1530 Gantry Loader

Safety Operating Procedures

The 1530 Gantry Loader supplied by Wanka Factory is a large-scale automated lifting equipment. It can handle plates weighing up to 800kg and has a wide operating range. Improper operation can lead to serious accidents. All operators, maintenance personnel and management staff must unconditionally abide by the following regulations:

1.1 Personnel Qualifications and Training

Only personnel who have received professional training from Wanka Technology or its authorized party and passed the assessment are allowed to operate the equipment. Operators must master skills such as starting and stopping the equipment, emergency stop reset, manual/automatic mode switching, and fault code identification. Those who have not received training are strictly prohibited from touching the control panel or entering the equipment operation area. Re-training should be conducted every six months.

1.2 Daily Startup Inspection

Check the vacuum suction cup system: Check for any cracks, aging, or detachment of the suction cups, whether the air pipe connectors are loose, and whether the vacuum filter is clogged. Check if the air source pressure gauge is stable within the range of 0.6-0.7 MPa. Check if there are any alarms on the power supply voltage and the servo driver. Check if there are any iron filings, welding slag, or tools left on the guide rails of the gantry frame. Check if there are any personnel or obstacles within the operating range. Confirm that the safety interlock and emergency stop button functions are normal.

1.3 Safety Prohibitions During Operation

When the equipment is in operation, no one is allowed to enter the area covered by the gantry truss. Physical isolation barriers or conspicuous warning lines must be set up around the equipment, and the sign "Automatic operation in progress, no entry allowed" should be posted. Operators should stand in a safe area to monitor the equipment and must not insert their hands or any part of their body between the suction cup and the sheet. Overloading operation is strictly prohibited - the actual weight of the sheet should not exceed 90% of the equipment's nominal load capacity. It is forbidden to stack other heavy objects above the sheet.

1.4 Emergency Handling

In case of the suction cup suddenly falling off the board, making abnormal noises, emitting smoke, or when someone accidentally enters the area, immediately press the red emergency stop button. All movements of the equipment will stop immediately. Before identifying the cause and resolving the fault, the emergency stop cannot be released. If the board falls, first confirm that there is no one below, then use the manual mode to raise the suction cup frame to a safe height, and then clean the site. Any safety accident must be recorded and reported.

1.5 Maintenance and Safety

Before conducting any maintenance, cleaning or repair, the main power supply and gas source of the equipment must be disconnected, and a lock reading "Maintenance in progress, do not close the switch" should be hung. During the maintenance, safety pads or ladders for climbing should be used. Climbing the gantry truss is prohibited. After replacing the suction cups or gas tubes, a pressure retention test must be conducted before restarting the equipment.

Common Mistake Usage Reminder

The following are the most common mistakes that customers are likely to make when using the 1530 Gantry Loader. Please be sure to avoid them:

2.1 Inconsistent number of suction cups and plate size

Error: For smaller-sized plates (such as 800×800mm), the peripheral suction cups were not closed, resulting in some suction cups being suspended and leaking air, insufficient vacuum, and the plates falling off during transportation.

Correct approach: Input the actual size of the plate on the touch screen. The PLC will automatically close the suction cups that are beyond the plate's range. You can also manually select the suction cup group. Make sure only the suction cups pressing on the plate are involved in the adsorption process.

2.2 Ignoring Damaged Suction Cups

Error: After months of use, the suction cup develops cracks or the rubber hardens, but it is still used, eventually causing the sheet to fall off.

Correct Approach: Check the condition of the suction cup every two weeks. If cracks, permanent deformation, or hardening are found, replace it immediately. It is recommended to have 1-2 sets of the same model of suction cups in stock.

2.3 Poor Air Quality or Insufficient Pressure

Error: The workshop air source did not have a dryer and filter installed, and water- and oil-contaminated gas entered the vacuum system, causing the vacuum generator to get clogged or the suction cups to slip.

Correct Approach: Install a three-piece assembly (pressure regulating filter + oil mist separator) before the equipment's air intake, and drain regularly. Ensure that the air source pressure is always ≥ 0.6 MPa.

2.4 Place the items on the gantry track

Error: Workers temporarily placed tools and parts on the crossbeam or guide rail of the door， causing collisions or jams during the operation of the mechanical hand.

Correct approach： It is strictly prohibited to place any items on any part of the龙门桁架. The guide rail and surrounding areas should be cleaned up before the end of each workday.

2.5 Excessive oil on the surface of the sheet

Error: Plates with excessive pressurized or rust-preventing oil are directly fed into the machine, and the suction cups cannot create sufficient vacuum.

Correct approach: For plates with severe oil contamination, use oil-resistant rubber suction cups or increase the number of suction cups. If necessary, wipe off the oil in the adsorption area. Alternatively, select sponge suction cups to adapt to the oil-contaminated surface.

2.6 Excessive speed during manual operation

Error: In manual mode, the operator sets the movement speed of each axis to the maximum, resulting in the suction cup or the workpiece colliding with surrounding equipment.

Correct approach: In manual mode, the speed should be limited to within 20%, and it should be gradually slowed down and fine-tuned as it approaches the target position. The emergency stop button should be easily accessible at all times.

2.7 Ignoring Regular Lubrication

Error: The guide rails and gear teeth were not lubricated for a long time, resulting in increased walking noise, accelerated wear of the gear teeth, and decreased positioning accuracy.

Correct Approach: Apply lithium-based lubricant to the guide rails and gear teeth once every two weeks. Check the wear of the gear teeth every six months.

Core selling points

Optimized for wide-width and heavy-load applications

Independent vacuum control system for each zone

Full servo high-precision positioning

Intelligent formula storage and remote monitoring

Seamless connection with mainstream cutting machines

Multiple safety protections

Certification and Quality Assurance

Wanka Technology has obtained ISO9001:2015 quality system certification and CE certification. They implement full-process quality control for the 1530 type gantry material handling machine from design to delivery.

4.1 Key Component Brands

- Vacuum System: German SCHMALZ or SMC vacuum generators with suction cups, response time ≤ 0.3 seconds, vacuum degree ≥ -85 kPa.

- Servo Drive: Hua Chuang or Teda absolute value servo, overload capacity 3 times.

- Guide Rail and Rack: Taiwan Shangying guide rail (HGH series), gear rack module 6, tooth surface quenched HRC 50.

- PLC: Hua Chuang or Mitsubishi, with Ethernet port.

- Pneumatic Components: Yadea or Festo.

4.2 Factory Testing Items

Before leaving the factory, each 1530 Gantry Loader must undergo the following tests and provide reports:

- No-load running test: Full travel reciprocating operation for 12 hours, with each axis temperature rise ≤ 30℃, and no abnormal sounds.

- Load grasping test: Conduct 200 consecutive automatic handling cycles with an 800kg counterweight plate, simulating actual working conditions, with no suction cup detachment and no positioning deviation.

- Repeated positioning accuracy test: Measured using a laser interferometer, the actual measurement accuracy is ≤ ±0.08mm (better than the nominal value).

- Vacuum pressure retention test: Cut off the air supply after adsorption, with the retention time ≥ 6 minutes.

- Safety function test: Verify the emergency stop, limit switch, photoelectric sensor, and air cut-off protection one by one.

All test data can be traced and an electronic version of the report will be provided along with the goods.

4.3 Certification and Graphic Materials

Wanka Technology can provide: ISO9001 certificate, CE certification (application required in advance), product nameplate photos, factory production line real photos (numerical control cutting, robot welding, large-scale shot blasting room, automatic spraying line, assembly workshop), quality control inspection diagrams (three-coordinate measurement, flaw detection operations). Customers are welcome to schedule a visit to the factory in JinYanghai Industrial Park, Jiyang City, Shandong Province for on-site inspection.

Realistic User Experience - Feedback from Customers of the 1530 Type Cantilever Feeder Machine

Case 1: A large-scale steel structure group in Zhengzhou, Henan Province

This enterprise undertakes the processing of bridge steel structures. Every day, it needs to handle hundreds of 1500×3000mm steel plates with a thickness of 12-20mm, with each plate weighing up to 700kg. Previously, they used cranes and electromagnetic hoists for manual loading, and each plate required 2 people to cooperate for 10 minutes. Moreover, the electromagnetic hoist would magnetize the steel plates, affecting the subsequent welding. In 2024, two 1530-style gantry loading machines were purchased and used in conjunction with two laser cutting machines. After the renovation, the loading time was reduced to 50 seconds per plate, and the number of workers was decreased by 4. The annual savings in labor costs was approximately 300,000 yuan. The workshop director commented: "The aspect I am most satisfied with is the partition control of the suction cups. For the 1500-wide plates, all suction cups are activated. When changing to 1000mm small plates, the suction cups on both sides are automatically closed, avoiding waste of air and plate dropping."

Case 2: A stainless steel products company in Foshan, Guangdong

It mainly processes 1.5 - 4mm thick 304 stainless steel plates with a width of 1500 × 3000mm. The customer has extremely high requirements for the surface of the plates and does not allow any scratches. Previously, manual handling often left fingerprints and scratches, resulting in a waste rate of up to 5%. By using our 1530 Gantry Loader, combined with non-scratch silicone suction cups, and adding brush baffles to prevent scratches on the edges of the plates, the waste rate caused by scratches dropped to below 0.5% after half a year of operation. The production director of the company commented: "Wanka's loading machine is half the price of a European brand we previously saw, but its precision and stability fully meet the requirements, and the after-sales service is also prompt."