Thomas Unise
Overhead pick-and-place gantries are essential components in modern automotive manufacturing, but traditional heavy-duty systems are often overbuilt and expensive for small to midsize applications. ServoBelt technology has emerged as a game-changing solution, offering industrial-grade durability at a fraction of the cost with shorter lead times.
The Challenge in Automotive Manufacturing
Automotive manufacturers have traditionally faced limited options when selecting gantry systems. Conventional systems from large equipment suppliers typically feature:
- Massive steel fabrications designed for extreme payloads
- Premium pricing
- Extended lead times
- Limited customization options
This creates a critical mismatch for smaller applications that don’t require such robust capabilities but still need reliable performance.
ServoBelt Technology: The Solution
ServoBelt technology fills this gap by providing high-performance gantry systems with several key advantages:
- Industrial-grade durability at significantly lower costs
- Lead times often less than half of those from larger suppliers
- Advanced beam engineering using T-slot extrusions
- Structural performance matching traditional rack and pinion equipment
Case Study: Progressive Machine & Design Implementation
Progressive Machine & Design (PMD) successfully implemented a ServoBelt-powered gantry system for a Tier 1 automotive supplier’s diesel engine camshaft manufacturing operation. The system was designed to transport camshafts weighing approximately 80 kg through multiple machining operations.
Key features of the implementation included:
- Design flexibility to fit specific plant layout constraints
- Performance of 3 m/s travel speed with quarter-millimeter positioning accuracy
- Unique belt-rack design eliminating belt stretch over long distances
- Modular nature supporting future expansion
Innovative Composite Beam Design
To meet automotive industry structural standards, Bell-Everman developed a composite beam construction using T-slot extrusions skinned in anodized aluminum. This approach:
- Eliminated deflection between mounting points
- Provided necessary structural rigidity
- Offered an aesthetic appearance of premium industrial equipment
- Maintained customizability advantages
Custom Safety and Reliability Features
The system incorporated several safety and reliability enhancements:
- Allen Bradley drives and motors with Neugart gearboxes
- Schunk grippers with safety lock features
- Redundant Z-axis brakes
- Safe Torque Off (STO) capability
- Custom-designed drip trays to contain coolant and prevent worker injuries
Results and Benefits
The ServoBelt-powered gantry system successfully automated the camshaft transport process with several notable outcomes:
- Seamless integration with existing machining centers and MES database
- Enhanced safety and reliability features
- High-end linear motor performance at significantly lower cost
- A viable alternative to oversized systems for small to midsize payload applications
As PMD’s Chief Mechanical Engineer Brent Stratton noted, the collaborative approach with Bell-Everman and their ability to meet unique requests created a solution that could adapt and expand as needs change.
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