Branched monorail system — aerospace composites hall
Under-slung branched monorail with switchgear integrated to automated tooling at each bay, handling wet-layup modules between process stations.
Client: Tier-one aerospace composites manufacturer (confidential)
Challenge
A tier-one aerospace composites manufacturer was scaling a new wet-layup line and needed a handling system that could move tooling between a fixed sequence of process stations without disturbing the composite surface during transfer. Standard single-line monorails couldn't accommodate the required station sequencing.
Engineering response
Somers Handling designed a bespoke under-slung monorail with three branched tracks and four motorised switches, integrating with the station automation so transfers were sequenced by the line control system. Tooling was handled on a balanced lifter matched to the monorail hoists. The installation passed a low-particulate environmental audit at commissioning.
Outcome
The line went live on schedule. Transfer cycles between stations run hands-free, with the line control system sequencing switches and hoists. Parts-per-hour throughput matched the original capacity model at commissioning, with headroom for a second shift.
Composite wet-layup lines are unforgiving. Tooling carrying uncured layup has to move between layup, debulk, cure-prep and cure stations in a precise sequence, and any vibration or surface contact during transfer risks the part. The customer wanted a handling system that integrated directly with their line-control automation — not a separate system operated by a banksman.
Somers designed the layout alongside the customer’s process engineers — three branched tracks, four motorised switches, and hoist-station drops matched to each tooling position. The switchgear was wired into the line-control PLC so transfers happened on process signals, with manual override via pendant. Commissioning included a low-particulate environmental audit; the monorail dropped no detectable contamination.
Outcomes
- Line commissioned on schedule; first-pass yield matched pre-build model.
- Hands-free transfers between stations — line control drives the monorail.
- Audit passed for low-particulate environmental compliance.
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