How to Choose the Right Wire Basket

How to Choose the

Right Basket?

Drew Greenblatt

President

Marlin Steel Wire Products

How To Choose the Right Wire Basket

Table of Contents:

Part I. Typical Basket Applications………………………….4-18

Material Handling Applications………………………5-9

High Temperature Applications………….………10-11

Cleaning Applications…………..…………………...12-17

Part II. Custom Basket Options……………………….……18-46

Wire or Sheet Metal……………….......…………...19-23

Material of the Basket………………………….......24-25

Dividers……………………………………………………..26-30

Lids……………………………………………………………28-31

Handles………….………………………………………….31-32

© Marlin Steel - Quality Engineered Quick "How To Choose The Right Wire Basket?"

2

Table of Contents:

Basket Tags for Kitted Parts………………………….34-35

Stacking Designs…………………………………….…...36-42

Hoist Baskets………………………………………………….…43

Coatings…………………………………………………….…44-45

Part III. How to Create the Right Basket for the Job..46-69

The Questionnaire……………………………………….47-49

Productivity Considerations………………………….50-54

Choosing the Right Basket……………………………54-69


3

Typical Basket Applications

-Material Handling Applications

-High Temperature Applications

-Cleaning Applications


Part I.

4

Bulk Material Handling

Features Typically Include:

• Durable 30+ years

• Repurposed later

• Parts may touch each other

• Part contact satisfactory

• Parts scratching not a concern

• Can be manufactured with a wide variety of custom coatings which correspond to environmental conditions


5

Bulk Material Handling


The dimensions of the parts that your basket will be holding give our engineers the ability to design a basket that will fit your machine like a glove.

Too much space, and a part could rattle around excessively, creating a risk of damage to that part. Too little space, and the part will not fit in the first place. Naturally, the tolerance for extra space in a materials handling basket will differ based on the individual parts and washing process involved.

6

Baskets that hold cylinders

With wire “pegs,” hollow cylinders can be held securely in place so that they do not fall out of the basket or impact one another during a wash cycle.


7

Baskets – Confirm all parts are where they should be

• Baskets can be custom manufactured to hold several different parts at once.

• When using such baskets, it is important to ensure that all slots/holders have the right parts in them.


8

Stacking Conveyor Material Handling Basket

• When designing a basket for conveyor belts, it is important to know the characteristics of the belt (solid, segmented, roller-type, etc.).

• Adjust base of basket based on type of conveyor system.


9

Heat Treat Baskets

• Below 1600 Degrees Fahrenheit

– Stainless Steel 304 or 316

• High temps 1600 Fahrenheit

– Stainless Steel Grade 330

– Inconel


10

“These baskets will run through a hot water washer with no soap. Water temp = 210 degrees F / Air Blow Dry temp= 140 degrees F / Wash cycle duration = 9 minutes”


11

Washing Systems & Baskets


With grade 304 SS and grade 316 SS, our washing baskets are corrosion-resistant. They’re an ideal basket to hold your delicate equipment and parts when being ran through washing processes.

12

“Baskets will be used to transport our components to our coater and then run through a washing process.”


13

Ultrasonic Cleaning Racks

Baskets need to have an open design to allow cleaning medium to reach parts easily and drain away after washing.

Basket needs to be able to endure ultrasonic vibration and cavitation for thousands of uses.

Dimensions of basket need to meet exacting specifications for both the machine and the parts to be held.


14

Disk Basket


These baskets are designed to hold round, flat metal objects without obstructing the wash process.

The baskets feature two handles that can be built in an A-frame design to stick above the basket, usually so they “nest” in a stack. Other times, steel wire by sheet metal can form “drop handles” that can fold up or down.

15

“The baskets should be as open as possible to allow for more effective washing and drying of the parts.”


16

Articulate Parts to Maximize Washing Basket


The basket must be sturdy enough to withstand the agitation, cleaning agents and temperatures of a wash process, while keeping parts from being scratched during loading and unloading.

The design must also maximize flow to remove the most particulates and debris possible.

17

Custom Basket Options

-Wire or Sheet Metal -Stacking Designs

-Material of the Basket -Pins

-Dividers, Lids, Handles -Hooks Coatings

-Basket Tags for Kitted Parts


Part II.

18

Common Basket Materials

• Mild Plain Steel 1008 or 1010– Cheap– Rusts

• Stainless Steel Grade 304– Inhibits Rust

• Stainless Steel Grade 316– Pharmaceutical– Harsh Environment

• Stainless Steel Grade 330 – Heat Treat Application


19

When Are Wire Mesh Baskets Best?

• Rounded surface of the wire provides no flat spot for liquids to settle.

• Open Area – uniform heating and cooling of parts.

• Fast drainage.• Effective in ultrasonic cleaning.

– Four openings per linear inch

– 0.063” wire diameter is standard

• Pressure agitation.


20


“The open area of a wire mesh product can range anywhere from 20 to 80 percent of the surface area of the mesh basket.”

21

When are Perforated Sheet Metal Baskets best?

• Lower cost.

• Will not dry as efficiently as wire.

• Resistant to abusive environments.

• Higher structural integrity due to fewer points of

contact versus wire mesh.


22

Sheet Metal & Wire –Mixed Media Solution

• Combine benefits of sheet metal and wire forms.

• Sheet metal provides tensile strength/load capacity, wires provide ease of access/custom shaping to better hold parts.

• Often used in basket designs to ensure best design flexibility.


23

Downside to Plastic Bins?


Steel is better than plastic for a number of reasons:-More temperature resistant-More corrosion resistant -More versatile -Cleaner -Greater protection against fire-More sustainable-Less expensive long-term-Less expensive to make -Less water absorption

24

Plastic Bins

• Chipping – Plastic goes in engine, it can ruin transmission

• Collect Dust

• Opaque – hard to see how many parts are inside

• Chips of plastic can fall in parts

• Inhibits Sprinkler Operation - Fire Marshal, Insurance Companies prefer non flammable porous handling devices


25

Individual Parts Holding

• Individual parts holding - divided baskets.

• Keep groups of parts that go through similar processes separated.

• They are easily identifiable.

• Precision Orientation.

• Eliminates damage to parts from handling or part to part contact.

• Can be used for multiple types of parts at once, assuming all part types fit in dividers.


26

Automotive Component Basket

• Parts need to be held securely in place so that they do not bounce around and become scratched.

• Designs for these baskets can vary wildly based on part dimensions and finishing processes.


27


Baskets with Lids and Dividers

28

Divider Basket with Lid and Lock


Left to sit loose in a basket, parts that are not properly constrained will bounce and roll around, hitting each other and potentially causing damage.

These baskets, with welded basket dividers, are generally sturdier and lower the likelihood of losing basket parts. It also eliminates the possibility of using the wrong dividers with the wrong baskets, which may happen with a basket with removable dividers.

29


30

Bulk Basket with Handles & Locking Lid


Baskets with lids are especially useful for washing/finishing processes where the parts in the basket need to be rotated to get the best results.

A lid will secure your parts so that they do not become lost or damaged.

After we have the dimensions of your basket down, we design your basket using precision computer software.

31


“The handles of the basket are part of the stacking mechanism. The handles, which feature a precision-bent hook design, can be flipped into or out of the basket.”

Baskets with Handles

32

Cylinder Baskets for Parts Shaking


33

Basket Holding Precision Parts from Inside


34

Basket Tags for Kitted Parts

• Help organize parts by batch.

• Keep multiple baskets with similar designs separate to ensure that right basket is used for the job.

• Keep parts from going to the wrong finishing/wash process.


35

Stacking Baskets Holding Delicate Parts


“These baskets take up minimal space when not in use, but are able to be stacked without putting pressure on the contents when in use.”

36

Stacking Gear Baskets


Different clients will have different priorities. During the initial design phase, Marlin Steel’s engineers ask clients to rate these key characteristics of the final product in importance: • Functionality • Appearance • Cost• Delivery

Generally, for stacking gear baskets, clients rank functionality as high priority over appearance.

37

Mobile Baskets? Locking & Swiveling Casters

• Heavy-gauge wire for high weight tolerance.

• Caster wheels for ease of manual transport.

• Lid keeps parts and materials from falling out in case of basket upset to minimize lost time from accidents.


38


“Stacking baskets are a great solution for protecting delicate machined parts from scratching. This protection will save you from rework and additional inspections.”

39

Stacking Basket to Hold Canisters With Handles

• Needs to hold many objects at once.

• Large handles for ease of manual handling.

• Stacks to conserve space on the factory floor.


40


“As you can see here, Marlin Steel stacking baskets for holding delicate parts will stack with existing baskets. This way, you can have the option of using them singularly or together.”

41

“The baskets will be stacked on top of one another, therefore the baskets above become the top of the basket below. These will be robot loaded and palletized so they will need to have nesting features similar to our baskets now.”


42

Hoist Baskets with Knock Down Sides

• Designed to be lifted with a mechanical hoist.

• Needs to have high weight tolerance.

• Knock-down sides enable easy access to basket contents once set down.


43

Best Basket Coating for Your Application?


44

Basket Coatings Impact Design…Example

• Problem:

Bridges and bubbling can occur in corners.

Solution:

Coat internal components separate from the basket and then rivet them in place as opposed to welding.


45

How to Create the Right Basket for the Job-The Questionnaire -Robotics

-Productivity Considerations -Choosing the Right Basket


Part III.

46

Better Engineering leads to 33% throughput improvement and 60%

handling reduction


The perfect custom metal form you’re looking for come from our talented staff. Over 20% are degreed mechanical engineers, which means they have the tools, training and experience needed to help design your next project.

47

Basket Questionnaire

• Mechanical Engineers Probe & Understand:

– Fit

– Form

– Function


48

Goal: Cradle to Grave Processing

• Keep parts in same basket from start of process to end of process.

• Less time handling parts from one area to the next.

• Parts can be processed in the baskets.


49

Productivity Considerations: Tight Tolerance Handling Racks


The tolerance of the handling rack you need is critical to know.

Our steel has great tensile strength and is durable; made to stand the test of time.

Computer modeling and virtual testing helps ensure final product will hold the desired shape during heavy use.

50

Productivity Considerations: Part Numbering of Baskets


Marlin Steel uses part numbering for baskets to keep track of the different part sets quickly and easily. This makes the parts quick to identify how many sets of a parts load are on the floor for assembly.

Instead of simply placing a temporary label on a basket, you can have plates with custom-cut numbers integrated with the baskets. Numbering baskets in this way is much more durable than using a barcode.

51

Productivity Considerations: Unique Machined Parts Basket


The automated manufacturing robots enable Marlin Steel to complete custom machined parts baskets with both precision and speed.

Because of this, it is possible to build a custom parts cleaning basket for unusually-designed parts.

52

Productivity Considerations: Jar or Bottle Baskets


Jar and bottle baskets pose many design considerations. Every time such a basket order is made, Marlin’s engineers consider not only the dimensions of the machinery of the client, the processes the basket will be used for, and the dimensions of the bottles or jars to be held, but the materials such contents will be made of.

53

Productivity Considerations: Gripping Delicate Parts

• Delicate parts need to be held securely so that they do not bounce around or fall out.

• Scratches can ruin the functionality of delicate objects.

• Wire forms allow for parts to be held securely so that they do not move.


54

Other Basket Attributes?

Design Features?

• Lid?

• Dividers?

• Hinges?

• Locking

• Wall Mounting?

• Mobile?

• Hoist Friendly?

• Conveyor Friendly?

Best Way to Store Baskets?

• Stacking?

• Nesting?

• Stacking & Nesting?


55

Ways to Weld Baskets

• Resistance– Heat + force + time (60

cycles)

• Mig– Add solder, generates

spatter – more clean up

• Tig– Add solder

• Medium Frequency– Heat + force + time (2

cycles)


56

Robotic Interaction

• Presenting a manufactured part to a machine.

• Robotic arm can pick the part from its nesting spot, perform a series of operations and then return it to the original position.

• Develop correct tolerances to interact effectively in repeatable machine


57

Benefits of Medium Frequency Welding for Precision Baskets

• Reduces Scratching on Parts– less cycle time and

creates less heat. • Tighter tolerances

– Less warping and distortion

– Flatter parts• Robotics/Automated

machinery – Small Room for error– interacting with

baskets.


58

Laser Cut Elements Improve Safety for Precision Parts

• Platforms to Hold Parts Precisely.

• Delicate Zones of Parts Safe.

• Grip Parts so they are constrained in Washers.

• Customized Orientations for Water Jets.

• Dividers.• Hinges.• Latches.


59

Laser Cutting +/-0.004” tolerance


Our laser cutting machines use the intense, and tightly-focused, heat generated by a laser to quickly make cuts in sheet metal. The laser will repeat these cuts over and over, hundreds of times per hour. Once the machine is programmed with the right cutting patterns, it makes the cuts on its own.

All risk of human error is eliminated by automating the laser cutting process. Marlin Steel can effectively create the perfect parts that will fit together every time.

60

Precision Part Holding with Laser Cut Sheet Metal

• Laser-tight tolerances allow cut sheet metal to hold parts precisely.

• Laser cutting can be run at peak speed for hours on end.

• Leaves smooth cuts in metal plates.


61

Precision 4 axis bending – for improved part and divider layouts


Marlin Steel’s 4th axis offers us with a greater range of motion and reduces changes in the tooling operation, which helps ensure the tightest tolerances.

62

Louvers for air flow and beads for stands – holding delicate parts


63

Punch: roll threading, perforations and louvers in line

• CNC punch machine can quickly and efficiently punch holes into sheet metal, and bend it into specific shapes.

• The TruPunch 2020 can perform the following:

• Cluster punching.

• Tool rotation.

• Square tool nibbling.

• Extruding and tapping.

• Wheel forming, deburring, and offset.

• Multi-bend of sheet metal.


64

Basket Decision Matrix

Holding

Weight

Durability Flexibility

Lead Time

Tolerance Chemical

Temperature

Cost


65

Mounting Baskets –How will it adhere to a wall or

machine?• Can design mounted

baskets to hang from hooks in a wall, or from integrated plate with screws or nails.

• Mounting baskets often used for bicycles and offices.


66

Baskets to Hold Discs for Robotic Loading

In this design, the parts needed to be held in precise positions to allow an automated machine to retrieve parts without damage.

Using manufacturing robots allows these baskets to be made to the incredibly tight tolerances needed to ensure that robotic loaders can work at maximum efficiency.


67

Baskets that Kit Delicate Parts

• Baskets that hold multiple types of parts that go through the same wash/finishing process help to streamline final assembly by putting all of the needed parts together.

• Parts are protected by being kept separate.


68

Basket Packaging –every detail must be executed well

• Packing materials need to be sufficient to keep baskets from being damaged.

• Box/crate must be easy to open at destination without risking damage to contents.

• Proper shipping labels must be on box to facilitate ease of transition at checkpoints.


69

Repeatable Clear Process

• Team enjoys step by step methodology

• Craves consistency

• Visual Cues

• Easier to Innovate with Repeatable Quality

• ISO 9001: 2008


70

Thank You! Drew Greenblatt

Marlin Steel Wire Products

www.marlinwire.com

[email protected]

410.644.7456


71

http://www.marlinwire.com

mailto:[email protected]

Date post:	22-Jan-2018
Category:	Engineering
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