Align Production Systems: Innovation in Movement
- 2. Who We Are • Align is a designer, manufacturer and integrator of material handling and manufacturing automation systems • Our emphasis: to help our clients overcome production obstacles and maximize productivity by leveraging the latest movement and positioning technologies
- 3. History • 50 years of heavy load movement experience under the Airfloat banner • Spun off turntable and lift businesses in 2013 • Became exclusive North American partner of Silvestrini the same year • Now go to market under the parent company name Align Production Systems
- 4. Parent Company and Brands
- 6. Airfloat
- 7. Who We Are • Primarily known as a manufacturer of air-film equipment • Innovator of the air bearing (or “air caster”) • Enable other heavy manufacturers to better automate their manufacturing process • 50 years of experience
- 8. What is an Air Bearing? • Pneumatic device similar to a hovercraft • Compressed air passes through a flexible polyurethane diaphragm • Forms a thin air film beneath load • Enables nearly frictionless, omnidirectional movement • Made of chemical- and wear-resistant material
- 9. Typical Air Skid Setup • Typically deployed in circuits of three or four (like wheels) • Used in rigging applications and semi-annual maintenance moves • Kits available in wide range of sizes and capacities • Include a multi-port controller and air hoses
- 10. Kentucky Trailer – Louisville, Ky. Workers move 50-ft.-long, 20,000-lb. trailers by hand, in any direction. This allows the trailers to fit in spaces too tight for fork trucks to safely maneuver.
- 11. GE Transportation – Erie, Penn. 75-ft.-long, 300,000-lb. diesel locomotives float on specially designed air transporters. The equipment helped boost output from 17 to 22 locomotives per month – a 29% gain.
- 12. Progress Rail – Muncie, Indiana 100-ft.-long, 500,000-lb. diesel locomotives float on specially designed air bearing shuttle. The equipment allowed the customer to have four times the throughput in the painting of locomotives.
- 13. • Progress Rail • CNH • Bombardier • Caterpillar • … and More More Recent Projects
- 14. Primary Benefits Outstanding ROI Low capital investment Increase productivity Lower energy costs Supports Lean Manufacturing Easily reconfigure assembly lines No in-ground installation Minimize wasted movement (e.g., attaching lifting straps, etc.)
- 15. Primary Benefits (cont.) Safety Improve ergonomics Reduce worker strain and injury Reduce dependence on forklifts Maintenance Lower maintenance costs – few moving parts to break Reduce floor and wall damage Better housekeeping habits
- 16. Air Bearing Myths • “It’s really loud…” • “It creates a lot of dust…” • “It requires tremendous air pressure…” • “It won’t work on our floor…” • “It’s difficult to control…” All Incorrect!
- 17. Air Bearing Requirements • Floor – flat, level, smooth and non-porous • Most power-troweled concrete floors are OK • Easy, low-cost floor improvements are available • Air – most plant air systems are suitable • Need sufficient airflow volume and pressure • Air consumption is proportional to air bearing perimeter
- 20. Some Axial Turntables: Multi-Positional Fitted with Air-bearings Fitted with Slewing bearings Custom
- 21. Air Bearing Turntables Available in many different sizes and capacities, with or without drive motors. Often used for container handling in factory settings. May include integrated lift/tilt tables or other attachments.
- 23. John Deere Photo Lab Turntable Pit-mounted Air Bearing Turntable
- 24. Ford Motor Company – Woodblock flush floor air bearing 28’ turntable with four independent inset turntables. Designed to handle 80,000 lb load. Electric edge drive with back up drive. Pit-mounted Air Bearing Turntable
- 25. General Motors – Six- position rack indexing turntable, with remote operator control stand feeding to controls box with PLC for plant interface. Floor-mounted Air Bearing Turntable
- 26. Robotic Turntables – Heavy duty glass rack turntable designed for robotic interface. Electric Edge Drive. Robotic Cell Air Bearing Turntable
- 27. Mechanical Slewing Bearing Turntables Available in many different sizes and capacities, with or without drive motors.
- 28. Available in many different sizes and capacities, with or without drive motors. Mechanical Wheeled Turntables
- 29. INDUSTRIAL LIFTING & POSITIONING SOLUTIONS
- 30. Scissor Lift Tables • Pneumatic & Hydraulic Scissor Lifts • Capacities from 2,000 lbs. to 10,000 lbs. • Modular design for easy addition of container tilts or turntables • Available in double and triple scissor lift models for maximum raised height • Electric trip bar, internal power packs, casters and other options available
- 31. Specialty Scissor Lifts ‘Super Series’ Hydraulic Lifts • Capacities from 10,000 lbs. to 25,000 lbs. • Built for extreme lifting applications Loading Dock Lifts • Safer and less expensive than concrete ramps • Work with variety of trucks and trailers
- 32. Additional Safebilt Products Container Tilts • Capacities from 2,000 lbs. to 6,000 lbs. • 30⁰ and 45⁰ tilt models • Bolt-on or standalone operation Pneumatic Pallet Jack • 7,500 lb. capacity • Spark-free operation • Ideal for explosive or hazardous environments
- 34. Silvestrini N.A. • Heavy duty welding positioners • Headstock & tailstock positioners • Two- and three-axis industrial manipulators • Pipe/vessel turning rollers
- 35. Silvestrini N.A. • Founded in Bologna, Italy • 100-year history, fourth-generation owned • Maker of hydraulic positioners, manipulators, and turntables for welding and assembly • Has historically gravitated toward heavy, difficult positioning challenges • Now available in North America in partnership with Align Production Systems
- 36. Silvestrini Equipment Pipe-Turning Rollers Three-Axis Orbital Positioners Two-Axis Welding Positioners Three-Axis Welding Positioners
- 37. Two-Axis Welding Positioners • Capacities from 400 lbs. to 40 tons • Offer tilting and variable-speed rotation • Manual, motor-driven and hydraulic tilt models available • Positioner need not be anchored to the floor • Heavy-duty SA models are virtually maintenance-free and last 30 years or more under normal conditions • Reduce cycle time by 45-50% over static positioning
- 38. Three-Axis Welding Positioners • Capacities from 1,000 lbs. to 40 tons • Offer tilting, variable-speed rotation and hydraulic lifting • Robust 5-to-1 Factor of Safety (FoS) • Machine feet are located behind the table so that large pieces rotate freely, even when table is in vertical position (90° tilt) • Heavy-duty AVSA models are virtually maintenance-free and last 30 years or more under normal conditions • Reduce cycle time by 55-60% for larger work pieces
- 39. Headstock & Tailstock Positioners • Offer hydraulic lifting and electric gear-motor rotation • Capacities from 1,000 kg. to 40 tons • 5 to 1 Factor of Safety (FoS) • Hydraulic safety cutoff • Slide positioning for varying fixture lengths • Optional work-holding jigs and fixtures
- 40. Three-Axis Orbital Positioners • Offer rotation, lifting and tilting • Capacities from 1,000 kg. to 40 tons • 5 to 1 Factor of Safety (FoS) • Advanced motion control for smooth rotation • Hydraulic safety cutoff • Optional clamping system (chuck)
- 41. Pipe-Turning Roller Positioners • Capacities from 1,000 kg. to 90 tons • Includes motorized driver section and idle section • Rotate pipes/tanks up to 8 meters in diameter and 80 meters long • Powered by two three- phase 380V 50Hz motors
- 42. Our Capabilities Concept Engineering Fabrication Assembly Service Next: Industries Served
- 43. More about Align •Headquartered in Decatur, IL since 1964 •Sales offices in Detroit and St. Louis •Design & manufacture everything we sell •Projects completed with 90% of Fortune 500 •60,000 sq. ft. of manufacturing space •3,000 sq. ft. ‘Innovation Center’ for engineering •Laser-cutter reduction used on all designs •Service and/or refurbish what we sell
- 44. Industries Served • Aerospace • Agriculture • Appliance • Automotive • Chemical • Construction • Locomotive • Mining • Nuclear • Prefabricated Home • Printing • Rigging • Ship Building • Steel • Theater and Stadium Seating Next: Our Clients … and Many More
- 45. Our Clients Include: Next: Air Bearing Myths
- 46. European Clients • Fiat • CNH • Caterpillar • Hitachi • Komatsu • General Electric • Bell/Agusta (BAAC) • Alcoa • Daewoo • Peugeot • ABB • Citroen Silvestrini equipment is found in over 20 countries
- 47. Recent Awards & Achievements • 2000 – Awarded Q1 Preferred Quality Award by Ford Motor Co. • 2008 – Partnered with GE Transportation to create world’s first moving assembly line for locomotives (Erie, Penn.) • 2009 – Awarded Performance Excellence Award (Gold Level) by Boeing for excellent supplier performance • 2012 – Awarded Recognition in Innovation by Steel Manufacturers Association (SMA) Next: Final Questions