Slip Sheet Installation
Turnkey install slipsheet dispenser unit encompassing the design, fabrication, and PLC/controls of a new slipsheet dispenser unit.
Client Name
Building Materials Manufacturing Corporation
Industry
Roofing Material Manufacturer
Location
Wayne, NJ
Goal
Turnkey install slipsheet dispenser unit encompassing the design, fabrication, and PLC/controls of a new slipsheet dispenser unit.
Project Summary
Provide a turnkey and complete project encompassing the design, fabrication, and PLC/controls of a new slipsheet dispenser unit (matching the West line unit). Includes field installation and integration with existing east line palletizer and pallet dispenser. This installation will include all rigging, mechanical, PLC/controls, and commissioning work required for an automated, operational, and seamlessly integrated system. Installation will be coordinated with onsite operations and includes startup and training for operators. Quote encompasses all labor, materials, tools and equipment required to complete the project.
Project Scope
- Based on site visits and matching the West line unit, built and installed Aug. 4th, 2024. The East line will be a MIRROR image/unit of SSQ Drawings titled “S-SQ-MA-600000.EASM” the proposed encompasses the following work completed, equipment supplied, and services rendered.
Project Steps
- Project Preparation
- Project Installation
- Project Requirements
- Project Recommendations
- Project Notes
1. Project Preparation
2. Project Equipment
3. Project Installation
4. Project Recommendations and Requirements
1. Project Preparation
1. Main Electrical Drops
One (1) electrical power drop with local disconnects was required for the proposed new line. Drops were needed to be 480V/3ph/60Hz and estimated at 30-50 FLA per drop. (Amp draws will be confirmed at time of order and options requested). Steel Square advised contacting current in-house/contracted electrician to ensure consistency of work completed and comply with building electrical designs.
- 1) Electrical drop for load transfer & conveyors (reuse existing in place drop)
- (1) Network Drop (reuse existing in place drop)
- (1) Safety interlock drop (reuse existing in place drop)
2. Site Visit and Project Review
Steel Square completed a site visit and project review that assessed the functionality, after 30 days of being in use, of the West line, and complete a final review of the East line confirming space allowance and measurements. While onsite:
- Utilities requirements were confirmed, and work needed for completion. (Electric and Air)
- Equipment elevations and floor layout were confirmed for fit and finish of new equipment installed in place. Review existing conveyors for obstructions to new equipment.
- New Electrical enclosure location – Reusing runs required for existing pallet dispenser. Existing cable runs were used when possible and new runs needed were laid. Confirmed door swings and available work room/clearance
- New Hydraulic Pump – Updated hydraulic pump
- Safety – locations of e-stops, fencing, highway guarding, bollards, accessible/usable HMI locations
- Operations - Adopted requested changes by operations and updated changes to the West line followed by implementing those updates into the new East line equipment.
2. Project Equipment
1. Equipment Operation
- Slip sheets, corrugated and plywood, will be loaded by forklift operator into the queue of the slipsheet dispenser. The load process will be assisted by built in machine frame setback, guide & deflection ramp, side guides, wheel stop, and standoffs built for each slipsheet type. Once loaded and the forklift clear of the present sensor, the unit liftable will raise the slipsheet stack to a set top layer height for a consistent and repeatable pick point. A single sheet will be picked from the top of the stack and travel over a palletizing load based on a gantry system with horizontal and vertical travel. The vertical travel will be accomplished by electric cylinder with 60” stroke to ensure clearance from palletizing loads and existing palletizer. The horizontal travel will be accomplished with a ¾ HP induction motor. Sheets will be picked and held with three (3) Piab vacuum bars ensuring holding strength and redundancy in holding. Once a sheet is picked the unit will travel over the palletizing load and wait for confirmation by the customers palletizer as to the layer to place a sheet and when clear of obstructions. Once a sheet is deposited the unit will raise, return to the queue, pick the next sheet, and return out over the palletizing load ready to deposit the next sheet at specified layer. Unit will match performance, metrics, and be a duplicate of the West line unit.
2. Performance Conditions and Service Requirements:
- GAF/OT: Unit complies with GAF Performance Guarantees & Standards as well as OT standards
- System Controls: Allen Bradley Compact GuardLogix 5380 controller, drives, motor starters, power supply, 12” HMI, AB Stratix ethernet switch, panel air conditioner units, and disconnect switch furnished and installed in a Nema 12, UL enclosure. Safety scanners installed on infeed and discharge conveyors.
- Vertical and Horizontal travel controlled by Allen Bradley Kinetix 5700 drives.
- Electrical Enclosure: A new electrical enclosure complete with all components, AC units, and wiring was provided with the equipment and replaced the existing east electrical enclosure. The enclosure will maintain separation of voltage 480V and 24VDC sided enclosure.
3. Project Installation
Slipsheet Dispenser w/ New Replacement Electrical Enclosure & Demolition of Existing Slip Dispenser & Electrical Panel
Manually installed were one (of each) new slipsheet dispenser, new hydraulic pump, and new electrical enclosure. The unit is part of a larger system which includes the coordination and integration of the existing pallet dispenser and the East palletizer. The existing slipsheet dispenser and the electrical enclosure were removed and replaced with new equipment. This installation included all rigging, mechanical, PLC/controls, and commissioning work required for an automated, operational, and seamlessly integrated system. Installation was coordinated with onsite operations and includes startup and training for operators.
PLC integration- Logic and handshakes were created between the new equipment and integrate the slipsheet dispenser with the East Palletizer. Incorporates additional debug.
4. Project Recommendations and Requirements
1. Slipsheet Dispenser
- Horizontal Travel Upgraded to 4 HP Servo Motor
- Corrugate brushes, Forklift load Ramp & Guides
- Airline Upgrades – Add Airline filter
- Two (2) Year Service and Warranty Package
2. HMI Performance Package
- System equipped with 12-15" HMI screen for larger print, more screens, and greater visuals, easier navigation, and troubleshooting.
- Two (2) Year Service and Warranty Package
3. New Pallet Dispenser
- The entire pallet dispenser and conveyor section was replaced and upgraded with a new dispenser. The new unit has a superior design and is operationally equivalent to that of the new slipsheet dispenser and includes two (2) Chain Driven Roller (CDLR) conveyors.
- Two (2) Year Service and Warranty Package
Project Notes
1. Project Equipment – This installation required one warehouse fork truck, propane powered, to unload equipment and one scissors lift to assemble equipment. All equipment was supplied by Steel Square.
2. Pre or Onsite Safety Training – Steel Square included 1 hour of safety training per person and/or testing that was either plant specific or above and beyond 3rd party certifications. For commissioning, start up, I/O checks, and debug a review of company policy was reviewed to meet safety policies and acceptable practices.
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