ABB installed a new punching machine in its production facility, and the production waste generated during its operation needed to be automatically directed to the factory’s existing waste handling line. To achieve this, a system consisting of three conveyors had to be designed to connect the new machine with the existing waste management infrastructure.
Revismo’s task was to carry out on-site measurements, develop the mechanical engineering solution for the conveyors, and prepare the detailed design documentation required for manufacturing.
Designing into Existing Floor Channels
The conveyors had to be installed into existing floor channels within the factory. Before starting the detailed design work, Revismo’s engineers measured the site and the channels to verify the actual dimensions, connection points, and the space required for installation and maintenance.
When designing equipment for an existing production facility, building drawings alone are not always sufficient. On-site measurements help reduce the risk that manufactured equipment will not fit into the available space or will require modifications during installation.
Three Conveyors as One Integrated System
Due to the location of the new punching machine and the existing waste line, three interconnected conveyors were required.
During the design process, the following aspects had to be resolved:
- receiving waste from the new punching machine;
- ensuring material movement through all three conveyors;
- designing the transfer points between the conveyors;
- connecting the system to the existing waste line;
- ensuring transportability, installability, and maintainability of the equipment.
These were not standard conveyors, but a custom-engineered solution designed specifically for ABB’s production environment, the existing floor channels, and the new punching machine.
Detailed Mechanical Engineering Design
Based on the measurements collected on site and the input data provided by ABB, Revismo prepared detailed 3D CAD models and manufacturing drawings for all three conveyors.
The project also included the necessary engineering and strength calculations. These were used to assess, among other things, the reaction forces acting on the conveyor supports, the load-bearing capacity of the structures, and the loads related to lifting the equipment.
In addition to mechanical design, Revismo prepared risk assessments as well as operation and maintenance manuals for the conveyors.
The design, manufacturing, and installation of the conveyors had to be completed within a defined timeframe, as the system needed to be installed before the final setup of the new punching machine. The efficient communication from ABB’s team helped keep the design work on schedule and enabled technical questions to be resolved quickly.
As a result of the project, a technical solution was developed that fits seamlessly into the existing production environment and whose implementation was supported by well-coordinated cooperation between all parties.