Automation & Guarding using Al Extrusion

I've used Al extrusion (both Bosch & 80/20) for several test benches, fixtures, and enclosures. I personally find the material to be easy to use and lightweight compared to alternate materials. One nice feature is that you can use the structure as a pneumatic manifold, which helps in keeping air lines/hoses out of the way if you are working on a project requiring compressed air.

One of the pitfalls I've noticed is joint integrity. If you use gussets or plates to assemble your structure, the joint quality seems to be a little on the weak side. This can be resolved (usually) by drilling / tapping / fastening the pieces together. Which is fine, but it adds time and work to the job.

Do you have any exposure to "Item" extrusion? German based extruder specializing in linear motion. I have had great success using their extrusion in pick n place applications. I'm currently designing a very large "conveyor" that welds cross members to spreader chain. It's been quite a bit of an adventure just getting the company to except the extrusion, I do believe the proof will be in the pudding when it's done though. We have a very good 80/20 rep near us which helps but I haven't been as impressed with the 80/20.

Joint integrity is critical and I find most people do it incorrectly. Using a "standard fastener" (per Item), the loading of a joint is pretty substantial. Like you mentioned, it requires tapping the core bore of the extrusion and drilling wrench clearance holes.

Just to clarify, I have no affiliation with Item, 80/20, or any other extruder. I just have my preferences.

I haven't used Item yet, however next time I have extrusion needs I'll give them a look. I think I'm pretty much in the same boat as you with 80/20, but I've had good experiences with Bosch (Rexroth) products. Like yourself I have no affiliation to the extrusion biz, I work in Automotive R&D & Academia.

You may want to also look at to other companies. Parker-Hannafin has their own line called IPS (Industrial Profile System). I have used theirs in the past with much success. The nice thing about them is they will anodize in multliple colors. I designed and built a pick and place unit using black anodized aluminum with smoked plexi-glass. It turned out very nice, very clean looking. They also have a great linear motion line that utilizes the same profile. The p & p unit I built had a x travel of almost 26 feet, all supported with nothing but extrusion.

Another company you may want to look at is Faztek, they have a knock off brand of extrusion that is usually a little cheaper. I have never used them but I have had them quote some designs and they are always cheaper. Being that they are cheaper, they lack some of the extra components an IPS or 80/20 offers.

The only detractor to aluminum extrusions I have found is that some of the old school engineers and plant managers do not like it because it looks cheap and thrown together. I have actually had people decline the extrusion in favor of a more exspensive and heavier weldment.

I have had great experiences with Bosch Rexroth parts and reps.

One thing that would be nice to see would be a wider range of coatings and treatments other than just anodizing.

More products that facilitate electrical grounding and isolation could be useful.

The fasteners are fairly good and varied, but overpriced for what they are. Better quick-release type fasteners that require no tools would be nice as well.

I'll have to check out the anodized extrusion, that would be a nice feature! I didn't realize that there was an IPS line out there.

There is the perception that aluminum won't hold up over time and that vibration will cause it to loosen and fall apart. Like it was stated earlier, the old school engineers favor traditional machine building over Al extrusion. I met with a guy who designed a machine that drills out the pins in spreader chain, he put the who deal on a weldment that had a 2.5" thick steel table top! You could latch onto that during a tornado and be OK, not to mention the cost and renting a rigging unit to move it!

I'll have to try and post some pictures of the system I'm designing, the fact that we convinced the customer to use extrusion was pretty amazing. It's a very old company in the construction/farming industry.

Anybody come across an application that wasn't conducive to extrusion?

Are you still looking for a guarding system? I have an option for you that is different from alum extrusion systems.