Handling serpentine tubes in boiler manufacturing can be challenging due to their length, shape, and arrangement. Traditional lifting methods using slings and hooks often require considerable manual effort and can create risks of slipping, surface damage, and inefficient material handling.
To address these challenges, HVR MAG developed a customized electro-permanent magnetic lifter for Wuxi Huaguang Environmental Energy Group. The system is designed to handle multiple serpentine tubes in a single lifting operation, helping improve workshop handling efficiency and reduce manual intervention.
Project Overview
The project involves handling serpentine tubes in a boiler manufacturing workshop, mainly during welding and inspection processes.
The customer previously relied on manual slings and hooks to lift and transfer the workpieces. This method required workers to repeatedly climb up and down to position the lifting accessories. It also presented challenges in terms of handling safety, efficiency, and workpiece protection.
The main project requirements included:
Batch Handling: Lift seven serpentine tubes in one operation.
Power-Failure Protection Maintain magnetic holding force without continuous power supply.
Selective Lifting: Lift only the intended layer without picking up tubes from the layer below.
Workpiece Protection: Avoid surface damage during lifting and transfer.
Automated Handling: Support integration with the customer’s overhead crane system.
Workpiece Specifications
The magnetic lifting system is designed for the customer’s serpentine tube handling requirements.
Key workpiece specifications include:
– Workpiece: Serpentine tubes
– Planned lifting quantity: 7 tubes per operation
– Length of each tube: 8,000 mm
– Pipe outer diameter: 60 mm
– Wall thickness: 9 mm
– Total load: Approximately 600 kg
The system is also designed to accommodate different workpiece dimensions:
– Length: 2,000–8,000 mm
– Width: 1,000–2,600 mm
– Pipe diameter: 32–60 mm
– Wall thickness: 3.5–9 mm
These dimensions provide flexibility for handling different serpentine tube specifications within the customer’s production workshop.
Customized Magnetic Lifter Solution
HVR MAG designed an electro-permanent magnetic lifter using two HEPMT-265031G magnetic units arranged in a 1×2 configuration.
The system is equipped with one HEPC5-300A2 controller and two independently controlled magnetic groups.
The main configuration includes:
– Magnetic Units: 2 × electro-permanent magnets
– Controller: 1 × HEPC5-300A2
– Control Groups: 2 independent groups
– Lifting Arrangement: 1×2 configuration
The two independently controlled magnetic groups allow the system to adapt to different workpiece specifications and lifting conditions.
Key Features of the Magnetic Lifting System
1. Selective Lifting to Avoid Picking Up the Second Layer
One of the main challenges in this project is lifting serpentine tubes arranged in multiple layers.
The magnetic lifter needs to pick up the target tubes without unintentionally lifting the layer underneath. To address this requirement, the system uses two independently controlled magnetic units.
This configuration allows more flexible magnetic control during the lifting process and supports selective handling of the intended workpieces.
2. Electro-Permanent Technology for Power-Failure Protection
The system uses electro-permanent magnetic technology. Electrical pulses are required for magnetization and demagnetization, while no continuous power supply is needed to maintain the magnetic holding force.
This means the magnetic holding state is maintained during normal lifting operations even if the external power supply is interrupted, subject to proper system design and operating conditions.
3. Reduced Manual Handling
With the magnetic lifter integrated into the overhead crane, the handling process can be carried out with less manual positioning of slings and hooks.
This helps reduce repetitive manual work and supports a more efficient workflow during loading, unloading, welding, and inspection operations.
4. No Pneumatic Lines Required
The customized solution does not require additional pneumatic lines for its lifting operation.
This simplifies the equipment configuration and avoids the need for pneumatic connections between the lifting device and the workshop infrastructure.
5. Flexible Handling for Different Specifications
The two-group control arrangement provides flexibility when handling serpentine tubes with different dimensions and configurations.
The system is designed around the customer’s specified range of tube lengths, widths, diameters, and wall thicknesses.
Improving Serpentine Tube Handling in Boiler Manufacturing
Compared with traditional sling-and-hook handling, an electro-permanent magnetic lifter provides a more integrated approach to lifting and transferring serpentine tubes.
For this project, the customized solution focuses on three key aspects:
– Reducing manual lifting and positioning work.
– Improving control when handling multiple layers of serpentine tubes.
– Supporting automated material handling through overhead crane integration.
The system provides a customized magnetic lifting approach for the specific requirements of boiler manufacturing workshops, where long and specially shaped tubular workpieces need to be handled efficiently and carefully.
خاتمة
This project demonstrates how a customized magnetic lifter can support serpentine tube handling in boiler manufacturing.
By combining electro-permanent magnetic technology, independent control groups, and overhead crane integration, HVR MAG provides a lifting solution designed to reduce manual handling and improve control during material transfer.
For manufacturers handling serpentine tubes, steel pipes, and other long metal workpieces, selecting a magnetic lifting system based on the actual workpiece dimensions and production requirements is essential for achieving reliable and efficient handling.
