Optimizing Helicopter Component Handling with Automated Crane Synchronization

Industry:
Aerospace Manufacturing

About the Customer:
A leading aerospace manufacturer with a focus on precision-engineered components, this company operates facilities designed for complex manufacturing and assembly tasks. The facility in question required efficient handling solutions for large, delicate components—specifically, helicopter fins—through multiple processing stations.

The Challenge:
The customer’s existing shed was originally designed for handling loads up to 5 tons and was equipped with a 3-ton EOT crane. The component in question, a helicopter fin measuring approximately 6 meters in length and weighing around 600 kg, required a specialized tackle weighing 4.3 tons, bringing the total lifting weight to 4.9 tons. This setup posed several challenges:

  • Space Optimization: The component needed to pass through six processing stations, each requiring precise placement and occasional tilting at a 16° angle for specific operations. Using the same shed without modifications to its structure necessitated careful space management.
  • Automation and Precision: The fin needed to be handled automatically between stations, requiring highly synchronized crane operation for safe, efficient movement along the production line.
  • Safety and Control: The process required various safety interlocks and precise control mechanisms to avoid collision, ensure load stability, and facilitate automated transitions between stations.

The Solution:
To address these requirements, Sparkline proposed an optimized solution tailored to the unique spatial and operational needs of the facility. Key aspects of the solution included:

  1. High-Capacity Crane System: Initially, the plan was to install two 5-ton cranes to lift and move the component along its length. However, Sparkline recommended lifting the component along its width to make better use of the available space. The company provided two 6.3-ton cranes, each equipped with two 5-ton hoists, for safe, controlled lifting.
  2. Crane Configuration for Each Station: A total of six cranes—one for each station—were installed. Each crane was equipped with two synchronized hoists to handle the component efficiently. Rather than synchronizing two separate cranes, Sparkline synchronized the two hoists on each crane, optimizing control and precision for handling the fin.
  3. Automated Control System: Sparkline integrated a programmable logic controller (PLC) into the crane system, enabling automatic positioning at each station. Inputs from the PLC allowed for precise adjustment, tilting, and positioning of the fin as needed. Each crane could be controlled by a master joystick and a slave remote control, ensuring seamless transitions across stations.
  4. Safety and Monitoring Features: The cranes were equipped with advanced safety interlocks, including Incremental Encoders for hoists, anti-collision devices, gear limit switches, and feedback systems that relayed real-time information to the PLC. These features provided enhanced safety, preventing collisions and ensuring stability during each lift and transfer.

A Statement of Overall Benefit:
Sparkline’s innovative, synchronized crane solution allowed the customer to handle large helicopter components safely and precisely within the constraints of their existing shed. The automated system improved handling efficiency, reduced manual intervention, and optimized space utilization, enabling seamless operations across multiple stations.

Benefits:

  • Optimized Use of Available Space: By lifting the component along its width, Sparkline maximized available floor space, enabling the system to function efficiently within the original shed layout.
  • Increased Automation and Precision: The PLC integration and synchronized hoist operation allowed the cranes to operate autonomously across stations, reducing manual handling and improving process accuracy.
  • Enhanced Safety and Control: Safety features like anti-collision devices and gear limit switches, combined with real-time feedback to the PLC, ensured reliable, collision-free operations.
  • Cost and Time Savings: The automated system minimized the need for manual adjustments, reducing downtime and improving overall workflow efficiency.

Sparkline’s synchronized, automated crane solution provided the customer with a tailored approach to meet the complex handling requirements for helicopter fins, ensuring safe and efficient operations in a space-constrained environment.