Context and Challenge

One of our customers, active in tyre production, needed a system for handling rubber reels destined for the manufacture of their products. These reels, which are particularly elastic and delicate, presented a significant challenge to traditional gripping and handling methods. Furthermore, it was essential to ensure compatibility with the different types of reels (varying diameter, height and weight) used by the customer, with a maximum weight of 55 kg.

The reels had to be picked up exclusively from the peg of the customer’s winding machine, and released on specific pallets or supports. Critical requirements included safety, precision and adaptability to different materials and geometries.

The Solution

We developed an innovative, custom-designed handling system to address the critical issues posed by the customer. The solution was based on a device with the following main features:

  • Self-centring pneumatic gripper : Gripping is done by means of a pneumatic gripper that self-centres on the reel peg. No adjustment of the reel diameter is required, but a single adjustment is available for the reel height.
  • Pressure switches for gripper control: Two pressure switches constantly monitor the pressure of the cylinder chambers that drive the gripper. Only when the optimum parameters are reached is the lifting of the load authorised, ensuring a safe and reliable grip.
  • Advanced safety: Clamp closure is only possible with simultaneous activation of both workpiece presence sensors. In addition, the equipment is equipped with non-return valves on the cylinders, which prevent uncontrolled movements in the event of a pneumatic supply failure.
  • Step-by-step movements: Gripping and tilting movements are made by means of two-hand controls, ensuring maximum operator safety. One hand activates the grip/release/tilt buttons, while the other acts on a sensitive handle equipped with a photocell.
  • Adjustable pneumatic centre of gravity: A pneumatic centre of gravity system automatically adapts to the different stages of the work cycle, improving ergonomics and stability during handling.
  • Customised gripping system: To address the specific challenge of the elastic consistency of rubber reels, a specially designed gripping system was developed, different from those commonly used for reels of rigid materials. This approach ensures gentle and safe handling of the material without compromising its integrity.
  • Quick interchange ofgripping rollers: The flexibility of the device is further increased by a quick interchange system of gripping rollers, allowing the equipment to be quickly adapted to different types of reels.

Results

Thanks to this solution, the customer was able to:

  • Ensure safe and controlled handling of reels, reducing risks to operators and material.
  • Optimise the production process, thanks to the speed and precision of the step-by-step movements.
  • Adapt the system to different types of reels without the need for complex reconfigurations.

Our collaboration has resulted in a customised system that combines technological innovation and attention to detail, effectively meeting the specific needs of the tyre manufacturing industry.