MACHINERY Automation & Robotics (MAR) has installed a robotic palletising system at an Australian manufacturer’s facility in Sydney, automating a new production line and improving safety standards.
Where manual systems are used the palletising industry is labour intensive, time consuming and subject to higher occupational health and safety risks associated with heavy lifting.
According to the company, by using a robotic palletising system, occupational health and safety issues cease to be a problem. Additionally, labour costs can be reduced, and production capacity can be increased.
MAR installed a single robot system to handle cartons and pallets and automate stretchwrapping. A touch screen allows for the entire palletising system to be controlled by a single operator.
When the system starts up, the operator loads a stack of up to ten empty pallets into each of the Chep and Export pallet stack frames. These pallets are then automatically conveyed to the pallet pick-up position.
The robot system comprises of a robot which distributes the empty pallet stacks to the loading stations. The robot can pick and place a pallet layer sheet onto the appropriate empty pallet. As cartons are received at the infeed conveyor, sensors count the required quantity to commence pallet layering.
When the correct number of cartons is reached, a stop plate prevents additional cartons from entering the final pick-off point. The robot moves to the conveyor and grips a set of cartons, transferring them to the loading station and continuing the palletising process until a pallet load is complete.
Fully loaded pallets are removed from the loading station to the 90-degree conveyor transfer, from where it travels along the main trunk line before exiting the cell through the muted safety light curtain. The pallet then enters the stretchwrapper where it may be wrapped prior to exiting the system for the pallet pick-off point.
The pallatising system allows manual stretchwrapper infeed in addition to the fully automated process. A pallet conveyor section between the robot cell exit and the stretchwrapper entry points allows the forklift operator to safely place a pallet for automatic stretchwrapping.
Completed pallets exit the system can then be removed by a forklift operator. When the forklift breaks the light curtain in the output area, the conveyor stops, allowing the forklift driver to load the pallet and exit the section.
The system is controlled by a colour touch screen and a ten-page program said to be easy to navigate. The program allows basic system start and stop functions, manual control of conveyors, manual control of the gripper, shift production data, error reporting, robot control in service position and elevated home position, and access control for maintenance.
The automated system has two safety features incorporated into its design. No part of the robot or gripper makes contact with the perimeter fence or the four surrounding walls. The area within the cell has also been maximised to allow free access around the robot and conveyors for cleaning and maintenance operations.
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