Custom Coil Rack Manufacturing Case Study

By Author: Joe DiSabantonio
Total Articles: 15
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Project Scope:

Cranes and man-lift manufacturers have faced problems handling their various gages of twisted metal cables with welded fittings. The cables are coiled flat, secured with the plastic cable ties and stacked in paper corrugated bulk containers by the supplier.

The coils involved are 19od x 3 girth and contained by plastic cable ties as well. Once the coils are in the user's plant there must be another way to handle the coils and deliver them to the final production line.

These heavy coils, (up to 100 lbs,) must be repackaged into smaller plastic pallet containers in order to fit in the narrow areas of the production lines. Each coil must be able to be removed from the plastic container and placed on the floor of the production line. Several cables are required for the manufacturing of the equipment.

The cables must be uncoiled and laid flat with lengths up to 70'. In addition, these cables must have no kinks when placed into the boom or mast of the equipment.

Design Expectations:

Eliminating the flat coil stacking is critical. A dispenser design must allow for any of the ...
... seven coil sizes to be placed directly in the manufacturing process. Floor space is limited and the dispenser rack must be stackable and hold a desired number of 12 coils.

The design must work with the supplier's manufacturing processes, which are mechanical, and incorporate some handwork in the final steps of the packaging. The design should be easy to use and not have a large number of loose parts.

Final Product:

The final product has four formed cores, on two levels, with a center space that allows for the coiled cable to be placed three per side. Included removable covers with openings that will allow the operator on the line easy access for cutting the plastic ties. The release of the coiled cable is contained inside these covers. They also keep the cable from being tangled and provide for controlled unwinding of each cable coil. The two longer sides, (facing in view shown) have removable cross bars. These provide easy access to the covered coils.

The weight of the coils will rotate on the corners of the dispenser. Heavy gages of steel are used, and in order to extend the years of service needed each product has rollers. These rollers are located at the corners of the rear and upper positions. This provides easier movement for the heavy coils and reduces the wear and tear on the dispenser.
Stephens Packaging Supplies (http://spsidealsolutions.com) has been providing custom storage, industrial rack & shipping solutions for over 30 years. We design & manufacture a broad range of products including storage racks, rail racks, shipping racks, shipping containers, custom racks, coil racks, engine transport racks.