A diesel engine manufacturer engaged ACS to replace an aging gravity conveyor system used to stage parts for one of its diesel engine assembly lines. The decades-old conveyor posed safety risks to the operators and increased the potential for damaging parts. The manufacturer had stringent project requirements, including precise specifications for many aspects of the custom conveyor system, such as materials, electronics, and branding. It also required ACS to incorporate the company’s preferred equipment choices in the new chain conveyor. As long-standing partners, the engine manufacturer had confidence in ACS’ flexibility and its ability to deliver engineered solutions that adapted to the client’s wide array of project standards and requirements.
The manufacturer’s original approach was for ACS to replicate a motorized chain conveyor system design used elsewhere in its facility. ACS engineers quickly recognized that a direct copy wouldn’t meet the needs of this specific diesel engine assembly line or reflect the customer’s updated equipment standards. The engine variants staged on this line required changes to pallet dimensions and part spacing. Specified components had changed since the reference system was installed, and the application required a revised control strategy. ACS worked with the customer to redesign the custom conveyor system accordingly, modifying the layout and selecting components and materials that aligned with the requirements.
ACS fabricated custom pallets using Nylatron plastic, as specified by the manufacturer. This material choice required precise machining to meet tight durability and dimensional tolerances. The team sourced SEW motors and coordinated the procurement of a conveyor chain with a 24-week lead time from an overseas supplier.
As part of its safety and productivity initiatives, the customer wanted a system that would be functionally impossible for operators to misuse. In response, ACS integrated mechanical and control features to enforce correct operation. These included fixed guarding to eliminate pinch points, directional controls to prevent pallets from being sent backward, and design elements that prevented operators with varying skill levels from hurting themselves. Pneumatic system components were routed and fitted according to customer-defined layouts, with all connection details included in the final design package as specified by the client.
What was planned as a system replication evolved into a custom conveyor system tailored to the customer’s specific application and internal requirements. The engine manufacturer had a detailed set of factory acceptance test items, which ACS worked through, confirming that the chain conveyor met its safety, usability, and operational goals. Despite the complexity introduced by lead times, material specifications, and facility integration standards, ACS delivered a chain conveyor solution that met the customer’s requirements. The new custom conveyor system supports efficient, controlled part staging on the diesel engine assembly line, with built-in protections that reduce the risk of operator error or part damage. By adapting to the customer’s requirements and working within their established standards, ACS delivered a modernized solution that integrated into the engine manufacturer’s production environment and aligned with the company’s safety and productivity programs.