Automated pallet feed increases ergonomics and efficiency
Task
An automotive supplier manufactures high-precision plug connectors for temperature monitoring in car chassis. The connectors are produced using injection moulding: Prefabricated inlays with integrated contact pins are precisely positioned in an injection moulding machine and overmoulded with a plastic connector frame.
The inlays are provided in large-format, customer-provided pallets and manually transferred to the existing production cell. The cell processes one pallet with a cycle time of approx. 30 minutes. In the cell, the parts are removed by a robot and inserted into the injection moulding machine. The finished plug connectors are discharged from the cell via a separate belt conveyor.
The production cell is now to be expanded to include an automated feed and buffer section in order to improve ergonomics and system availability.
Solution from mk
mk developed a pallet changing system over two levels. Each level consists of a three metre long ZRF-P 2045 timing belt conveyor. Due to the very limited installation space, these conveyors were connected at the ends by lifting units with integrated pushers in order to move the pallets from one level to the other.
The manually loaded pallets are transferred to the feeder on the lower conveyor level at an ergonomically optimised height. Using two-hand control, the pallet is released and the lifting unit lifts the pallet to the upper conveyor level in a controlled manner. From there, the pallets are automatically fed into the production cell.
Once the inlays have been removed, the second lifting unit lowers the empty pallet back down to the lower level and automatically transports it towards the loading station. The cycle starts again.
The design with three pallets in circulation creates a buffer section that enables the production cell to operate autonomously and compensates for fluctuations in cycle time in the manual area.
The changing system is also equipped with a protective unit to safeguard the work and automation area
Customer benefits
- Ergonomics and occupational safety: Ergonomic handling increases safety and reduces physical strain.
- Process stability and autonomous operation: Three pallets in circulation ensure continuous supply to the cell.
- Increased productivity: Automated feed and return minimises downtimes.
- Modular integration: The solution is compact and integrates flexibly into existing systems.
Products used
> ZRF-P 2045 timing belt conveyor
> Guarding
