Align Production SystemsOverview
Who We Are• Align is a designer, manufacturer and
integrator of material handling and manufacturing automation systems
• Our emphasis: to help our clients overcome production obstacles and maximize productivity by leveraging the latest movement and positioning technologies
History
• 50 years of heavy load movement experience under the Airfloat banner
• Spun off turntable and lift businesses in 2013• Became exclusive North American partner of
Silvestrini the same year• Now go to market under the parent company
name Align Production Systems
Parent Company and Brands
AIR BEARING EQUIPMENT
Airfloat
Who We Are
• Primarily known as a manufacturer of air-film equipment• Innovator of the air bearing (or “air caster”)• Enable other heavy manufacturers to better automate their
manufacturing process• 50 years of experience
What is an Air Bearing?• Pneumatic device
similar to a hovercraft
• Compressed air passes through a flexible polyurethane diaphragm
• Forms a thin air film beneath load
• Enables nearly frictionless, omnidirectional movement
• Made of chemical- and wear-resistant material
Typical Air Skid Setup
• Typically deployed in circuits of three or four (like wheels)
• Used in rigging applications and semi-annual maintenance moves
• Kits available in wide range of sizes and capacities
• Include a multi-port controller and air hoses
Kentucky Trailer – Louisville, Ky.Workers move 50-ft.-long, 20,000-lb. trailers by hand, in any direction. This allows the trailers to fit in spaces too tight for fork trucks to safely maneuver.
GE Transportation – Erie, Penn.75-ft.-long, 300,000-lb. diesel locomotives float on specially designed air transporters. The equipment helped boost output from 17 to 22 locomotives per month – a 29% gain.
Progress Rail – Muncie, Indiana100-ft.-long, 500,000-lb. diesel locomotives float on specially designed air bearing shuttle. The equipment allowed the customer to have four times the throughput in the painting of locomotives.
• Progress Rail
• CNH
• Bombardier
• Caterpillar
• … and More
More Recent Projects
Primary BenefitsOutstanding ROI
Low capital investmentIncrease productivityLower energy costs
Supports Lean ManufacturingEasily reconfigure assembly lines
No in-ground installationMinimize wasted movement (e.g.,
attaching lifting straps, etc.)
Primary Benefits (cont.)Safety
Improve ergonomicsReduce worker strain and injuryReduce dependence on forklifts
MaintenanceLower maintenance costs – few
moving parts to breakReduce floor and wall damage
Better housekeeping habits
Air Bearing Myths• “It’s really loud…”• “It creates a lot of
dust…”• “It requires
tremendous air pressure…”
• “It won’t work on our floor…”
• “It’s difficult to control…”
All Incorrect!
Air Bearing Requirements
• Floor – flat, level, smooth and non-porous
• Most power-troweled concrete floors are OK
• Easy, low-cost floor improvements are available
• Air – most plant air systems are suitable
• Need sufficient airflow volume and pressure
• Air consumption is proportional to air bearing perimeter
Axial Industrial Turntables
Some Axial Turntables:Multi-Positional Fitted with Air-bearings
Fitted with Slewing bearingsCustom
Air Bearing TurntablesAvailable in many different sizes and capacities, with or without drive motors. Often used for container handling in factory settings. May include integrated lift/tilt tables or other attachments.
Air Bearing Turntables
John Deere Photo Lab Turntable
Pit-mounted Air Bearing Turntable
Ford Motor Company – Woodblock flush floor air bearing 28’ turntable with four independent inset turntables. Designed to handle 80,000 lb load. Electric edge drive with back up drive.
Pit-mounted Air Bearing Turntable
General Motors – Six- position rack indexing turntable, with remote operator control stand feeding to controls box with PLC for plant interface.
Floor-mounted Air Bearing Turntable
Robotic Turntables – Heavy duty glass rack turntable designed for robotic interface. Electric Edge Drive.
Robotic Cell Air Bearing Turntable
Mechanical Slewing Bearing Turntables
Available in many different sizes and capacities, with or without drive motors.
Available in many different sizes and capacities, with or without drive motors.
Mechanical Wheeled Turntables
INDUSTRIAL LIFTING & POSITIONING SOLUTIONS
Scissor Lift Tables
• Pneumatic & Hydraulic Scissor Lifts
• Capacities from 2,000 lbs. to 10,000 lbs.
• Modular design for easy addition of container tilts or turntables
• Available in double and triple scissor lift models for maximum raised height
• Electric trip bar, internal power packs, casters and other options available
Specialty Scissor Lifts
‘Super Series’ Hydraulic Lifts• Capacities from 10,000 lbs.
to 25,000 lbs.• Built for extreme lifting
applications
Loading Dock Lifts• Safer and less expensive
than concrete ramps• Work with variety of trucks
and trailers
Additional Safebilt Products
Container Tilts• Capacities from 2,000 lbs.
to 6,000 lbs.• 30⁰ and 45⁰ tilt models• Bolt-on or standalone
operation
Pneumatic Pallet Jack• 7,500 lb. capacity• Spark-free operation• Ideal for explosive or
hazardous environments
INDUSTRIAL POSITIONERS
Silvestrini N.A.
• Heavy duty welding positioners
• Headstock & tailstock positioners
• Two- and three-axis industrial manipulators
• Pipe/vessel turning rollers
Silvestrini N.A.• Founded in Bologna, Italy• 100-year history, fourth-generation owned• Maker of hydraulic positioners, manipulators,
and turntables for welding and assembly• Has historically gravitated toward heavy,
difficult positioning challenges• Now available in North America in partnership
with Align Production Systems
Silvestrini Equipment
Pipe-Turning Rollers Three-Axis Orbital Positioners
Two-Axis Welding Positioners Three-Axis Welding Positioners
Two-Axis Welding Positioners
• Capacities from 400 lbs. to 40 tons• Offer tilting and variable-speed
rotation• Manual, motor-driven and hydraulic
tilt models available• Positioner need not be anchored to
the floor• Heavy-duty SA models are virtually
maintenance-free and last 30 years or more under normal conditions
• Reduce cycle time by 45-50% over static positioning
Three-Axis Welding Positioners• Capacities from 1,000 lbs. to 40 tons• Offer tilting, variable-speed rotation
and hydraulic lifting• Robust 5-to-1 Factor of Safety (FoS)• Machine feet are located behind the
table so that large pieces rotate freely, even when table is in vertical position (90° tilt)
• Heavy-duty AVSA models are virtually maintenance-free and last 30 years or more under normal conditions
• Reduce cycle time by 55-60% for larger work pieces
Headstock & Tailstock Positioners
• Offer hydraulic lifting and electric gear-motor rotation
• Capacities from 1,000 kg. to 40 tons
• 5 to 1 Factor of Safety (FoS)• Hydraulic safety cutoff• Slide positioning for varying
fixture lengths• Optional work-holding jigs
and fixtures
Three-Axis Orbital Positioners
• Offer rotation, lifting and tilting
• Capacities from 1,000 kg. to 40 tons
• 5 to 1 Factor of Safety (FoS)• Advanced motion control
for smooth rotation• Hydraulic safety cutoff• Optional clamping system
(chuck)
Pipe-Turning Roller Positioners
• Capacities from 1,000 kg. to 90 tons
• Includes motorized driver section and idle section
• Rotate pipes/tanks up to 8 meters in diameter and 80 meters long
• Powered by two three-phase 380V 50Hz motors
Our Capabilities
Concept Engineering Fabrication Assembly Service
Next: Industries Served
More about Align
•Headquartered in Decatur, IL since 1964•Sales offices in Detroit and St. Louis•Design & manufacture everything we sell•Projects completed with 90% of Fortune 500•60,000 sq. ft. of manufacturing space•3,000 sq. ft. ‘Innovation Center’ for engineering•Laser-cutter reduction used on all designs•Service and/or refurbish what we sell
Industries Served• Aerospace• Agriculture• Appliance• Automotive• Chemical• Construction• Locomotive• Mining
• Nuclear• Prefabricated Home• Printing• Rigging• Ship Building• Steel• Theater and Stadium
Seating
Next: Our Clients
… and Many More
Our Clients Include:
Next: Air Bearing Myths
European Clients• Fiat• CNH• Caterpillar• Hitachi• Komatsu• General Electric
• Bell/Agusta (BAAC)• Alcoa• Daewoo• Peugeot• ABB• Citroen
Silvestrini equipment is found in over 20 countries
Recent Awards & Achievements
• 2000 – Awarded Q1 Preferred Quality Award by Ford Motor Co.
• 2008 – Partnered with GE Transportation to create world’s first moving assembly line for locomotives (Erie, Penn.)
• 2009 – Awarded Performance Excellence Award (Gold Level) by Boeing for excellent supplier performance
• 2012 – Awarded Recognition in Innovation by Steel Manufacturers Association (SMA)
Next: Final Questions
Thank YouQuestions?