Bergrohr in Germany is one of the world’s leading manufacturers of large diameter steel tubes and the production facility is exceptionally quiet for a steel processing company. There is not a sound to be heard except the sizzling of the welding equipment being used to put a longitudinal welded joint into the 12 metre long steel tubes. This is due to the firm’s internal logistics system.
Special and standard steel tubes carry water, gas and oil over long distances. They stabilise roof structures in large buildings and are used in bridge building. The longest bridge in Europe, the 17 kilometre long Vasco da Gama Bridge, spans the River Tagus and is the shortest traffic link between Lisbon and southern Portugal. Its foundations are reinforced by 35 000 tons of steel tubes manufactured by Bergrohr.
Up to 30 000 kg of heavyweight tubes seem to effortlessly glide through the production halls with nothing more than a faint buzzing noise. This exceptional noise reduction is achieved by a rail-mounted, automated transportation system that uses contactless energy transfer and has been in operation at Bergrohr for around two years. The company originally wanted to switch its workshop logistics systems over to this type of rail-mounted system 10 years ago. However, at the time the necessary drive technology was not yet available on the market. It was only when contactless energy transfer systems were developed around two years ago that Bergrohr was finally able to put its plans into action. SEW-Eurodrive’s Movitrans system made the changeover possible and the long-awaited project was implemented.
Another innovation from SEW-Eurodrive is the Movidrive inverter and this is being used in combination with Movitrans. This unit controls the travel velocity of up to 30 metres per minute, as well as acceleration and braking for the 40 compact transportation vehicles that convey up to 30 tons of heavy steel tubes to the individual processing stations. Movement and braking processes need to be fluent and harmonious at all times as some work pieces project several metres ahead, below or behind the vehicle. They are also sometimes processed directly on the transportation unit and must not under any circumstances tip over when brakes are fully applied. Movidrive provides an optimum solution for this delicate task.
In order to keep waste such as slag and cuttings away from the rails, the electrical conductors of the Movitrans system, Bergrohr procured a high performance sweeping machine that thoroughly clears the hall floor at regular intervals. Employees were also trained how to use the new transportation system, and were instructed that they must not place any tools or similar objects on the tracks or cover the conductors during hot-wire welding or grinding work. The workforce quickly got used to the new technology once it had been implemented. It has created a working environment that is exceptionally clean for the steel processing industry and, above all else, extraordinarily quiet.
Everyone at Bergrohr is happy with the innovative logistics system. It has run virtually without a hitch and boosted tube throughput by some 20%. Due to the many inquiries that have been received since the new technology was installed, the co-operation partners have already decided to offer this innovative transport system to other companies.
“Up until two years ago, our special steel tubes were transported between workstations using roller tables, gantry cranes and transfer tables. This technology was relatively slow and proved insufficient when we wanted to expand our product range for our customers and process additional wall thicknesses and grades of steel. The cranes were no longer able to lift the heavier tubes. The Movitrans system gives us the freedom and flexibility in product development that our customers expect,” said Dr Henning Grebe, technical director, Bergrohr.
For more information contact Rene Rose, Sew-Eurodrive, +27 (0)11 248 7000, [email protected], www.sew.co.za
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| Email: | [email protected] |
| www: | www.sew-eurodrive.co.za |
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