Royal Enfield, the name has it all...  first things that pops-up in our minds is toughness and reliability.A company which is known worldwide for manufacturing quality motorcycles, acompany which dominated and still dominates motorcycle exports to Europe and other countries.
Royal Enfield has a huge manufacturing facility at Chennai with all modern techniques of manufacturing,improved design methods and latest automation systems withstate-of-art infrastructure. It also conducts a factory tour for enthusiasts, where they manufacture the Bullet 350ccalongside the Thunderbirds and Bullet Classics.

We are currently working on an‘Automated Vertical Reciprocating Conveyor’ (Auto-VRC) in thisplant.It is automated system designed for transfer of bins between two levels. The objective of the system is to transfer maximum number ofbins between two levelsand be in continuous operation. The system would be visible to the visitors so that they would know flowprocess. The system is designed to transfer 240 empty bins/hour from the ground floor to the first level and the same quantity of kitted bins from first level to ground level!!!

The system has two cycles, namely-empty bin handling cycle & kitted bin handling cycle.Empty bin handling cycle transfers the material from ground floor to first floor,while kitted bin handling cycle transfersit to ground floor to the required area.For horizontal transportation of the bins powered roller conveyors were selected,while vertical transportation was carried out by Vertical eciprocating Conveyor (VRC) with “Z” loading.The purpose of selecting powered roller conveyors for this particular application istheir longer life,sturdiness as compared to other conveyors.The Auto-VRC mainly comprises of eight powered roller conveyors, one powered 90 degree bend,one vertical reciprocating conveyor and four motorized vertical rising doors.Motorized rolling shutters are used at entry and exit of VRC at both the floors.


The empty bin handling cycle started with loading of bins at ground floor from the entry side of VRC in the form of 3 stacks each having 3 binsie. total of 9 bins.For further movement of bins it is required that they travel as one whole unit! A pneumatically powered stopper served the purpose, whose operation is programmed in such a fashion that it aligns all the bins.Then, this whole unit of 9 bins travels through VRC and gets unloaded on the opposite sideof VRC at first floor through a powered roller conveyor.


Auto VRC system
The kitted bin handling cycle starts with loading of kitted bins at first floor from entry side of VRC in the same stack arrangement.These bins are again aligned before they enter theVRC and travel through the VRC and get unloaded at the required area at ground floor.

While designing this system we faced numerous challenges,one of them was keeping the loading height for the conveyors as low as possible for ease of manual loading.We have optimized it to a level which has been appreciated by the Royal Enfieldteam. Secondly,efficient and smooth transfer of bins between successive system elementsis an important criterion for the system to be successful. Keeping this in mind,we have made provisions both in mechanical as well as electrical design for the same.

Specific arrangement and selection of sensors is made for this type of application.Programming requires out-of-the box thinking,since system demands simultaneous operation of both the cycles. We have considered all the cases of failure that can take place whilethe system is in operation. For this, systematic step-by-step tracking of bin is done during both cycles.Also,the sensors are precisely positioned to collectsignals at the right time from the system.

We have designed a system which is robust,smooth and efficient in its operation, without compromising on its aesthetics and long life,dependability.


Written by : Mr.Chaitanya Nene



Our Clients

Content on this page requires a newer version of Adobe Flash Player.

Get Adobe Flash player

View All