ROBOTIC STACKING AND PALLETIZATION OF LABELS IN THE POLYGRAPHIC INDUSTRY
One of the activities that are often replaced by automated or robotic line is product labelling, check and manipulation. The advantage of robotic solution is the possibility of function adjustment of the robot in the case of change of technological procedure (labelling, packaging, mass etc.) The assignment of our specialists was this: to find a solution for placing a package of labels into a box with further palletization and thus substitute the demanding work of handlers. The result made us happy!
B:TECH’s robotic units were created directly in operation where human labor cannot be completely replaced. Great emphasis was placed on the simplicity of equipment operation while adhering to the machine safety standards. The work place is divided into zones by photocells so that during manual manipulation with pallet, the robot can remove products from the line without interruption. The worker doesn’t need to open any covers or gates, they only need to push a button in order to request access into the equipment and the robot adjust its work to their presence. We are proud that we were able to built and program the equipment in such a way that it can manipulate with products of many shapes and sizes without difficult format conversion.
HUMAN HANDS ARE A MIRACLE AND ITS BAD TO WATE THEM ON SOME ACTIVITIES
Robotization is useful for automatization of physically demanding, routine and mechanical activities or for activities that require pace or great precision, which is the robot's strong side. Again, there are reduced operational costs of jobs at the end of our story. The robotization has opened an opportunity for the workers to change job title with the possibility to apply value added by human labor.
MODERNIZATION “UNDER THE COVER”
Our reviving of technology in the conditions made difficult by the coronavirus situation was conducted meeting all preventive measures and without interruption. Aside from current epidemiological situation, another challenge was the limited space that requires keeping isles for manipulation. In this case, great advantage was brought by simulation programs that help with economical correctness and the robots have expected reach.
Our company uses Visual Components software for visualization that enables to design everything and test the functionality in a virtual environment, thus helping us to specify the assignment and the customer’s expectation. This dialogue can be complicated in current conditions that do not favor personal meetings. It is, however, key for a successful implementation. Thanks to simulations, we can shorten the duration of this phase and make everything crystal clear, even at a long distance.
MAIN ROLE PLAYED BY FANUC ROBOTS
This particular robotic palletization unit application is based on the integration of 2 FANUC M-710iC/50 and M-10iD/12 robots. In this case, the important parameters were their speed and reach. The first robot assembles the box, seals it, labels it, puts products into the box, palletizes it and lays spacers on the pallet. The second robot removes the product from the line and groups it for the transfer to the box. In the video below you can see them working together.
UNIVERSAL PALLETIZATION UNIT
As part of the project, we have developed a universal palletizing solution for small spaces adapted for operation with pallet handling by hand-operated carts:
- Space 3,6 x 3,6 m
- 6 boxes per minute
- 2 pallet spaces of EUR-pallet on the ground
- Service with pallet cart
- Inserting spacers on the pallet and between the layers
- Pallet replacement and spacers insertion without stopping the palletization
- The workspace is protected by photocells, thus without the need to open gates manually
Tomáš Sedláček, Byznys leader, Robotics department
" As a part of this project we have implemented two identical workplaces at the same time, in a small space and in record time for us. The application is very complex in the terms of the number of handled products, or rather their shapes and sizes. Nonetheless, we were able to keep it simple in the terms of moving the machine between products. It is an intelligent solution regarding the customer’s needs where we have fully utilized our programming capabilities of complex applications controlled by PLC. The equipment allows to replace the pallet and replenish the stack of boxes without covers manipulation and stopping the machine. Nevertheless, it fully complies with CE-related standards.”
FACTS IN A NUTSHELL
- Two identical workplaces implemented at the same time
- FANUC M-710iC/50 and M-10iD/12 robots
- The first robot assembles the box, seals it, labels it, puts products into the box, palletizes it and lays spacers on the pallet
- The second robot removes the product from the line and groups it for the transfer to the box
- Tens of shapes and sizes of products were packaged, 2 boxes sizes
- The solution allows the handling with pallets and replenishing the stack of boxes withoutstopping