FLOWTUBE DESIGN & ASSEMBLY GUIDE

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1 FLOWTUBE DESIGN & ASSEMBLY GUIDE

WHAT IS FLOWTUBE? FlowTube is a versatile modular component framework system, made up of steel tubes, rapid assembly steel joints and an extensive range of components and accessories.

2 WHAT IS FLOWTUBE? FlowTube is a versatile modular component framework system, made up of steel tubes, rapid assembly steel joints and an extensive range of components and accessories. The system is designed to suit a wide variety of applications including manual handling, storage, assembly and manufacturing. Can also be used for display and exhibition stands, and in commercial, retail and institutional applications. Solutions are simple to design, quick to assemble and are completely reusable, suiting environments where Kaizen (continuous improvement) or Lean Manufacturing methods are employed. Assembled solutions can be quickly and easily modified, changed or rebuilt into something completely different. Only basic technical skills are required to achieve desired results; assemblies can be quickly constructed without the need for special tooling and require no welding or painting. There is little waste, as structures can easily be modified or rebuild. The tube and joint components may be reused to build new solutions allowing continuous and cost-effective improvement to designs. THE SYSTEM Tubes are steel pipes, nominally 28mm in outer diameter, ABS plastic-coated in various colour finishes or stainless steel. Painted finish available as special order. Joints comprise of interlocking steel bracket components, clamped over the tubes and fastened in position with captive nuts & socket head bolts. Accessories including roller tracks, castors, hinges, latches and a wide range of other components fix also to the tubular framework in a simple snap or clip on manner. Tools include a hacksaw to cut the tubes, a 5mm Allen key for rapid assembly of joints and a measuring tape to ensure solutions are cut and built to size. 2

WHY USE FLOWTUBE? Alternative To Fabrication FlowTube is an effective alternative to welded or fabricated solutions.

time-consuming welding and painting operations.

to suit different applications. Quick & Easy To Use FlowTube solutions are very quick and simple to design and assemble.

working solution. FlowTube solutions typically use 30% less manpower than conventional systems to achieve the desired results.

Kaizen (Continuous Improvement) FlowTube provides maximum flexibility to a solution with minimum material wastage, allowing the system to be continually updated, modified and

3 WHY USE FLOWTUBE? Alternative To Fabrication FlowTube is an effective alternative to welded or fabricated solutions. Tubes, joints and accessories, supplied as standard stock items, are quick and clean to assemble, providing an effective means for producing a rapid solution, avoiding messy and time-consuming welding and painting operations. In addition all components are reusable, which means constructions can be easily modified and reconfigured to better suit the application or even recycled to create new equipment to suit different applications. Quick & Easy To Use FlowTube solutions are very quick and simple to design and assemble. Effective solutions for assembly lines, manufacturing cells, packing stations or almost any other material handling application can be quickly realised by operators to provide a working solution. FlowTube solutions typically use 30% less manpower than conventional systems to achieve the desired results. 1) Sketch 2) Cut 3) Assemble 4) Use workstation, garment rail, trolley! Kaizen (Continuous Improvement) FlowTube provides maximum flexibility to a solution with minimum material wastage, allowing the system to be continually updated, modified and improved in order to improve efficiency and improve suitability for specific storage requirements, assembly or manufacturing operations. Lean Manufacturing & Production FlowTube enables waste elimination, focussing resources on value added process, achieved by: Space saving - solutions are created to maximise storage space and reduce footprint Time saving - improve the flow of products, reducing waiting or TAKT times Ergonomics - designs are tailored towards specific picking or assembly operations Cost saving - waste is eliminated, defects minimised, production efficiency increases 3

HOW IS FLOWTUBE SUPPLIED? Flowstore Systems Ltd stocks and supplies the FlowTube system, from its base in Hayes, UK.

Flowstore supplies stock, customer designs & assembles FLOWSTORE CUSTOMER (1) DESIGN CUT / PICK ASSEMBLE DELIVER USE (2) DESIGN CUT / PICK DELIVER ASSEMBLE USE (3) PICK DELIVER DESIGN CUT ASSEMBLE

FlowTube system in the Automotive Manufacturing Industry, plus a team of qualified CAD Engineers and an assembly team with safety accreditation and installation experience across the UK and Europe.

4 HOW IS FLOWTUBE SUPPLIED? Flowstore Systems Ltd stocks and supplies the FlowTube system, from its base in Hayes, UK. Supply Options There are 3 main ways in which FlowTube can be supplied (1) Flowstore designs and supplies assembled solution (2) Flowstore designs and supplies kit solution, customer assembles (3) Flowstore supplies stock, customer designs & assembles FLOWSTORE CUSTOMER (1) DESIGN CUT / PICK ASSEMBLE DELIVER USE (2) DESIGN CUT / PICK DELIVER ASSEMBLE USE (3) PICK DELIVER DESIGN CUT ASSEMBLE USE DESIGN & ASSEMBLY SERVICE Flowstore Systems supports FlowTube in the UK and across Europe with a Sales Team whose members include Kaizen and Lean Manufacturing experts with experience using the FlowTube system in the Automotive Manufacturing Industry, plus a team of qualified CAD Engineers and an assembly team with safety accreditation and installation experience across the UK and Europe. Design Sales representatives visit site, to discuss, consult and advise, before offering a FlowTube solution for almost any material handling application. Sketches, design briefs and site visit notes are developed into technical drawings, using the latest CAD and design software. Following an order for a Flowstore designed solution, customers receive a detailed specification prior to manufacture and delivery including fully scaled and dimensioned drawings plus an optional 360 3D view (using software available as a free download). Assembly A proportion of customers choose to have their solutions delivered fully assembled. So, following drawing approval, Flowstore will build the solution in-house and deliver to customer, ready for use. Some larger solutions are delivered to site in partially assembled, and then finally completed by Flowstore s installation team. CAD Team CAD Design Manufacturing Drawings Assembly 4

FLOWTUBE DESIGN GUIDE To ensure a FlowTube solution is successful it is advisable that sensible

The most important stage of planning is the design phase as this takes into consideration both the

But, before design begins, some basics must be understood, such as the component names, their

Terminology It is quick to become familiar with terminology: G parts are joined together to form a

G-1 [GA-1] G-1 And some versatile parts e.g.

5 FLOWTUBE DESIGN GUIDE To ensure a FlowTube solution is successful it is advisable that sensible planning is implemented before any building or assembly commences. The most important stage of planning is the design phase as this takes into consideration both the application and function of the solution and any safety implications. But, before design begins, some basics must be understood, such as the component names, their respective functions and dimensions. Terminology It is quick to become familiar with terminology: G parts are joined together to form a number of standard assembled GA joints, for example a GA-1 is made from 2x G-1 s. G-1 [GA-1] G-1 And some versatile parts e.g. G-2 being used as part of all assemblies GA-2, GA-3, GA-5, but this means the assembled number doesn t always correspond to the part number; for example GA-3 is made of 2x G-2 s and 1x G-4. [GA-2] [GA-3] [GA-5] G-2 G-2 G-2 G-4 G-2 G-2 G-2 G-2 G-3 GP adaptors are associated with track and GS adaptors with tube. GP-B GS-A 5

Component Application Planning ahead will ensure a successful solution is produced with minimal effort and waste.

or the ability to add to the design post build for continuous improvement.

For example a three-way tube assembly may be achieved using the GA-2 joint assembly in different orientations to give different application benefits.

6 Component Application Planning ahead will ensure a successful solution is produced with minimal effort and waste. FlowTube has the capabilities of producing various solutions to a brief, but design factors such as ease of adjustability can be built in using Design for Assembly techniques, or the ability to add to the design post build for continuous improvement. These factors may be a simple case of asking which orientation is the joint going to be used to gain the maximum benefit. For example a three-way tube assembly may be achieved using the GA-2 joint assembly in different orientations to give different application benefits. Tube terminates Max joint strength tube terminates into the joint, no chance of joint slipping but vertical dimension is fixed Rotating the joint 90 degrees, the adjustability is in a different plane Adjustability Adjustability Dimensions Tubes are nominally 28mm in outer diameter, joints 28mm in inner and 33mm in outer diameter. FlowTube solutions are dimensioned to tube centres, as if wireframe assemblies. Front Side 6

This gives an optimum gravity roll speed for boxes in most cases.

7 Isometric Most tube lengths are terminated within a joint sleeve, and so their lengths are calculated as joint centres minus 70mm (2x35mm). Roller Tracks Gradients Typically roller track is installed at 6% gradient. This gives an optimum gravity roll speed for boxes in most cases. Depending on the roller track pitch, the depth of the racking is determined by the full wheel pitch increment cut of the track i.e. every 36mm for the GP-40A track. 7

8 Design Options Select desired options from the FlowTube product range to best suit the application. Below is a guide for selecting the best castor / feet options. Application: Rack, bench trolley, display stand etc Mobile Fixed Light Duty: Insert/expander castors (e.g. 3 or 4 ) Heavy Duty: Use plated castors (4, 5 or 6 wheel) Permanent: Floor fix to ground with stanchion mounts Threaded Insert Adjustable Foot: Height of thread? Metric or Imperial? Rubber or Steel base? Specification: Type Fixed, Swivel, Swivel Braked Load rating Wheel material e.g. Non marking Wheel size (3,4,5 ) Thread spec metric/imperial N.b. Mobile units requiring to be towed by mechanical means need additional re-enforcement. Details on application to Flowstore Systems. Ergonomics The ergonomics of the system need careful planning to ensure safe use and efficient operation are achieved. Working heights, picking heights, bending & reaching limits etc. for the most part are the responsibility of the company using FlowTube; some cover this in their own Health and Safety policies. Refer to the Manual Handling Regulations for guidance The HSE web site can provide resources 8

FLOWTUBE SAFE DESIGN What is the safe working load (SWL) of the FlowTube system? Is the system safe for the application it is designed for? How can I calculate the SWL for my design?

Safe design ensures that the system does not fail causing damage to equipment or stock and avoids injury or accident.

9 FLOWTUBE SAFE DESIGN What is the safe working load (SWL) of the FlowTube system? Is the system safe for the application it is designed for? How can I calculate the SWL for my design? Remember to always work well inside the guidance figures of loads which follow, to allow a safety margin. Safe design ensures that the system does not fail causing damage to equipment or stock and avoids injury or accident. Safe design includes considerations for the following Joint strength Tube strength Track strength Floor loading Stability Common sense & experience All the points above need to be considered before deciding a system safe for use. For example, a rack may not overload any of the tubes or joints, but the castors may be under specification and so not suited to the intended load. Once each of the failure modes are considered and the applied loads considered safe, then the system is considered to be fit for use. Joint Strength Each assembled joint has a maximum load capacity of 80kg in shear before slippage. This is based on an approximate bolt torque of 10Nm for each of the fixings in a joint assembly. This applies to tubes being pulled out of a joint (X direction) and through a joint (Y direction) X X Y Y X Y X X Tube Strength Tube makes up the framework of the FlowTube system, connected together by joints. Tubes will flex and bend under an applied load and, up to a certain point this is acceptable and the tubes will not permanently deform, returning to their original state when the load is removed. However, beyond a certain load, the bending of the tube will be permanent and even lead to failure. This load varies with the length of the tube under load, decreasing as the unsupported span of a tube increases. Typically horizontal tubes, with a central point load are considered to be the worst load case and vertical tubes considered the best load case under gravity applied loading. 9

10 Roller Track Strength Similar to tube loading, roller tracks will flex and bend under load. However, loads are almost always applied to a horizontal roller track, with a slight gradient of about 6%. Two considerations for the roller track are the failure load for the roller track profile and the failure load for an individual wheel or spindle. Floor Loading Loads in a FlowTube system must all be transferred to the floor, either through tubes, feet or castors. In all cases ensure the floor is capable of supporting the loads. Tube safe floor loading is achieved providing the tube in contact with the floor is not subjected to loads that exceed the recommended safe weight limits. Feet generally have threaded steel stems, which fix into threaded steel inserts fitted into the end of a vertical tube. Castors are load rated, which varies with wheel size, castor type and specification. For a four-castor arrangement, maximum loads must be calculated on three of the castors and for six-castor arrangement on four of the castors. Stability To ensure a FlowTube assembly is stable, the height to width ratio of static units should not exceed 5:1 unless permanently floor fixed. Units with castors should in certain cases use a lower ratio, since if they hit an obstruction on the floor, they can topple. The table below however, illustrates a 5: 1 ratio. The arrangement of the castors or feet determines the effective base dimensions, so this is crucial for determining the maximum safe structure height. Each application needs individual consideration. In the table below, for example, it can be seen that insert castors provide the greatest stability as they have the greatest base width. Also, simply repositioning the plated castors moves the point of floor contact, changing the base width and in turn affecting the safe working height. Rack Width (centres in mm) Castor Size (mm) Base Width (mm) Height To Base Ratio Max Height (mm) 1) Insert Castors : ) Plated Castors (Crossways Mounted) : ) Plated Castors (Lengthways Mounted) :

E.g. Worst Case Scenario for 500mm rack widths all castors facing inwards: 1) Insert Castors 2) Plated Castors (crossways mounted) 3) Plated

sense safety considerations must also be a factor of the design process.

. Also, as a rule of thumb, if a FlowTube solution is to be loaded and picked from by hand, then generally it is the right system.

FLOWTUBE DESIGN TIPS Despite each application being customised in terms of size, design and loading, there are a few basic structural procedures

Note the images have been over-exaggerated for explanation purposes and these issues only occur for much larger structures than drawn here.

11 E.g. Worst Case Scenario for 500mm rack widths all castors facing inwards: 1) Insert Castors 2) Plated Castors (crossways mounted) 3) Plated Castors (lengthways mounted) (Perpendicular cross bracing with GA6s) 380mm 165mm 290mm Common Sense When designing a FlowTube solution, common sense safety considerations must also be a factor of the design process. For example, consider where the centre of gravity will be on both a fully loaded and partially loaded rack.. Also, as a rule of thumb, if a FlowTube solution is to be loaded and picked from by hand, then generally it is the right system. If loading and unloading require mechanical assistance, then perhaps an alternative solution should be used. FLOWTUBE DESIGN TIPS Despite each application being customised in terms of size, design and loading, there are a few basic structural procedures that should be adhered to for safety and stability. Note the images have been over-exaggerated for explanation purposes and these issues only occur for much larger structures than drawn here. Bracing Add diagonal bracing for durability and to reduce the risk of the application moving out of square, thus reducing the risk of the joints coming apart. Similarly, where parallel tubes run for fitting plated castors, add perpendicular cross ties (using GA-6). Depth Depending on the load, tube and track should not in most cases exceed 1500mm span without the addition of further supports (refer to load tables). 11

12 1500mm (max) Plan squareness (i.e. a square footprint should always be designed-in by using GA-2 joints at the 4 corners of the rack base, or by suitable diagonal ties in the base of the rack as a minimum to keep it square. Mobile units may require addition bracing to retain rigidity if moved when loaded. 12

Dimensional Tolerance FlowTube is designed with +/-1mm tolerance. This ensures that tube lengths are fully inserted into joints, which maximises the effectiveness of the clamping friction.

Width Constraints According to anticipated loads the maximum width of a rack should generally not exceed 1500mm before adding additional uprights to reduce the deflection.

13 Dimensional Tolerance FlowTube is designed with +/-1mm tolerance. This ensures that tube lengths are fully inserted into joints, which maximises the effectiveness of the clamping friction. Similarly rack depths for roller tracks are set around a full pitch length of the roller track, to ensure roller tracks sit fully in the adapter brackets. Width Constraints According to anticipated loads the maximum width of a rack should generally not exceed 1500mm before adding additional uprights to reduce the deflection. Alternatively individual modules can be built and joined together. 1500mm is a guide only, since load applications will vary. Cross-tubes taking excessive loading (see recommended safe weight limits chart) can be strengthened by using double tubes, advisable for racks over 1500mm wide. W >1500mm use Double tube 13

ASSEMBLY GUIDELINES Assembly of a FlowTube solution can be done from either a pre-designed solution, where the tube lengths, joint and component quantities are fully specified from a drawing

Either way, certain assembly guidelines need to be adhered to. Tubes Tubes are very basic and therefore simple to prepare.

14 ASSEMBLY GUIDELINES Assembly of a FlowTube solution can be done from either a pre-designed solution, where the tube lengths, joint and component quantities are fully specified from a drawing materials list and the outcome is known prior to assembly; or by developing the design as the solution is being built, adjusting and modifying until the desired solution is reached. Either way, certain assembly guidelines need to be adhered to. Tubes Tubes are very basic and therefore simple to prepare. Cut the tubes to length, with hacksaw, chop saw of band and de-burr cut ends; a sharp cutting blade will minimise burring. Tube & Joint Interfaces It is important that tubes are correctly inserted into the joints. This ensures that tubes are being correctly clamped and maximises the stability and safety of the system. Ensure the tubes are fully inserted into the joint before tightening. For joints in which a tube terminates, there should be 30mm of joint sleeving the tube. Do not splice, or join two tube ends inside a joint head. This is not considered a safe practice. 14

Joint Assembly Position the joint components in place over a tube.

of the nut sticking through the hole and the flat edges captivated by the recess sides.

the outside of the rack, there the bolt head may be tightened by hand at first, then by 5mm Allen key or

T-Nut(s) Insert T-Nut(s) into recess(es) on joint component Bolt(s) Insert bolt(s) from outside of assembly

inside of the joint assembly. Note, some joints need to dovetail over the tube, before being fixed together.

An approximate torque of 10Nm is recommended for optimum clamping strength; too much under this torque and

clamping force. Joints can be removed and re-assembled.

15 Joint Assembly Position the joint components in place over a tube. Insert the T-nut(s) into the recess(es) on the least accessible side of the joint assembly, with the shoulder of the nut sticking through the hole and the flat edges captivated by the recess sides. The bolt may then be inserted into the joint assembly from a more accessible side of the joint, typically on the outside of the rack, there the bolt head may be tightened by hand at first, then by 5mm Allen key or power tool with suitable adapter. T-Nut(s) Insert T-Nut(s) into recess(es) on joint component Bolt(s) Insert bolt(s) from outside of assembly The shoulder of the nut will improve the interface between the nut and bolt, allowing the threads to engage inside of the joint assembly. Note, some joints need to dovetail over the tube, before being fixed together. Ensure they interlock and clamp the tube correctly. An approximate torque of 10Nm is recommended for optimum clamping strength; too much under this torque and the joints may slip; too much over this torque and the joint components may deform under the excessive clamping force. Joints can be removed and re-assembled. Optional self-locking nuts and bolts are available for a more permanent solution. Inserts & End Caps Threaded inserts and inner end caps are push fit and hammered into the open tube ends. Inner Cap Adapters, Accessories & Components All other components are quick an easy to use; their application implicit, so require little or no training for assembly and use. Threaded Insert 15

16 ASSEMBLY SEQUENCE GUIDE This section follows the suggested assembly route for an example of a FIFO - 4 level feed/1 return flowrack showing examples of different variations at each stage on the left hand side: 1: Build side frames with feet Stanchion Mount Rubber Adjustable 2: Add structural bracing 45 degree Straight Adjustable angle Adjustable angle 3: Add cross-tubes Single Double 16

4: Fix castors 5: Fit track and guide at set height

17 4: Fix castors 5: Fit track and guide at set height Track slots into track adaptors that is then a push fit onto the cross tube. Guide simply slides onto the track before attaching track adaptors. Track generally supported underneath with at least 1x cross tube. 6: Fit remaining levels Set levels at required pitch with track at 6% nom. Gradient 7: Add & secure accessories Attach any Melamine faced worktops/steel panels/tool rails etc. Add inner caps Check dimensions against drawing, ensure joints fully inserted and appropriate joints are perpendicular 17

ABOUT FLOWSTORE SYSTEMS Flowstore Systems Ltd, based in Hayes, UK, has over 25 years experience of supplying

markets. Founded in 1983 Flowstore Systems is a privately owned business motivated and committed to excellence.

provide all-embracing, cost effective solutions.

applications and provides a fast and efficient picking system utilising FIFO storage (first in, first out) and

18 ABOUT FLOWSTORE SYSTEMS Flowstore Systems Ltd, based in Hayes, UK, has over 25 years experience of supplying custom made solutions for storage, distribution and material handling systems for the UK, European and Worldwide markets. Founded in 1983 Flowstore Systems is a privately owned business motivated and committed to excellence. We pride ourselves on our ability to understand challenges that face a diverse range of industry sectors and provide all-embracing, cost effective solutions. We adopt quality controlled project management policies for a seamless delivery service from concept through to completion. Flowstore also offers LS2 Carton Live Storage system, which offers a solution for parts or order picking applications and provides a fast and efficient picking system utilising FIFO storage (first in, first out) and condensed pick faces; and DuraFlow, a system which converts existing pallet racks into carton flow rack. We offer a personal service from professional staff that care and want to be part of your success. OUR CUSTOMERS The following companies are a choice selection of customers currently using FlowTube 18

19 FLOWTUBE APPLICATIONS FIFO / Flowracks / Gravity Feed Lineside Order Picking Assembly Lines Work Benches Work Stations Multi Function Work Station Trolleys / Carts Tool Trolleys Mobile Storage Storage Shelving Pigeon Hole Dunnage Bags Display Stands / Notice Boards Tables Part Stands Bespoke Solutions 19

20 FLOWTUBE IN OPERATION Order & parts picking Assembly & manufacture Mobile storage & picking Custom 20

The only limit is your imagination Fairview Business Centre, 29-31 Clayton Road, Hayes, Middlesex UB3 1AN

21 The only limit is your imagination Fairview Business Centre, Clayton Road, Hayes, Middlesex UB3 1AN Tel: +44 (0) Fax: +44 (0) Web:

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