Modern Living Solutions / Greystar (USA)
Modern Living Solutions / Greystar (USA)
Design and Development of an Overhead Rail Wall System and Box Build
Summary:
Dodd Modular was contracted to design and build a bespoke handling system for delivering wall frames to the box build area for a new US client – Modern Living Solutions.
The project included the development and design of the feed system and subsequent box build system.
Dodd were contracted to provide the design, 3D modelling and ‘first in class’ product development. This included prototype build and test of the system, followed by the build and commissioning of the developed system.
The project required a new and innovative design of system both mechanically and electronically capable of moving the wall frames consistently and most importantly around 90 and 180 degrees. This issue had not been solved by US suppliers which was the reason the client approached Dodd Modular.
The prototype systems were required to resolve the following technological uncertainties:
- Consistent and safe movement of the wall frames
- Moving the walls in 90 and 180 degrees
- Ease of movement throughout the system
- Handle the walls without damage or marking
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Whether the designed conveyor systems
- Could handle the different sizes and weights through the production line
- Could handle the uneven weight distribution
- Not damage the boards - Whether the conveyor system could be capable of carrying different board types of differing sizes, weights and centres of gravity
- Whether the designed system would satisfy the client’s requirements in terms of ergonomic and shop floor design
- Whether the designed system can accommodate multiple size and weight options
The resolution of these technological uncertainties was not readily deducible. Through detailed design reviews and numerous revisions, followed by significant prototype development throughout the commissioning processes.
The prototypes designed, built, tested and developed included:
- Trial conveyor and control systems
- Prototype 90 and 180 degree movement systems
