Above: Steel Storage Systems developed a gravityfed system with pneumatically actuated cams to feed and index pipe into 10 positions.
October, 2024: Sometimes the solution to a material handling challenge requires a fresh approach. Steel Storage Systems Inc. realized that need when it recently designed and built a custom material handling system in connection with the production of risers for a manufacturer of fire hydrants and valves that wanted a way to feed ductile iron pipe to a flange-mounting machine, says Josh Couch, mechanical engineer for the Commerce City, Colorado, company. Steel Storage Systems manufactures equipment for storing and handling metal efficiently.
The customer needs to transfer 2- to 10-foot-long sections of pipe up to 10 inches in diameter from a CNC lathe, where the ends are threaded, to a machine that spins a flange onto the pipe, Couch explains. Previously, a 6-axis robot picked up a threaded pipe and put it on load rails, on which the material would roll along until the next station.
Although the load rails were adjustable, they could only be adjusted to one specific length at a time, so the hydrant manufacturer was only able to process one size of pipe at a time, Couch adds. That scenario required the company to prioritize scheduling, even though certain lengths of pipe might not be ideal for its schedule. “They were looking for the ability to optimize their cut length, reduce their waste and speed up their process,” he says. The new system will change how they schedule these cuts. “Now they can actually run the pipe through the system for just-in-time delivery.”
WORKING WITH GRAVITY
Over the course of several months, Couch says Steel Storage Systems worked with the customer to develop a cost-effective, gravity-fed system with pneumatically actuated cams to feed and index the pipe into 10 positions, with the robot repurposed to load the system from the CNC machine. Each row of cams shares a common pneumatic drive, which rotates forward to allow the pipe to roll down the incline from one position to the next.
“Once the system is completely full, all 10 positions have a piece,” he says. “As the operator unloads that last piece on the bottom of the system, every single cylinder fires and all the pieces index forward at once. That frees up the top position for the robot to put a new piece on.”
Once a pipe is indexed out of the system, an adjustable cradle with wheels catches the pipe, Couch notes. “I think this system could very easily integrate with our own conveyors or our transfer equipment.”
The customer was familiar with Steel Storage Systems prior to ordering the pipe loading and indexing system because it has several of the company’s SpaceSaver rollout cantilever racks for storing long material, Couch says. “And they’re looking to get a few more.”
Constant communication was essential to help with the design and production of the pipe handling system, which was a novel idea, according to Couch. “We were providing them with our 3D models as we were building it just to make sure that it would fit in their footprint, and they were happy with the look and the design. On the back end, we’re going to provide them with detailed installation drawings, full support. We’ll stay in constant communication with them.”
When installed, the system will be about 16 feet long by 10 feet wide, he adds. Steel Storage Systems successfully completed the run-off of the system and plans to ship it for installation, as of press time. “The installation should be extremely quick and easy. It uses pneumatics, which makes it extremely simple. They just have to hook up one air hose to the system.” In addition, being pneumatically actuated minimizes maintenance, Couch says, because there is no oil or lubrication that is needed or a hydraulic power unit to take care of. The system is also adjustable. Adjustable legs enable changing the slope of the system if pipe is rolling too fast or not quickly enough, and the cylinder speed, air pressure and return stroke are also adjustable.
Couch adds that this type of pipe system can be configured to fit many different needs. “We can customize it to fit any size round. We can customize the length, the size of the position and the width of the table.”
Josh Couch with the custom handling system for loading and indexing pipe
HANDS OFF
Besides efficiency, the pipe system also enhances worker safety, he says. The design removed the operator from the CNC machine and robot side of the process. Previously, the operator had to access that side and manually adjust the load rails to the required pipe length and might have to perform that task several times a day, depending on the lengths that were scheduled to run.
The pipe loading and indexing system uses pneumatics, which enables a quick and easy installation process.
“Now it’s completely hands off until the pipe is delivered to the bottom of our system. Then they have a manual operator coming on and starting the thread on the flange machine and the machine spins the flange on.”
Couch says Steel Storage Systems typically provides controls for the system but this time the customer had its own controls. Owning the controls avoids having to use a controls contractor to try to get a parameter changed. “They feel ownership in the system. They can tweak it on the fly. They wanted the ability to integrate with their existing control system without having a third party being involved.”
Having that ownership enabled the customer to hook up its programmable logic controller and test it during system run-off, he adds. “Everything worked out great for them. We were working on the mechanical side of things, and they were able to spend their time working on the control side of things.”
Being a custom design for a material handling system, Couch says Steel Storage Systems wants to determine its ruggedness and ability to withstand the test of time. “We encourage them to really beat it up and try to break it. We’ll be here to fix anything that comes up if anything does.”
Steel Storage Systems Inc., 800/442-0291, steelstorage.com.
