Blokset Assembly Line

The Issue:

A switchgear manufacturer set up a new production line to assemble Blokset switchboards. The line started from scratch, with no dedicated equipment for handling the large steel switchboard frames.

Each frame is assembled laid down, then moved between assembly stations and has to be stood upright. Done by hand, this means several operators lifting and turning heavy frames. That is slow, it is a safety risk, and it can damage painted parts.

Suggested Solution:

• Hydraulic tilting assembly station: the frame is assembled laid down, then tilted hydraulically to upright as the final stage, with no manual lifting
• Fold-up side extensions: the tilting table has side roller sections that raise up to support bigger frames, so one station handles different switchboard sizes
• Roller-top design: frames roll from the conveyor straight onto the station, so they are never lifted by hand
• Aluminum-profile roller conveyor lines: carry frames between assembly stations on non-marking plastic rollers that protect painted surfaces
• Adjustable roller width: the roller tracks slide along the aluminum-profile frame, so the conveyor width can be set to match each frame size
• Modular construction: conveyor sections can be extended or re-arranged as the client’s production grows

Design:

ADAPTIV managed the full cycle: site visit, process study, layout and engineering design, manufacturing, and installation. The station and conveyor heights and widths were sized around the Blokset frame and the client’s assembly sequence.

Results in Numbers:

• Tilting assembly stations: 1
• Conveyor length: 10 m
• Operators needed to stand a frame upright: 4 → 1
• Time to stand up and move a frame: 3 minutes → 30 seconds
• Project duration: 2 months
• Outcome: the client runs a dedicated Blokset assembly line with no manual lifting of switchboard frames

Customer Feedback:

"ADAPTIV built our Blokset line from scratch. The tilting station removed the manual lifting needed to stand frames upright, and the conveyor keeps the work flowing between stations."