Packaging & Palletising

Is your robot all it's cracked up to be? A Fanuc robot can lift layers of 400kg without losing grip.

Fanuc robots from Micromech can be tailored to suit customers packaging and palletising requirements. The powerful M-410iWW is the world's largest palletising robot with a maximum payload of 400 kg, but it has the kind of agility that would put many a Sumo to shame.

This is due to its cleverly designed overhung arm which gives it the ability to work through 360° and perform up to 730 standard cycles per hour for twenty four hours a day. The hollow wrist mechanism protects its electrical and pneumatic services from chafing or twisting. It can handle pallets of 1,600mm square by 2,100mm high or 1,300mm square by 2,450mm high. This makes it the ideal robot for 'complete layer' lifting of cases of bottles and foodstuffs as well as items such as wooden panels, steel bales or vehicle floor-pans.

The M-410iWW incorporates easy to use software so that the operator can optimise palletising patterns based on pallet and box sizes. The simple graphical user interface allows the operator to review stacking options without any specialised programming knowledge.

As system partners Micromech Robotics and Fanuc can specify, build and install the right equipment for you that is simple to programme and operate. Perhaps you are wrestling with a problem because you need a robot that combines the strength of a Sumo with the agility of a ballet dancer. If so please contact us, we can probably find a cost effective solution that wont have you tightening your belt!

Tile manufacturer gets increased flexibility from heavyweight robot with a sensitive touch

There seems to be a conflict in meeting the market demands of low price, high volume and the ability to make rapid design changes to suit fashion requirements. But this is the case not just in the textile business; it is equally a problem for manufacturers in the building industry. Falling into this category is the roofing tile market where they have a massive throughput yet still have to be flexible, able to adapt quickly and also offer an ever-widening variety of products.

For a new 'slate look-a-like' concrete tile that was introduced it presented the need for a complete review of the packaging area as unlike the traditional concrete tile, which has an even thickness over its area, the new tile had a thin leading edge which made it difficult to stack or strap using the existing equipment.

Automated systems within the facilities were an essential part of the process and the existing dedicated automated equipment was designed to package 120 tiles per minute (TPM). Other improvements carried out in the rest of the plant over the years had increased the handling requirement to a rate of 150 TPM at 80% utilisation. Although modifications to the original packaging equipment could have made this feasible, the costs could not be justified.

Following the successful installation of a robotic system in another area it was decided to investigate the robotic packaging route for this line. After an appraisal of several robot suppliers an order was placed with FANUC Robotics for a system which included two 4 axes FANUC Robot M-410iWW palletising robots, grippers, guarding and overall responsibility for interfacing all associated plant.

The overall system integration had the potential for particular problems as the tile delivery point to the packaging area, from the existing system, required modification together with the installation of two new strapping machines. These elements and the robotic system, plus the companies own engineering department's involvement meant that four companies were involved in the installation. Due to previous experience of working with FANUC in similar situations their capability to integrate all the equipment was not in question.

The two FANUC robots, each capable of lifting 400 Kgs at +/-0.5mm repeatability are positioned either side of the strapping area. The tile conveyor operating at up to 150 TPM delivers tiles to two pick-up points where they are orientated and positioned for the robot's gripper to locate. The weight being handled at this stage is a combination of tile pack at 170-200Kgs and gripper weight of 175Kgs.

The tile packs are then positioned either in one of twelve buffer storage areas to allow production to continue even if there is a line stoppage, or taken directly to the strapping machine. Once strapped the tile pack is picked up by the palletising robot and lowered towards the programmed pallet position.
The nature of the product being palletised means an allowance is made for large tolerances while still working at relatively high palletising speeds. When positioned on the pallet the tolerance build-up of tile pack and pallet can be anything up to +/-25mm.

The palletising gripper uses a sliding plate that locates under the pack and pulls out when the tiles are located on the pallet. The robot can be driven at speed to within 25mm of the stack and then reduce speed to 100mm per sec while monitoring motor current every 20msec. When the gripper plate contacts the stack, current increases and the robot programme instantly skips to the next programme step.

The system now operates at close to 150 TPM and is bringing major benefits from the new packaging equipment, delivering a much firmer package which for customer's means less breakages during shipment and overall a higher quality product. Reduced profile changeover times, increased reliability and flexibility of the system have all contributed to an improvement in utilisation in this area.

In a fast changing market the flexibility of utilising a robot are clear. As system partners Micromech Robotics and Fanuc can specify, build and install the right equipment that is simple to programme and operate. Perhaps you are not already using a robot and this has tempted you to re-construct your factory layout.