Market Research and Solutions

By : Choy Seong Chor RME 4 (02)

Supervised by : Dr. Lee Yoon Ket

 Loading unloading system using
mechanical lifting mechanism
Automated Manual
Loading/Unloading Loading/Unloading
1. Automated Loading/Unloading – A crane type of machine
assembly with a combination of equipments. For example:
using Rectangular Vacuum Cups or Electromagnets, the crane
can lift up and lower down the products in horizontal transfer.
2. Manual Loading/Unloading – Requires a working personal or
two to carry and transfer product to the stacking area.
 Vacuum Lifting (Automated)
 Vacuum lifting works similar to compressed
air systems.
 The air pressure is increased until a work
force is created in the compressed air system.
 Then, air pressure is decreased below the
atmospheric pressure in the vacuum system so
that the atmospheric pressure is higher. The
work force produced is suction to product
surface.
 To build a vacuum loading unloading system.
• Mechanical vacuum pump. (positive-displacement pump)
• Vacuum generator. (compressed air-powered vacuum generators)
• Choosing a vacuum pump. (things to consider: vacuum flow, vacuum
level and the ratios)
• Vacuum cup. (Rectangular Vacuum cups)
• Calculating the holding force and breakaway force.
Electromagnetic Lifting (Automated)

• Electro-magnetic lifter are normally used

correlatively with cranes.
• Magnetic conductive materials for example
iron or any ferrous material can be lifted up
by using cranes with electro-magnetic lifting
magnet.
• The system to operate an electric crane will
include a row of electromagnets and a
controller for the magnets to create the
magnetic field by controlling the current
flow into the electromagnets.
 Automatic loading & unloading roller systems
1. Inclining slat system : The system uses flat steel slats
that supports the product during extrusion. Then the
slat table would incline sideways to transfer product
to the loading area.
2. Conveyor system: The system runs by using slip
chains and roller tracks to carry product from the
loading area to stacking area.
3. Mechanical flipping: The system uses an actuator to
flip the product
 Advantages and Disadvantages
for each type of loading unloading system
Types of loading and unloading system Advantages Disadvantages

Vacuum Lifting - Little to no downtime between product handling, as - It cannot transfer product at a high speed.
there is no need to use chains or locking slings. - It occupies a large area.
- The vacuum lifting has high accuracy in handling - It is not portable once installed into place.
lifting. - Requires vacuum cup replacement every 2~3 years.
- Reduced labour expenses to one operator.
- The vacuum lifting is safe because it use suction
pressure force that is locked onto product which is
not affected by sudden power loss.
- It is flexible because it can lift various type of
surfaces for example: metal, wood and concrete.

Electromagnetic Lifting
- The electromagnets can be switch on and off by
cutting the supplied electrical current.
- It is easy and flexible to use to load and unload
metal type items.
- It is not heavy work for lifting heavy object which
is time saving when handling long bars.
- It only required one experienced technician for the
operation.
- The electromagnets will heat up very quickly.
- The lifting object must be a ferromagnetic material
to be lift up.
- The metal type object will stay magnetized after it
is lifted by the electromagnet.
- A constant supply of current is required to maintain
magnetism of the magnet.
Types of loading and unloading system
Manual lifting
Automated loading and unloading roller
Advantages Disadvantages
- Very flexible transfer time. - Longer lengths require more operators to
- Operate in per-order basis. support the product to prevent bending.
- Stacking is flexible as the operator can arrange and fit - Slow transition from conveyor to stacking
shorter and longer lengths together in a bundle. platform.
- May cause injury to the operators.
- The power roller have great stabilization during product - It cost more than roller wheel-type
transfer. conveyors.
- Working stability is high. - It is not portable and flexible once installed.
- Design is not complicated. - Occupies an even larger surface area than
crane assembly.
- Unable to have human intervention if any of
the mechanism malfunction.
 Conceptual design
Conceptual design 1: Automated unloading system using electromagnetic force.
1. The first part is the electromagnet holder which will be held with a platform which
includes a stepping motor, linear bush holder, actuator and ball screw cylinder. The
purpose of the platform is to stabilize the transferring process.
2. The second part is the linear guide which will move left and right to help transferring the
item.
3. The third part is the stand that fix on the floor which will hold the linear guide and the
electromagnet platform.
Magnetic Stacker
 Mechanisms found
- Electromagnetic stacking crane
- Scissor configuration with Pulley