The Challenge: Overcoming heavy payload and precision constraints
Van der Graaf (VDG) manufactures drum motors for belt conveyors at their 270,000-square-foot facility. A specific operational bottleneck emerged regarding the repetitive loading and offloading of metal cylinders into an industrial lathe. Operators performed this task every fifteen minutes.
From a civil and operational engineering perspective, the existing material handling infrastructure proved insufficient. The facility used an overhead traveling bridge crane. While this equipment handled heavy lifting, it lacked the multi-axis precision necessary for delicate lathe loading. The large hook geometry conflicted with the lathe's intake mechanism. Using the main bridge crane for these frequent, short-cycle lifts also created downtime for other manufacturing cells relying on the same asset. This resulted in a fragmented workflow and increased ergonomic risk for operators handling heavy loads manually or with improper equipment.
The Solution: The Gorbel® Easy Arm® intelligent assist device
VDG required an intermediary system. It needed to be more advanced than a basic jib crane but less complex than a robotic cell. They selected the Gorbel® Easy Arm® Intelligent Assist Device. This system integrates G-Force® Intelligent Lifting Technology using a servo-drive processor to track operator hand movements.
The unit provides infinite variable speed control up to 180 ft/min for exact load placement. The articulating design spans up to 14 feet in freestanding or underhung options. This fits within the tight geometry of the lathe station. Additionally, the Float Mode feature allows the operator to guide the load with as little as 1/2 lb of force. This effectively negates the weight of the cylinder during manipulation.
The Execution: Seamless integration and weightless operation
Installation of the Easy Arm® transformed the workspace. Operators engage the metal cylinder using a custom end-effector. They maneuver the articulating jib arm to the staging area where the "weightless" feel allows for rapid, single-handed positioning. The cylinder moves toward the lathe as the articulating joints navigate around column obstructions and machine guards that would block a rigid linear beam.
During the critical insertion phase, high-precision low-speed control aligns the cylinder to the millimeter. This eliminates the pendulum effect common in chain hoists. The system allows for a seamless disconnect so the operator can return to the control panel immediately. The Operations Production Manager described this biomechanical advantage as making them "feel like Superman" by significantly reducing operator fatigue.
The Result: Operational efficiency and safety gains
Implementing the Gorbel® Easy Arm® yielded measurable improvements in VDG's production metrics. The ability to offload and load without changing rigging hardware or waiting for the facility-wide bridge crane eliminated idle time. Servo-controlled limits and weightless handling minimized the risk of crush injuries and musculoskeletal strain. This dedicated lifting solution decoupled the lathe station from the main overhead crane and restored flow to the broader manufacturing floor.