In the balance

Lifting aids are in focus when it comes to ergonomics in logistics and material flow. They facilitate the stacking of thousands of packages a day and make it possible, for example, to place wooden boards weighing up to 300 kilograms on the work table of the CNC machine without getting backache. They can be found in the automotive industry as well as in drugstore warehouses. J. Schmalz GmbH advises its customers when a JumboFlex is preferable to the JumboErgo and whether the VacuMaster should be ordered with or without a swivel device. But that is only the end of the system. Before that, the vacuum experts look up. They know which crane ideally complements the ergonomic lifting aid. The range is as diverse as the application scenarios: Suspension and gantry crane systems enable large working areas and carry up to 1,200 kilograms. Slewing cranes can be attached to existing hall pillars or the wall to save space. In the absence of these, they are doweled to the floor with the crane column and base plate and ensure ergonomic handling for loads up to 1,000 kilograms. Special solutions make it possible to go around interfering contours or to use vacuum tube lifters in lower spaces. The common denominator: they all have a modular design and can be flexibly integrated. In addition - and here it becomes clear that they offer much more than just additional reach - they are made of aluminium and are therefore particularly smooth-running. The effort required to start up and move them is reduced by 60 percent compared to a steel alternative. In short: they provide additional ergonomics in everyday handling.

"We achieve this through the very favourable ratio of dead weight to payload and with the help of special low-friction rollers," explains Michael Schlaich. He has been responsible for Handling Business Development since October 2018. The switch from steel to aluminium came about 15 years ago: Instead of buying steel cranes, Schmalz developed a modular system for crane systems based on aluminium profiles. This is specially designed for optional combination with vacuum tube lifters from the Jumbo family, vacuum lifting devices from the VacuMaster series and chain hoists. Based on five different extruded aluminium profiles with hollow chambers, the consultants configure a weight-, load- and cost-optimised crane system together with the user. Numerous additional components are available to them for the design of individual crane solutions, such as jacks for adapting the crane system to low room heights or service stations for the simple exchange of transport trailers. Taking measurements is also part of the service, as are practical tests on sample cranes at Schmalz's premises. "Our modular system has many advantages. One is that we can implement the right solution for every task in a short time," Schlaich explains. In addition, thanks to the modular design, Schmalz is quickly on site with spare parts and can replace individual components or expand the system. Whether new or expanded - safety is always guaranteed, as Michael Schlaich affirms: "All our systems are tested by independent strength calculations of all load-bearing components and are therefore safe!"

"The column-mounted slewing crane is the most frequently requested. It is universal and does not necessarily need a wall or ceiling. The variant with crane column and mobile base plate can be flexibly implemented with the help of a forklift truck if the customer changes the hall layout," explains the Head of Business Development. "Most of the time, the maximum load capacity of a crane is not decisive. In combination with the vacuum tube lifter, what counts more are the dynamics, ease of movement and thus the user-friendliness and the benefit for the user's health," the manager emphasises. The jib can be up to six metres long and can be swivelled through 270 degrees if desired.

In addition to the standard version, there are several special versions: With the aluminium flat boom, Schmalz launched a variant on the market in 2018 that allows the use of vacuum tube lifters even in lower spaces. "Before that, we used a steel construction. This was harder to move and did not build as flat. Now we not only gain almost ten centimetres, but also solve handling tasks with maximum ergonomics in lower rooms," Schlaich adds. The new Schmalz V-Chain energy supply system saves additional space: it packs the hose package of the vacuum supply into a drag chain - no hanging loops mean that forklift trucks can also pass under the boom without danger. If hall pillars or machines are in the way or if work areas are difficult to reach, the knuckle boom or telescopic boom are used. "Both special cranes are now also available as a modular system. This enables individual crane configurations and thus even more flexible handling solutions," reports Michael Schlaich.

If higher loads have to be carried or a larger working area has to be covered, Schmalz designs portal or suspension cranes. "The systems that span an area of several square metres are particularly impressive," says Schlaich. Often, several vacuum lifters are suspended in one system - so one rail system covers several workplaces, for example in shipping, assembly lines or baggage handling at the airport.

An electric travel drive optionally supports the user when moving and positioning loads up to 800 kilograms in suspension crane systems. Soft start and stop make starting and stopping quiet and reduce vibrations. "The drive is an ideal extension for our chain hoist, which lifts heavy loads solo or in combination with the vacuum lifting device VacuMaster," Schlaich adds. It doesn't always have to be the complete system of crane and vacuum handling system. Schmalz also configures crane systems that users can combine with customer-specific lifting solutions such as belts.

Schmalz is known for its smart vacuum systems. In the crane sector, things are more down-to-earth. But where it makes sense, there are points of contact, as shown, for example, by the swivel angle limiter with process monitoring. A two-channel switch with roller lever is mounted on the side of the crane jib. The control system of the surrounding plant communicates with it in order to release or block travel paths or processing steps and machines. "Of course, the crane also participates in digitalisation. But so far it has been more of an extra. The paradigm shift is taking place through the various vacuum handling systems," Schlaich explains.