Founded in 2006 by Werner and Jürgen (= Double Ju) Schmidt, the company has set itself the task of simplifying reel handling for the industry. Double Ju International's reel handling equipment lifts, turns and tilts reels weighing between 30 kilograms and 30 tons. The handling systems ensure that the reels are transported from A to B undamaged and that employees can work ergonomically and efficiently. According to legal requirements, women are allowed to lift 20 kilograms and men 25 kilograms on a regular basis, which means that the rolls can only be produced in a small format. But even at this weight, lifting the castors regularly can lead to health problems. This is where the roll handling products from Double Ju International come into their own, as their use protects the health of employees. As the reels no longer have to be transported by hand, larger reels can be produced and plant productivity can be increased.

Different application scenarios possible
The purely mechanical and easy-to-maintain devices are used in different areas: In paper and plastic film manufacturing and processing companies or in the printing and packaging industry. Roll handling systems can be found wherever hollow roll material needs to be moved or turned. This includes the new articulated roll turner for picking up and turning rolls. The task of the turner is to lift rolls in the horizontal position after production, pick them up, turn them and set them down again in a defined position. Purely mechanical, durable, stable and maintenance-free elements were the key requirements for the project.

The articulated roller turner is attached to an aluminum crane rail on the ceiling, on which the device can be guided from A to B through the room by a worker. The roller tedder can be lowered and raised using a motorized chain hoist. A safety mandrel holds the rollers by engaging in the hollow space in the rollers. The clamping shells are pulled back by a handle on the operating unit so that the mandrel can be inserted into the reel sleeve. When the handle is released, the tensioning shells tighten automatically so that the roller sits firmly on the mandrel. An adjustable ring allows the mandrel to be adapted to the roll width as required. This has the advantage that different roll widths can be accommodated with one mandrel. The mandrel is pulled up with the roll using the chain hoist. The swivel arm lock can be opened with a simple hand movement and the roll can be turned through 90 degrees using the swivel arm. It then engages automatically. The entire system is controlled with one hand using a switch on a guide handle. When empty, the reel turner is secured by a locking bolt in the suspension carriage, which must be released before commissioning.

Automatic load balancing
One challenge the developers encountered was balancing the weight of the reel after it had been picked up and in the horizontal and vertical position when empty. "Without a balancing system, the device would not be safe for the worker," explains Philipp Schmidt, Sales Manager at Double Ju International Ltd. "Rolls could not be picked up, rotated and set down precisely and reliably." The developers therefore decided to initially use an elaborately welded aluminum rail on which the various positions of the device had to be locked manually. However, this solution proved to be complex and cost-intensive. "Due to previous positive experiences with the energy chain and cable products from igus, we turned to the company with confidence and quickly found a solution that suited us," says Philipp Schmidt, explaining the decision. "With the drylin WSX high-profile rail, we now have a cost-effective, technically simple and maintenance-free solution in use that is also visually elegant." The rail with slide is used for automatic load balancing, making manual alignment obsolete.

Roller weights up to 200 kilograms
Thanks to the lubricant-free iglidur J200 linear plain bearing film made of high-performance plastics, the carriage glides smoothly on the aluminum rail and moves automatically to the three different positions by means of a cable balancer. "We were able to easily integrate the cable balancer for balancing the roller turner into the rail cavity. The linear bearing foils hold the carriage in the various positions with very good resistance," explains Schmidt. When lowering in the horizontal position of the empty device, the carriage moves to the end stop of the rail. After picking up the roll, the carriage slides up to the top stop. When picking up a roll in the vertical position, the carriage moves to the middle locking block to compensate for the weight. The drylin rail and carriage have the necessary resistance to support roll weights of up to 200 kilograms of the roll turner.

Customized design and individual accessories
The reel turner with automatic load balancing supports healthy working. To date, Double Ju International has developed two prototypes in different sizes for different reel types. Depending on customer requirements, the reel turner can be customized and supplied with additional accessories. The reel turner has already been sold to a large pharmaceutical company. The device is in daily use there and is working perfectly after more than six months and 8,500 load cycles.