The Challenge: Balancing high-throughput milling with precision material handling
Atlas Copco’s Gas and Process division engineers high-performance turbo compressors and expansion turbines for sectors including natural gas processing and power generation. At one of its major assembly facilities, the manufacturing workflow faced a severe operational bottleneck. Multiple work cells were forced to share a single heavy overhead crane system to handle various large components and sub-assemblies. This shared infrastructure led to costly operational downtime and frequently left technicians at a standstill while waiting for the crane to become available.
To bypass these systemic delays, operators would occasionally attempt to manually manipulate components. This practice introduced severe safety hazards and product quality liabilities. In high-throughput milling work cells, operators handle large, heavy stainless steel cylinders that act as impeller blanks. These blanks range from 5 to 15 inches in diameter and weigh anywhere from 15 to 400 pounds. As these blanks are milled down from raw bell-shaped components into finished impellers, they develop exceptionally sharp, aerodynamic blades. Moving these heavy components manually or with imprecise traditional hoists created a dual liability: a high probability of severe operator lacerations or musculoskeletal injuries, and a high risk of scratching or denting the precision-machined surfaces of the impellers and the expensive CNC milling fixtures.
The Solution: Intelligent assist via servo-powered technology
Recognizing the urgent need for dedicated, localized material handling, Atlas Copco targeted the milling application for a comprehensive process optimization. The facility installed dedicated Gorbel work station cranes to eliminate the productivity delays caused by the shared overhead crane system. However, integrating the right lifting device remained a major technical hurdle. The device needed to provide extreme precision, robust capacity, and intuitive control to allow operators to navigate tight tolerances inside the milling machine safely.
After evaluating several servo-powered lifting devices on the market, Atlas Copco selected the Gorbel G-Force Q Intelligent Assist Device (IAD) with a 660-pound lifting capacity. While conventional hoists rely on rigid up/down pendant buttons that lack tactile feedback, the G-Force Q utilizes advanced industrial electronics and a responsive servo drive system. Atlas Copco selected the G-Force specifically due to its unique Virtual Limit Package, its patented Float Mode feature, and its fluid, stable movement facilitated by a high-strength wire rope assembly.
The Execution: Seamless integration of Float Mode and virtual limits
The integration of the Gorbel G-Force Q fundamentally transformed the ergonomics of the work cell. To interface seamlessly with the G-Force, Atlas Copco engineered a custom mechanical tooling grip that locks securely onto the outer rim of the bell-shaped impeller blanks.
Visual analysis of the operational sequence reveals the efficiency of the execution. During component coupling and lift initiation, the operator positions the custom-designed semi-circular tooling arms over the impeller blank on a staging cart and clamps it securely onto the outer rim.
Next comes Float Mode activation. Once coupled, the operator engages Float Mode via the G-Force handle control. This mode shifts the control dynamics completely. The operator maneuvers the 15-to-400-pound load effortlessly by applying minimal manual force directly to the load or the gripping tool itself, which removes the lag associated with traditional hoist pendants.
For precision machine loading with Virtual Limits, the operator guides the suspended impeller blank into the enclosure of the CNC vertical milling machine. As the load approaches the sensitive milling fixture, the pre-programmed Virtual Limits of the G-Force automatically engage. The system enforces a speed reduction point and slows the descent to prevent impact.
This allows exact seating and zero-impact placement. As the impeller blank arrives at the exact seating position, the G-Force prohibits any further lowering beyond the designated coordinate. This ensures the blank is placed flush onto the fixture with zero mechanical impact.
Finally, the system ensures the safe extraction of finished components. Following the automated milling cycle, the enclosure opens to reveal a finished impeller with razor-sharp blades. The operator re-engages the tooling grip and lifts the finished component out of the machine smoothly, completely isolated from physical contact with the sharp edges.
The Result: Total risk elimination and accelerated throughput
The deployment of the Gorbel G-Force Q achieved all technical and safety benchmarks set by Atlas Copco. By eliminating reliance on the shared crane and replacing manual handling with servo-powered intelligence, the facility completely mitigated the risk of operator injury and expensive product damage.
Operator feedback has been exceptionally positive, particularly regarding the ease of aligning bolt holes and precision pins using Float Mode. By providing a solution that enhances, rather than hinders, operational speed and ergonomics, Atlas Copco achieved a 100% adoption rate among shop-floor personnel. This adoption secured long-term productivity and manufacturing excellence.