IllustrationA 280,000-lb Air Bearing Assembly Line for Locomotives
Air bearing platforms turned six static, crane-bound locomotive bays into a moving assembly line, and cut build time from weeks to hours.
A major transportation manufacturer built locomotives in six static bays. Every time a heavy component arrived, an overhead crane moved it and all work on the floor stopped.
Han-Tek turned those bays into a moving assembly line on AirFloat air bearing platforms that carry each 280,000 lb locomotive on a film of air. Build time dropped from days or weeks to hours, the system paid for itself in under a year, and the company could promise delivery dates for the first time.
Too heavy to convey, so everything waited on the crane
Each locomotive was built in place in its own bay. Parts came in by overhead crane, and the work stopped every time the crane moved.
Crane stoppages
Every lift cleared the floor, then tradesmen had to set their tools back up again.
No conveyor option
Locomotives were far too heavy for roller, belt or chain conveyor.
No firm delivery dates
Cycle times varied so much the company could not commit to customers.
Each tradesman could only work on one locomotive at a time, and idle time built up on every shift.
Bring the locomotive to the tradesmen
Han-Tek ruled out conventional conveyor and built the line on air bearing platforms. Here is how a locomotive moves through it.
- 1
Float on air
Low-pressure air inflates pads under two paired platforms, lifting the 280,000 lb locomotive on a thin film of air.
- 2
Steer in a straight line
One platform drops a guide pin into a slot in the floor. The other is driven by an operator with a variable-speed pendant.
- 3
Advance a station
An umbilical shares air and power between the pair, and locomotives step forward together to the next fixed station.
- Fixed stations: each station keeps its workers, tooling and setup in place all shift.
- Safe control: the pendant uses a hold-to-run control, so the platform stops the moment the operator lets go.
- No physical ties: locomotive sets advance in coordinated steps without being linked together.
- Clean floor: air bearings need a smooth, clean floor, so the shop floor was rehabilitated and a housekeeping standard set.
From weeks to hours, and dates customers can count on
| Area | Before: static bays | After: air bearing line |
|---|---|---|
| Build time per locomotive | Days or weeks | Hours |
| Moving the locomotive | Overhead crane, floor cleared | Floats to the next station |
| Tradesmen | Moved from unit to unit | Stay at fixed stations |
| Delivery dates | Could not be committed | Committed and met |
| Payback | Full system cost | Under 12 months |
- Weeks to hours: with everyone working at once and no crane stoppages, each locomotive is built in a fraction of the time.
- No more standing around: idle time was eliminated from every shift.
- Delivery dates kept: for the first time in company history, the manufacturer commits to and meets delivery dates.
- Safer floor: no overhead crane drop risk, with parts arriving at floor level at each station.
- Fast payback and repeat business: under 12 months to pay back, and the customer came back for a sixth set of platforms.
Questions about air bearing platforms
How does an air bearing platform work?
Low-pressure air inflates flexible pads under the platform and lifts it on a thin film of air, like an air hockey table in reverse. With almost no friction, about 1 lb of force moves 1,000 lb of load.
How heavy a load can air bearings move?
Very heavy. Here, two paired platforms rated at 140,000 lb each carry a 280,000 lb locomotive.
Do air bearings need rails or a special floor?
No rails, but the floor must be smooth and clean. This project included rehabilitating the shop floor and setting a housekeeping standard.
When does an air bearing line make sense?
When products are too large or heavy for conventional conveyor and are built in fixed bays with cranes, like rail cars, heavy vehicles or large machinery.
More heavy material handling projects
Let's turn your bays into a moving line.
Tell us what you build, what it weighs and how you move it today. A Han-Tek engineer will tell you whether air bearings fit.
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