Delivering an efficient and safe handling system for hot ingots through Ingersoll Rand Lifting Solutions

For nearly a century, Ingersoll Rand has been serving the material handling needs of industries around the globe. Ingersoll Rand pioneered the development of powered lifting, balancing, and handling equipment, thus becoming a world leader in the manufacturing of ergonomic, in process, manual assist, pick and place solutions. The company has been designing standard and custom handling device solutions for over 50 years. By using Ingersoll Rand solutions created for their material handling needs, users can expect improved productivity mandated by a global economy. At the same time, they can expect ergonomic solutions which improve operator performance and avoid labour downtime due to health or safety issues in using automation.

In line with its philosophy of enhancing the workplace environment and helping its clients be more productive, Ingersoll Rand is glad to showcase its solution for handling hot ingots specially targeted towards the Indian forging industry. Though forging industry in India has emerged as the largest exporter of the forgings, in recent times it has been increasingly under the cost pressures due to slowdown in the automotive sector and rising input costs. These companies need flexibility to adjust to such volatile demand scenarios to work at most productive levels but at optimal cost.

One of the important processes in forging industry is transfer of hot ingot from furnace to forging station and forged component from forging station to the storage area. In order to ensure the right quality of the forged components it is important to have minimum temperature loss from hot ingot during this transfer operation. During the forging operation there are also hazards for the operator because of the hot fumes and flying scales and an overall higher ambient temperature that can lead to safety and fatigue issues. The hot ingot handling solution from Ingersoll Rand focuses on improving the productivity of the transfer processes to make them more consistent and at the same time minimising operational hazards. The solution comprises of a pair of tongs at the end of a long arm pivoted at the centre and the operator side is counterbalanced with a pneumatic system (for zero gravity effect) mounted either on the X-Y rail system (for long transfers) or on the jib crane system (for short transfers).

The solution is equipped to handle hot ingots/components up to 250 kg and up to 400 mm diameter. In standard setting, three load variants can be handled by the system and additional can be configured upon customer requirements.

The tongs can be replaced with customized design to handle varying load sizes. The load can be positioned finely using the pneumatic controls provided at the fingertips of the operator and can be manipulated along all 12 DOFs. Customers looking for a lifting solution that can withstand high ambient temperatures and achieve productivity savings in their operations of material transfer but do not have a budget to invest in completely automated transfer using a robot, can opt for this semi-automated solution from Ingersoll Rand at optimal investment yet benefitting from significant productivity savings over completely manual operation. The unique value proposition of this solution lies in the capability of frictionless rail systems, zero gravity assistance and operator conscious design that eliminates operator stress during load manipulation and transfers along with ensuring safety. The pneumatic braking provides better control during transfer applications and heat resistant pneumatic cylinders, hoses and fittings that can withstand up to 70?C ambient ensure that the process runs uninterrupted.

With the use of this lifting solution, customers can realise productivity savings in multiple ways. Firstly, whole operation can be carried out by single person more efficiently with lesser stress thereby getting more work done in given time. Secondly, due to lesser transfer time between furnace and forging station compared to completely manual intervention, there is a minimal temperature drop of the ingot during transfers that ensures better quality final forging and increases energy efficiency.

Ingersoll Rand's primary and vital concern is safety in all solutions for material handling and lifting. The many years of manufacturing experience, ISO 9001 certification, and a 24 hour-service network has created a unique ability to respond to customers' needs with the highest quality material handling solutions, technology, and services available in the world. The hot ingot handling system is a result of Ingersoll Rand's continuous endeavour to help its customers achieve their material handling needs in the efficient manner and at reasonable investment.

(Contact: Bhushan S Kudale, Product Manager - Material Handling Business Unit, India Ingersoll Rand. Tel: 079-22846389. Mobile: 093270-05667. Email: bhushan_s_kudale@irco.com)