Workers in an industrial workspace using ergonomic equipment, including adjustable workbenches and lift-assist devices, while wearing safety gear. The scene highlights the importance of ergonomics in enhancing safety and productivity in industrial environments.

Ergonomics in Industrial Workspaces

The Importance of Ergonomics in Industrial Workspaces

In industrial settings, where heavy machinery, repetitive tasks, and physical labor are common, the design of the work environment is crucial. Ergonomics in industrial workspaces plays a vital role in boosting productivity, lowering injury risks, and improving worker well-being. This article explores why ergonomics is essential in industrial workplaces and how it benefits both workers and businesses.

Boosting Worker Efficiency

Productivity in industrial environments is closely tied to how efficiently workers can perform their tasks. Ergonomics in industrial workspaces helps by minimizing physical strain. For example, placing tools and machinery controls within easy reach reduces unnecessary movements. This allows workers to complete tasks quickly and comfortably. When workers are less tired and more comfortable, they can stay productive throughout their shifts.

Lowering the Risk of Injuries

Industrial workplaces often face a higher risk of injuries, especially those related to repetitive motions, heavy lifting, and awkward postures. Ergonomics in industrial workspaces works to reduce these risks by promoting safe body mechanics. Adjustable workbenches and lift-assist devices can reduce the physical strain on workers, lowering the chance of back injuries and other related issues. Learn more about workplace safety here.

Improving Safety and Well-being

Safety is a top concern in industrial settings. Ergonomics in industrial workspaces helps create a safer environment by reducing the physical demands on workers. This not only protects their health but also improves their overall well-being. When employees feel safe and comfortable, their job satisfaction and morale rise, leading to a more motivated and engaged workforce.

Improving Work Quality

The quality of work in industrial settings often depends on the physical condition of workers. Fatigue, discomfort, and injuries can lead to mistakes and lower product quality. Ergonomics in industrial workspaces helps by reducing strain and discomfort. For example, using ergonomic tools that lessen vibration and noise can help workers maintain precision and focus, resulting in better-quality outputs and fewer defects.

A Cost-effective Solution for Industrial Businesses

Investing in ergonomic solutions is a smart financial move for industrial businesses. While there may be upfront costs for ergonomic practices, the long-term benefits far outweigh these expenses. Lower injury rates mean reduced medical costs, fewer workers’ compensation claims, and less downtime due to injury. Additionally, better productivity and work quality can boost profitability. In short, ergonomics in industrial workspaces protects workers’ health while improving the company’s bottom line.

Adaptable Across Industrial Environments

Ergonomics in industrial workspaces is not a one-size-fits-all solution. It can be tailored to meet the specific needs of different industrial environments. Whether in manufacturing plants, warehouses, or construction sites, ergonomic principles create safer and more efficient workspaces. For example, in a manufacturing plant, ergonomics might involve designing workstations that allow for easy access to tools and materials, reducing the need for workers to bend, twist, or reach awkwardly. Check out our guide on ergonomic practices in manufacturing.

Conclusion

In the industrial sector, ergonomics in industrial workspaces is a necessity. By focusing on ergonomic design, businesses can boost productivity, reduce the risk of injuries, and improve overall safety and well-being. Whether in a factory, warehouse, or construction site, ergonomics is essential for creating a safe, efficient, and productive work environment. As the industrial landscape changes, the importance of ergonomics will only grow, making it a key consideration for companies that value the health and success of their workforce.

Malmedie Drum Couplings

Malmedie Drum Couplings

Pioneering Torque Transmission Solutions

Malmedie Drum Couplings have transformed coupling technology with the invention of the world’s first barrel-roller drum coupling. Malmedie has led the way in innovation, consistently improving mechanical torque transmission systems. Their drum couplings efficiently combine high-capacity torque transmission with a compact design. As a result, they are crucial for key applications across various industries, especially in hoisting operations that encounter high radial forces.

Technical Overview

Innovative Design

Malmedie’s latest drum couplings, including the TTXL series, significantly advance from earlier models like RTT, NTT, TTX, and TTXs. These improvements highlight Malmedie’s dedication to setting new benchmarks in capacity and operational safety, which further strengthens its leadership in the industry.

Mechanism of Action

Malmedie drum couplings use a unique design to ensure efficient torque transmission. Hardened barrel rollers, placed precisely within dual circular gearings, manage force transmission even under extreme radial forces, like those in crane operations. This innovative design reduces the risk of sudden failures, a common issue with traditional gear couplings that often break under stress.

Operational Excellence

Malmedie’s drum couplings withstand high radial forces while maintaining reliable torque transmission. The external wear control mechanism allows for easy inspections without requiring disassembly. Additionally, some models include an automatic wear control system, which enhances safety, improves operational efficiency and supports predictive maintenance.

Versatile Applications

The German company’s products serve a wide range of industries, including ports, steel mills, mining, and hydropower. They perform exceptionally well in hoisting mechanisms, winching systems, and conveyor belt operations. Their versatility makes them a preferred choice in demanding industrial environments.

Custom Engineering Solutions

The innovative engineering firm excels in delivering custom-engineered solutions to complex challenges. With a modular manufacturing approach and complete in-house production in Germany, the company offers flexible designs and fast delivery, tailored specifically to meet client needs.

Commitment to Quality

Quality drives Malmedie’s operations, supported by  ISO 9001 certification. This rigorous quality management process ensures that every product meets the highest standards, providing the reliability and performance clients expect.

Conclusion

In conclusion, Malmedie drum couplings are more than just mechanical components—they are thoughtfully engineered solutions designed for optimal torque transmission, safety, and adaptability across a broad spectrum of industrial applications. Malmedie’s unwavering focus on quality and innovation solidifies its position as a leader in industrial coupling technology.

Optimizing Steel-Making: The U-ONE-(SAFETY-) Compact Encoder System

Key Benefits

The U-ONE-(SAFETY-) Compact encoder system offers several key advantages over older solutions. First, it allows direct mounting on the application shaft. As a result, this eliminates the need for extra gears, reducing mechanical issues and potential failures. Additionally, the system improves measurement accuracy by removing mechanical play caused by distribution gears. Furthermore, it is easier to set up than older mechanical switches, which helps reduce downtime during installation and maintenance. Moreover, the system allows for quick starts and restarts after adjustments. This, in turn, minimizes delays and enhances overall efficiency. These benefits make the U-ONE-(SAFETY-) Compact system an effective solution for improving control and precision in steel-making plants.

Before

In traditional setups, steel-making plants typically use mechanical cam limit switches and absolute encoders. These are mounted using extra gears. Consequently, this approach often leads to mechanical problems and inaccuracies. Extra gears can introduce unwanted movement and delays in signal transmission. Additionally, mechanical cam limit switches are difficult to adjust. As a result, they often lack the precision needed for modern industrial applications. This complexity and lack of precision can hinder efficiency and affect overall performance. Therefore, there is a need for a more reliable and precise solution. This solution must address these issues and improve operational efficiency in steel-making plants.

After

The U-ONE-(SAFETY-) Compact system offers a modern solution. It combines electronic position switches and an absolute encoder in a single unit. This unit mounts directly on the application shaft. Consequently, it removes the need for extra gears, significantly enhancing system accuracy and reliability. Additionally, the compact design simplifies installation and reduces the system’s overall footprint. This makes it more efficient and space-saving. By integrating these components into one unit, the U-ONE-(SAFETY-) Compact system provides a more streamlined solution. It effectively addresses the limitations of traditional setups and improves control in steel-making plants.

Task

In steel-making plants, accurately measuring and controlling converter angles is essential. Traditionally, this has been done using absolute encoders and mechanical cam limit switches. These are mounted with extra gears. However, this setup often results in inaccuracies due to mechanical play. Moreover, it is challenging to adjust mechanical switches, leading to inefficiencies. These issues can, therefore, compromise plant performance and reduce productivity. Thus, a solution that addresses these challenges is critical. Improving accuracy and reliability ensures smooth operations in steel-making plants.

Solution

The U-ONE-(SAFETY-) Compact encoder system effectively addresses these challenges. It integrates an absolute encoder and electronic position switches into one compact unit. This mounts directly on the application shaft, thereby eliminating the need for extra gears. This reduces mechanical issues and improves accuracy. Furthermore, Hübner Giessen’s special torsion-resistant couplings ensure precise operation. Additionally, the system’s easy setup and quick restart after adjustments streamline operations. Moreover, the system is available with optional safety certification, meeting SIL 2 / PL d standards. This makes the U-ONE-(SAFETY-) Compact system ideal for enhancing accuracy, efficiency, and safety in steel-making plants.

Robust Encoders

Robust Encoders for Complex Applications

  • Greater functional component reliability
  • Higher converter plant availability
  • More precise measurement signals despite shock and vibration loads
  • Easy and time-saving programming

Before: Old skip-car control mechanism with two mechanical geared cam limit switches.

robust encoders

After: More precise signals because of robust encoders, combining bearing block and heavy-duty encoders

The skip-car control system used until now had two mechanical, geared cam limit switches that are slow to program. The mechanical overspeed switch can be unreliable when exposed to shock and vibration. These parts don’t have the needed accuracy, making them unsuitable for the modern needs of steel mill operations..

Upgrading to modern standards needs parts that are accurate, reliable, and easy to program. Hübner Giessen improved the system by replacing a geared cam limit switch with an FG 4 K incremental encoder and an AMS 4 K absolute encoder with an SSI interface. These encoders were mounted on a bearing block, boosting resistance to shock and vibration while compensating for slight mechanical differences in the current gearbox. In the next phase, the second cam limit switch will be replaced, along with the mechanical overspeed switch, which will be upgraded to a programmable electronic version. This plan ensures a stronger, more precise, and adaptable system, meeting the needs of modern applications.

In any case, you can count on our support for the complete project.
From the first discussion to the installation support on site. Contact us if you have questions about our robust encoders,

 

94 / Metals / Converter / Hoist
Case Studies

 

GN series motors

GN Series Motors

  • Rugged DC shunt-wound motors feature infinitely variable control
  • Designed for 20 journeys per shift (8h)
  • Short-term 3-fold overload permissible
  • Battery powered, automated guided vehicle system

Heavy-load transporters are used to transport the casting ladles from the warehouse to the casting house.

Battery powered and robust DC shunt-wound motor GN 17.17.4 for trouble-free operation without trailing cable.

To drive a 100-ton transport vehicle for casting ladles, the system needs adjustable DC motors powered by a 48V battery. These motors, connected to a gearbox, not only reach a speed of 10 m/min but also give full torque across the entire speed range, with a 3-fold short-term overload ability. Furthermore, the vehicle’s 625 Ah battery provides at least 200 minutes of runtime, allowing for 20 trips per shift. Therefore, the motor output must meet these needs effectively and reliably.

For each transport vehicle, Johannes Hübner Giessen supplied two low-voltage shunt-wound DC motors from the GN 17 series, along with a built-in spring-loaded brake. Additionally, these motors include a fan for cooling and are specifically designed for on-and-off use (S3 42% CDF). Moreover, they provide a rated torque of 17 Nm and can also handle a short-term overload of up to 50 Nm. Furthermore, a BAMOBIL battery controller effectively manages power to the DC motor, ensuring smooth and efficient operation.

 

88 / Metals / Casting / Ladle Transporter
Case Studies

 

Encoder solutions

Hot and Cold Rolling Mills – Encoder solutions

Hot and Cold Rolling Mills

Encoder solutions:

 

  • Easy exchange or extension of existing encoder solutions
  • Cost-efficient, as encoders can be exchanged selectively
  • Implementation in the shortest possible time, optionally SIL certified
  • Planning, delivery and mounting support from a single source

Exploded view

Exploded view

All around the world Hübner Giessen encoder solutions are installed at main drives of Hot and Cold Rolling Mills.

These large motors often run for many years and after a while the question about a possible encoder modernization arises to provide new or additional electrical outputs.

Our encoder solutions minimize the need for modernization. For example, the FGH 6 and FGH 8 encoders include an integrated mounting flange, which simplifies adding an additional encoder to the existing system.

You can add a freely programmable overspeed switch, a universal encoder system with fiber optic signal transmission (both optionally SIL certified), or an incremental encoder with a different pulse rate.

We provide full support throughout the entire project, from the first discussion to on-site installation assistance.

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