefore guardrails (5) 1100-mm high are installed on the roof, with a 150-mm toeboard.
  • SC2000K Drive unit
    SC2000K Drive unit
    The lift drive is provided by one unit installed above the car roof, equipped with three 7,5 kW electric motors with helical-bevel gears. In case of emergency, it is possible to lower the car and to stop the car precisely at the nearest landing.
  • SC2000K Safety brake
    SC2000K Safety brake
    The car is equipped with a UC-3.0A safety brake (1) and with an overload control system which prevents a normal startup when the rated load exceeds 20%.
  • SC2000K Overload control system
    SC2000K Overload control system
    The overload control system prevents a normal startup when the rated load exceeds 20%.
  • SC2000K Running of a cable
    SC2000K Running of a cable
    The car is connected with the upper or lower landing by means of the following cables laid permanently halfway up the mast height:
    - power cable H07RN-F 4 x 16
    - control cable H07RN-F 12 x 1.5
    and then with a travelling cable SEMOFLEX BAULIFT4x16+1x2,5+10x1,5 drawing through a cable carrying carriage.
Technical DataSC2000K
Payload 2000 kg or 20 persons
Speed 36 m/min
52 m/min
Lifting height >200 m
Max. free mast after topmost anchoring 1 m
Max. distance between anchors 4,52 m
Weight of the mast section 84 kg
Weight of the lift car 1400 kg
Operation temperature -25°C – +45 °C
Noise level to the surroundings [dB (A)] Max. 80 dB
Electrical DataSC2000K
Number of lifting motors 3
Motor rating 7,5 kW
Starting current 270 A
120 A 
Power consumption 22,5 kW 
Supply voltage 230/400 V  AC 50 Hz 
Lift control voltage
  • safety
  • control circuits
48 V AC
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
Technical Data for the
Lift Car and Lifting Mechanism
SC2000K
Car (internal)
  • width
  • depth
  • height
  • weight
  • 1170 mm
  • 1170 mm
  • 2100 mm
  • 1400 kg
Mast section
  • length
  • load bearing tubes spacing
  • mast bolts
  • weight
  • 1508 mm
  • 650 mm
  • M20 x 190-10.9 - 4 pc./section
  • 84 kg
Electric motor
  • type
  • nominal power
  • rated speed
  • supply voltage
  • rated current
  • weight
  • 132M4 - NORD
  • 7,5 kW
  • 1445 [1/min]
  • 400/690 V - 50 Hz
  • 14,8 A
  • 84 kg
Brake
  • operating principle
     
  • type
  • braking torque
  • weight
  • Disk type,
  • electro magnetically released
  • BRE60HL1 - NORD
  • 60 Nm
  • 10 kg
Gear
  • type
  • gear ratio
  • weight
  • SK9042.1 VXF B5I - NORD
  • 1:15.66
  • 6 kg
Driving pinion
  • module
  • number of teeth
  • rotation speed
  • 6 mm
  • 20
  • 91 [1/min]
Safety brake
  • operating principle
  • type
  • tripping speed
  • weight
  • Progressive, centrifugal action
  • UC – 3.0 A
  • 0,9 m/s
  • 32,5 kg
  • Feel free to leave us a message if you have any requests, questions or feedback and we'll get back to you as soon as possible.

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