The automotive industry is leading the way: No two cars are the same. Each one is customized, for example in terms of color, equipment and drive configuration. Challenges such as an increasing number of variants or ever shorter lifecycles increase the demands on all processes along the value chain - including handling. With constantly changing workpieces, weights and changing pick-up and deposit stations, the demands on operators and handling devices are increasing: depending on the configuration of the workpiece to be handled, the handling also changes - every minute, if not every second.

At the same time, however, there are a number of applications that focus on other objectives, such as high dynamics. The fact is that companies are increasingly having to adapt to different handling scenarios. And the respective application determines how digital or smart the appropriate handling technology needs to be.

"With our lifting devices and crane systems, we offer the right solution for all scenarios," says Michael Schlaich, Head of Business Development Process Handling. For example, the company offers devices that are used when lighter loads need to be handled in high cycle rates. Such devices are also becoming increasingly intelligent: they record real-time data from the handling process and provide information that can be used to optimize work and service processes.

For example, displays on filter status and operating hours are used for preventative maintenance, while information on whether a workpiece has been gripped supports the user directly in the work process. Data such as the number of workpieces moved is also recorded and stored by such devices for statistics and evaluation - ideally directly on the smartphone.

Rethinking manual handling
However, the production processes of the future are increasingly based on new systems, structures and procedures. Completely new devices are therefore needed to exploit the full potential offered by Industry 4.0 in handling technology. Schmalz is therefore going one step further and has developed a new class of lifting devices, the SRBC collaborative rope balancer, which has been designed from the ground up for use in the digital production environment.

"Collaborative" means much more than just adding intelligence functions to existing device classes. The innovative electric rope balancer thinks for the user, so to speak. What's more, it relieves the user of work, prevents errors and therefore also increases safety in the process. "The system knows exactly what it has to do in which situations," summarizes Michael Schlaich.

The new rope balancer from Schmalz is used whenever workpieces weighing up to 80 kilograms need to be picked dynamically or positioned precisely. Mechanical, electrical, pneumatic and vacuum load handling devices are available for handling, for example grippers for handling starter batteries. The device reacts to the movement impulses of the load guide: three motors - in the swivel bearing, for the trolley and for the lift - help the user to move and brake loads with virtually no effort and therefore ergonomically.

The operator does not have to press any buttons to lift, lower, swivel and move. The SRBC recognizes and supports the direction requested by the operator. It also complies with predefined limits when swiveling: Working ranges can be defined for each gripper, and damage caused by moving the boom too far is ruled out. Thanks to RFID-based gripper recognition, the rope balancer always knows which type of gripper is connected.

Intelligent system functions
The SRBC rope balancer also automatically reads out important process parameters, such as operating hours or the maximum permissible load. A software package ensures that the operator can concentrate fully on the task at hand and that system operation is intuitive. The software checks whether objects may be lifted or deposited, recognizes spatial limits and adjusts the dynamics of the longitudinal movement to the weight. Depending on the application, it also performs other safety functions: For example, operators can only pick up loads with the vacuum gripper if the vacuum value is correct. It also prevents the load from falling.

The user can adjust system limits, other storage positions or handling methods directly on the handle. "This allows fragile glass panes, for example, to be positioned carefully and precisely first, while the component frame is then lifted quickly to its installation location directly afterwards," explains Michael Schlaich. The entire behavior of the handling system can be changed to suit the specific object, with the aim of achieving simple and, above all, safe handling for both the operator and the component.

Part of the digital factory
Schmalz has designed the new handling system to meet the growing demands of digitalization: Equipped with various sensors, it records status and performance data that can be made available in future via IO-Link and Ethercat when integrated into a digital process landscape. This enables functions such as condition monitoring and predictive maintenance to improve the overall system.

The system reports any errors directly to the display in the operating handle. The semi-automated handling system therefore not only improves ergonomics at the workplace, but also ensures that the entire process chain runs safely. as