Tectra Automation has recently supplied two Schmalz vacuum handling systems to Iveco South Africa’s bus manufacturing facility in Rosslyn, Pretoria. The handling systems will lift and transport the roof and side panels for assembly and fitment onto the buses assembled at the plant.

Both systems consist of 150-mm silicon bellows cups, together with slide valves, tubing and a Schmalz EVE-TR40 vacuum pump. An additional safety system was implemented on each of the systems to warn operators of a loss in vacuum in the event of a power failure.

The roof panel handling system is used to transfer the parts from the storage pack to a workstation where they are prepared for assembly. Once completed, the system transports and places the finished panels onto the bus. 10 bellows cups are positioned over the entire length of the 14-m long, 2.8-m wide roof panels. These panels weigh approximately 200 kg.

Because of the rough side of the roof panel, the cups had to be capable of adapting to the uneven surface. This surface also required a vacuum pump that could provide a high airflow to compensate for the slight leakage resulting from the uneven surface.

The side panels are lifted from the storage rack in a vertical orientation, and transported to the bus for attachment. Tectra Automation designed and supplied the aluminium frame to house the vacuum components using Bosch Rexroth aluminium extrusions. The side panels are 11 m long, 1.5 m wide and weigh 180 kg, and are gripped by a system consisting of 22 bellows cups. As stipulated by Iveco, the system has been designed to accommodate a 15-m long panel in the future.

Through extensive expertise in the field of vacuum technology and system design, Tectra Automation provided a solution that is tailored to the handling requirements of the Iveco operation, which was achieved with maximum efficiency and safety.

The new system was installed and commissioned within two days.

Tectra Automation is a Hytec Group Company and an authorised distributor of Schmalz vacuum technology in sub-Saharan Africa