Handling Arc Shaped Steel Plate And Rectangular Tube With One Magnetic Lifter

An industrial machinery in Nanjing faced significant challenges in handling crane booms during production. Their traditional method using wire ropes, hooks, and chains required 3-4 workers per operation and often caused surface damage to the expensive components. The manual process was not only labor-intensive but also led to product deformation and workplace accidents. Workers struggled with time-consuming positioning and the physical strain of prying and clamping each boom section.

HVR Tailored Magnetic Lifter  

We developed a customized electro permanent magnetic lifter specifically for their crane boom assembly line. The solution featured ten electro permanent lifting magnets arranged in a 1×10 configuration, perfectly designed to handle both upper and lower boom sections. The upper magnets grip the flat exterior surfaces, while specially contoured lower magnets adapt to the inner curved surfaces with radii ranging from 162-457mm. The system works seamlessly with their existing 2.5T+2.5T electric hoists and offers both wireless remote and manual control options.

The difference was immediate and dramatic. Where workers previously struggled with heavy chains and clamps, a single operator can now effortlessly position and move boom sections up to 13 meters long and 3 tons in weight. The magnets' intelligent grouping capability automatically adjusts to different boom sizes and specifications, eliminating the need for manual reconfiguration between operations. Most importantly, the gentle magnetic grip completely eliminated the surface damage and deformation caused by mechanical clamps.

The production team reported outstanding improvements across all key metrics. Productivity more than doubled, with boom handling operations now completing in half the previous time. Quality issues from handling damage dropped to near zero, significantly reducing rework and scrap costs. The workforce reduction from 3-4 operators to just one created substantial labor savings, while the elimination of manual clamping and prying dramatically improved worker safety. Perhaps most telling, veteran operators remarked how the new system removed the most physically demanding aspects of their jobs.

Why Electro Permanent Magnetic Lifter Works  

The electro permanent magnetic lifter offers unique advantages for heavy industrial applications. Unlike traditional lifting methods, it requires no ongoing power to maintain its grip - only brief pulses during pickup and release. The carefully engineered magnetic field distribution ensures secure handling without causing internal stresses to the metal components. Our special curved magnet design maintains perfect contact with the boom's complex geometry, preventing any slippage during movement.

Conclusion  

This successful implementation demonstrates how modern magnetic handling technology can transform traditional manufacturing processes. The company is now exploring additional applications for this technology across other product lines. For manufacturers handling large, valuable metal components, this case study proves that upgrading to electro permanent magnetic lifters delivers both immediate operational benefits and long-term competitive advantages.