Ergonomic risks in high volume production
Operators at a railcar bearing facility faced a material handling problem. The workflow required moving 45 lb bearing cups by hand into and out of deep Gaylord bins. Daily production often hit 1,000 units. This meant workers moved 45,000 lb every shift. Repetitive strain and the postures needed to reach the bottom of bins caused fatigue, injuries, and low morale. The manufacturer needed a solution that matched manual speed but removed the physical strain.
The Gorbel Easy Arm solution
The company chose the Gorbel Easy Arm Intelligent Assist Device after looking at different lift options. This device combines the reach of a jib crane with G-Force technology. A custom Cynergy Magnet tool handles the specific shape of the bearing cups. This end-effector uses a pneumatic rare-earth magnet. It grips heavy steel parts without the slipping risks of mechanical grippers.
Implementation of force sensing technology
The Easy Arm turned the work cell into an efficient area. The in-line force-sensing handle is the main technical feature. It allows the operator to move the load naturally. The system senses user input and provides lifting force. This makes the 45 lb bearing feel weightless.
Attach and release triggers are at both ends of the handle. Operators keep their spines in a neutral position while reaching into the lower parts of a bin. A load cell release safety interlock stops the magnet from dropping a bearing while it is in the air. A status indicator shows if the magnet is active. Overhead lighting on the secondary arm helps the operator see inside the bins.
Impact on productivity and safety
The shift from manual handling to the Easy Arm provided results. The facility stopped having recordable injuries in this cell. Productivity increased and operator morale improved. The company now uses G-Force technology in other parts of the plant for different bearing components.
Technical Questions
1. How does the in-line force-sensing handle improve safety? The handle senses movement and provides a motor response. This stops the jerky movement seen in traditional hoists and allows for exact placement. This helps reduce the risk of musculoskeletal disorders.
2. What stops the magnet tool from dropping the load? The system uses a rare-earth magnet and a load cell safety interlock. The interlock prevents the magnet from releasing until the load sits on a surface.
3. Can the Easy Arm reach different bin depths? Yes, the system can be set up with different arm lengths and handle extensions. This ensures operators reach the bottom of Gaylord bins without bending or overextending their bodies.