• Magnetek Material Handling Flex Mini MBT
  • Material Handling Banner Application
  • Material Handling Banner
  • Magnetek Energy Engineered
  • Magnetek Material Handling Collision Avoidance
  • Magnetek Material Handling Flex Mini


Automation Success Stories

Magnetek’s Engineered Systems Group is dedicated to helping customers achieve maximum performance from their material handling equipment. We help our customers identify, select, and implement the best mix of motion control technologies and leading-edge product offerings available for their specific applications. With over 100 years of combined experience, the Engineered Systems Group has the expertise to serve your application needs from start to finish. This list is a sample of the types of new and retrofit control applications that Magnetek’s Engineered Systems Group has successfully built for customers.

Magnetek provides a complete turn-key controls solution by designing the panels, programming the PLCs, testing the equipment prior to shipment, and performing on-site start-up services and performance testing to meet the customer’s application requirements.

Waste Crane Success Story      Featured Success Story:  Automated Refuse Handling Crane System- Retrofit Application 
(Click to Download)

Material Handling Automation Success Stories



Success Stories: TDC Cranes

TDC Crane's All-Electric, Environmentally Friendly, Dredge Project


Products
IMPULSE®•G+ Series 4 Drives
IMPULSE®•VG+ Series 4 Drives
Blue Max®Inverter Duty Motors
Dynamic Braking Units and Resistors
Custom AC Control Panels
Advanced Bucket Control Custom Software
Static Stepless Simulation Custom Software

The System
Provide state-of-the-art adjustable frequency drive crane motor controls for the largest capacity, most technologically advanced, dredge crane operating in North America.

TDC Cranes - Download PDF



Success Stories: Automated Bridge Cranes

Automated Dry-Dock Boat Storage/Retrieval System

Products

The System
An automated dry dock boat storage system utilizing an overhead bridge crane. The facility accommodates 125 boats up to 52 feet in length. The automated crane eliminates the need for fork trucks to store and retrieve boats. While fork trucks emit soot and grease which gets on the boats and can damage the hulls, the automated bridge crane operates quietly and cleanly, which is good for the residential community in which it resides. The automated crane controls are located at ground level for easy access. An Allen-Bradley HMI is programmed to display the occupancy status of each storage location and to key in information relative to new boats being entered into the system. A teach function is also provided to initialize new boats into the storage-retrieval system.  

Evolution Article, Issue 40, Fall 2005 - Download PDF

Port Condo and Marina Maximizes Storage Space - Download PDF


Automated Tobacco Processing Crane System

Products

The System
An automated tobacco processing crane control system. The crane automatically transports trays of tobacco leaves from an inbound robot to a series of auto claves (dryers), and then to an outbound robot. All crane controls are located at ground level for easy access and troubleshooting, and for communication to the robot and auto claves. The Siemens HMI reports crane status, system faults, and diagnostic information. A teach function is also programmed into the PLC to add future autoclaves into the system. The crane is also programmed to automatically operate around obstructions in the facility.  


Automated Brake Press Servicing Bridge Cranes

Products
  • Electromotive Systems IMPULSE®•G+ Series 2 Adjustable Frequency Drives
  • Magnetek Festoon Systems
  • SBP2 Pushbutton Pendant Stations (manual back-up control)
  • Allen-Bradley PLC and HMI
  • Laser Positioning System

The System
Five automated bridge crane systems servicing unique work cells. Each work cell consists of six brake press machines, along with an inbound and outbound hopper location. An automatic-dispatch control system is provided for the overhead cranes to move materials from one location to another resulting in a safer, more reliable and efficient operating system. The automatic control of the speed and acceleration rates improve the material flow process by shortening the travel times and increasing the positioning accuracy of the bridge, hoist and trolley.

Auto-Dispatch Crane System 


Other Automated Bridge Applications:

Crane Collision Avoidance & Distance Detection Systems
Crane Anti-Skew & Positioning Control
Positioning Methods for Overhead Cranes & Monorails
Crane & Monorail Systems in Modern Foundries
Auto-Dispatch Systems for Overhead Cranes & Monorails
Crane Anti-Swing Control


Success Stories: Automated Monorail Systems

Automated Hot Metal Monorail System

Products
  • Electromotive Systems IMPULSE®•G+ Series 2 Adjustable Frequency Drives
  • PulseStar Radio Remote Controls (primary control)
  • SBP2® Pushbutton Pendant Stations (manual back-up control)
  • Allen-Bradley PLC

The System
Three semi-automated monorail carriers operating on a closed loop system. The carriers transport ladles of molten steel from a melt furnace to two pour locations, with collision avoidance systems between carriers. The hoist is positioned using a four-position geared limit switch and the trolley is positioned using proximity sensors. The radio remote control system allows any of six transmitters to control any of the three carriers based on a first-come first-serve method.

Automated Hot Metal Monorail System


Automated Cab Delivery System

Products
  • Electromotive Systems IMPULSE®•VG+G+ Series 2 Adjustable Frequency Drives
  • PulseStar Radio Remote Controls
  • SBP2 Pushbutton Pendant Stations (manual back-up control)
  • Allen-Bradley PLCs

The System
Six automated monorail carriers with a speed range of 1.75 FPM to 100 FPM and monorail system to conveyor system speed matching.


Automated Engine and Cab Delivery Monorail Systems - Retrofit Application

Products
  • Electromotive Systems IMPULSE® P3 Series 2 Adjustable Frequency Drives
  • PulseStar Radio Remote Controls
  • SBP2® Pushbutton Pendant Stations (manual back-up control)
  • Allen-Bradley PLCs
  • Wireless Data Communication

The System
Independent engine and cab delivery systems consisting of separate five and seven carrier automated monorail systems. The systems include call and send commands from the work stations to the carriers along with line speed matching between the monorail system and ground conveyor.


Automated Engine Paint Line Monorail System

Products
  • Electromotive Systems IMPULSE®•VG+/G+ Series 3 Adjustable Frequency Drives
  • PulseStar Radio Remote Controls (workstation operation)
  • SBP2® Pushbutton Pendant Stations (maintenance control)
  • FABA Conductor Bar
  • Allen-Bradley PLCs and HMIs
  • Wireless Data Communication

The System
Thirteen automated monorail carriers that interface with wash booths, paint system robots, ovens, conveyor systems, and the end user’s MRP system. The system’s speed range is 1.75 FPM to 30 FPM with monorail system to conveyor system speed matching and wireless Ethernet RF communication between the main system controller and the monorail carriers. RFID technology is used for product tracking and HMI color touch screen operator interfaces report system status and monitor system progress.

Caterpillar, Inc. Automated Paint Line Monorail System Project - Download PDF


Automated Engine and Axle Delivery System

Products
  • Electromotive Systems IMPULSE® G+ Series 3 Adjustable Frequency Drives
  • Telemotive telePilot Radio Remote Controls (workstation operation control)
  • SBP2® Pushbutton Pendant Stations (manual back-up control)
  • Allen-Bradley PLCs

The System
Two separate, eight and 10 carrier automated monorail systems. HMI color touch screen operator interfaces report system status and wireless Ethernet RF is used for communication between the system controller and the carriers. The system also includes code rail positioning and line speed matching to the on-ground conveyor system.


Automated Cab, Axle and Fifth-Wheel Delivery System

Products
  • Cab Set Monorail System - Retrofit Application
    - Electromotive Systems IMPULSE®•G+ Series 3 Adjustable Frequency Drives
    - SBP2® Pushbutton Pendant Stations (manual control)
    - Allen-Bradley PLCs and HMIs 
  • Axle Set Monorail System - New Application
    - Electromotive Systems IMPULSE®•G+ Series 3 Adjustable Frequency Drives
    - PulseStar Radio Remote Controls (manual bridge crane control)
    - SBP2® Pushbutton Pendant Stations (manual carrier control)
    - Allen-Bradley PLCs and HMIs 
  • 5th Wheel Monorail System - Retrofit Application
    - Electromotive Systems IMPULSE®•G+ Series 3 Adjustable Frequency Drives
    - SBP2® Pushbutton Pendant Stations (manual carrier control)
    - Allen-Bradley PLCs and HMIs

The System
Three independently operating automated monorail systems. The cab and axle systems consist of 10 automated carriers each, and the 5th wheel system contains three automated carriers. Each system contains wireless RF communication between an on-ground controller and the carriers, line speed matching between the carriers and a conveyor system, and HMIs for diagnostics and status reporting. Bar code technology is also utilized in the cab system to report cab production data to the automated process.

Peterbilt, Denton, Texas Automated Axle Set Monorail System, Automated Cab Set Monorail System, Fifth Wheel Monorail Systems - Download PDF

Evolution Article, Fall 2009 - Download PDF


Automated Wheel and Strut Paint Line Monorail System

Products

The System
An automated wheel and strut paint system consisting of 15 automated monorail carriers (nine initially, six added later) with two separate product lines sharing one prime-and-finish paint processing system. HMI color touch screen operator interfaces are used to report system status, wireless Ethernet RF is used for communication between system controller and carriers, and RFID technology is used for product tracking.

United States Air Force Base Lean Transformation Project - Download PDF


Automated Bus Assembly Monorail Systems

Products
  • Electromotive Systems IMPULSE®•P3 Series 2 Adjustable Frequency Drives
  • Contactor Controls (hoist operation)
  • SBP2® Pushbutton Pendant Stations (manual interface)
  • Allen-Bradley PLCs

The System
Two independently operating 3-carrier monorail systems for toe box and engine to chassis assembly. Each system includes line speed matching of the carriers to an on-ground conveyor. The hoist and trolley motions are controlled by IMPULSE adjustable frequency drives. An SBP2 pushbutton pendant station, suspended under the carrier, controls all hoist and carrier motion and is used to initiate the auto-dispatch functionality of the system.

Automated Bus Assembly Monorail System


Success Stories: Pulp/Paper/Films

Automated Lumber Handling Crane System

Products
  • Electromotive Systems IMPULSE®•G+/VG+ Series 2 Adjustable Frequency Drives
  • PulseStar Radio Remote Controls
  • Hoist and Trolley Synchronization Controls
  • Bridge Anti-skew Controls
  • Hoist Anti-sway Controls
  • Allen-Bradley PLC
  • Laser Positioning Systems

The System
Two automated lumber handling bridge cranes, installed in two different facilities.  Each crane contains two trolleys and utilizes Magnetek’s Hoist Synchronization Software, Trolley Synchronization, Bridge Anti-skew Control, and Hoist Anti-sway Control. The cranes are automatically dispatched between the train unload area, the lumber storage locations, an outbound loading area, and a saw used to shorten the bundles as needed. These automated overhead solutions eliminate the need for fork trucks, thus reducing the spacing between aisles and doubling the storage capacity of the facility.

Evolution article Issue 33, Winter 2002 - Download PDF

Automated Lumber Storage-Retrieval System


Automated Paper Roll Handling Crane

Products
  • Electromotive Systems IMPULSE®•G+/VG+ Series 2 Adjustable Frequency Drives
  • PulseStar Radio Remote Controls
  • Allen-Bradley PLC
  • Laser Positioning System

The System
The system controls an automated paper roll handling bridge crane.


Automated Mill Roll Handling System

Products

The System
Two fully automated bridge cranes and two automated transfer cars. The cranes and transfer cars interface with the end user’s inventory management system and also includes an external interface with the orientor, slitter, and slabber machines. An industrial PC is used for complete system integration and HMI color touch screens are used for entering data and reporting system information.

Automated Mill Roll Handling System


Other Pulp/Paper/Films Applications

Monorail Collision Avoidance & Distance Detection Systems


Success Stories: Dip Tank Systems

Automated Tractor Combine Electrostatic Dipping System

Products

The System
Seven automated dipping cranes working together over a series of cleaning, rinsing and painting tanks used in an electrostatic painting process for tractor combines. The process includes networked communication with incoming and outbound conveyor systems and an HMI color touch screen operator interface for reporting system status.


Automated Automotive Parts Dipping System

Products
  • Electromotive Systems IMPULSE®•G+ Series 2 Adjustable Frequency Drives
  • SBP2® Pushbutton Pendant Stations (manual back-up control)
  • Telemotive telePilot Radio Remote Controls    (manual back-up and maintenance control)
  • Marathon motors
  • Magnetek Festoon Systems
  • Allen-Bradley PLCs
  • Laser positioning systems

The System
Four automated dipping cranes operating over a series of 16 tanks used in the electrostatic painting process for automotive parts. Each crane’s rigid mast contains two hoists that are controlled separately and synchronously by two IMPULSE Drives. This allows the hoists to raise and lower the load evenly into and out of the tanks, and allows them to tilt in order to drain excess liquid from the parts before moving to the next tank. The bridge motions are also controlled by IMPULSE Drives. An HMI color touch screen operator interface is used for reporting system status and setting dipping cycle parameters.

Automated Tank Line Dipping System


Automated Flat Bed Truck Dipping System

Products

The System
Three separate automated dipping cranes are used to galvanize flatbed trucks. Parts move between cranes on a conveyor system. The cranes have rigid fixed masts for their hoists. Each crane’s hoist is controlled by an IMPULSE Drive. The bridge is also controlled by an IMPULSE Drive. All three cranes communicate with an off-board HMI color touch screen operator interface and external communication with incoming and outbound conveyor systems.

Automated Electro-static Painting System


Automated Gantry Crane Dipping System - Retrofit Application

Products
  • Electromotive Systems IMPULSE®•G+ Series 2 Adjustable Frequency Drives
  • Allen-Bradley PLCs

The System
The system controls an automated gantry dipping crane.


Other Dip Tank System Applications

Collision Avoidance & Distance Detection Systems
Automatic Crane & Monorail Process Control


Success Stories: Waste to Energy Systems

Automated Refuse Handling Crane Systems

Products
  • Electromotive Systems IMPULSE®•G+/VG+ Series 2 Adjustable Frequency Drives
  • Allen-Bradley PLCs & HMIs

The System
Two independently operated automated refuse handling crane systems are used to pick garbage from a pit and fill two furnace hoppers in a Class I, Div 2 environment. Operator pulpit controls are used for manual operation and an HMI color touch screen for operator interface.


Automated Refuse Handling Crane Systems - Retrofit Application

Products
  • Electromotive Systems IMPULSE®•G+/VG+ Series 3 Adjustable Frequency Drives
  • Magnetek Anti-Sway controls
  • Allen-Bradley PLCs
  • Encoder Positioning Systems

The System
Two automated refuse handling bridge cranes operate together on the same runway. The cranes are used to mix garbage in a large pit and feed three furnace hoppers. The end product of this facility is power generation. The system includes collision between cranes and operator pulpit controls for manual operation.

Olmsted Waste-to-Energy Facility Bridge Crane Project - Download PDF


Success Stories: Hydro Power Systems

Powerhouse Crane with Diagnostics and Monitoring System - Retrofit Application

Products
  • Electromotive Systems IMPULSE®•G+/VG+ Series 2 Adjustable Frequency Drives
  • Mondel Thruster Brakes
  • PulseStar Radio Remote Controls with weight display feedback
  • Allen-Bradley PLCs
  • Marathon Motors

The System
Two powerhouse cranes have simultaneous hoist and trolley operation and hoist weight display feedback on the radio transmitters.


Powerhouse Cranes with Diagnostics and Monitoring Systems- Retrofit Applications

Products
  • Electromotive Systems IMPULSE®•G+/VG+ Series 3 Adjustable Frequency Drives
  • Mondel Thruster Brakes
  • Telemotive MLTX Radio Remote Controls
  • Allen-Bradley PLCs & HMIs
  • Blue Max Motors

The System
Two powerhouse cranes have simultaneous hoist and trolley operation. An HMI touch screen is used for operator interface and to report system diagnostics.


Synchronized Powerhouse Cranes with Diagnostics and Monitoring Systems - Retrofit Application

Products
  • Electromotive Systems IMPULSE®•G+/VG+ Series 3 Adjustable Frequency Drives
  • Marathon Motors
  • Mondel Thruster Brakes
  • Enrange Flex M Radio Remote Controls
  • 700T Transmitter with weight display
  • Allen-Bradley PLCs & HMIs

The System
Two powerhouse cranes operate individually or in tandem with multiple combinations of individual and synchronous operation between two bridges, four trolleys and four hoists. An HMI touch screen operator interface is used for reporting system diagnostics to the cab operator. When the two cranes are mechanically and electrically linked together, one cab controls both cranes.


Success Stories: Pedestrian Bridge Lifting System

Superior Crane's Red River Pedestrian Bridge Project

Products

IMPULSE®∙VG+ Series 4 Adjustable Frequency Drives
IMPULSE® Drive Synchronization Software
Enrange™ Flex EX Radio Remote Controls

The System
Two hoists are located on towers at each end of the bridge and are powered by Magnetek’s IMPULSE∙VG+ adjustable frequency drives. Fiber optic cable trenched beneath the river allows for communication between the two isolated drives. Drive synchronization software precisely monitors speed and positioning of each end of the structure to maintain a balanced lift and can automatically re-synchronize drive motors. One person can use the Flex EX transmitter to operate hoists on both sides of the bridge at the same time, ensuring a balanced lift.  

Pedestrian Bridge Lifting System  - Download PDF



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