Multi-functional Conveying Path in the Tightest of Spaces
Task
To develop a space-saving and multi-functional conveying path
At a manufacturer of carton packaging, the carton blanks fed out from a production machine were stacked on pallets manually. The aim was to automate this process, with a robot taking over the palletising work in the future. However, the task of integrating the conveyor technology required to do so was complex, as the production machine runs on a continuous basis. Every 36 seconds, two stacks exit the machine and have to be transported away by the conveyor system. If problems occur during palletising, delays must not lead to jams or standstills. This called for an intelligent conveyor system with the ability to divert the stacks of cartons to a buffer zone when necessary. The system also had to be capable of diverting stacks away for quality control checks, and all of this needed to be done in a very tight space. Everything needed to be flexible. Everything needed to be compact.
The automation specialists found the ideal partner for this challenging task in mk. Together their experts developed a tailored, flexible and compact conveying solution using the mk modular construction kit.
Solution from mk
Conveyor system with a crossing point in the directions of the robot, buffer area and quality control
The new conveying route is made up of multiple conveyors that are arranged in the shape of a cross to save space. This is how it works: The stacks of cartons exit the production machine on an ejector belt. The end of the belt is where the solution from mk begins. The stack of cartons runs onto a GUF-P 2000 belt conveyor with a lower belt drive. A speed control system ensures a sufficient gap between the stacks, which are transported to the central element of the unit: the crossing point. Here, a lift and transfer module can switch the direction of the stack by 90°. The lift and transfer module consists of a four-line timing belt conveyor with electrically powered conveyor rollers between the lines. They raise the stack slightly and convey it on sideways, allowing for four different directions in a tight space. Sensors detect the exact position of the stack.
On the main line, the stacks are turned 90° onto a GUF-P 2000 belt conveyor and then guided onto a five-line timing belt conveyor, which forms part of the downstream, customer-supplied removal unit. There, the robot grips the stacks and accurately positions them on pallets – an efficient solution with repeat precision.
Alternatively, the stack can be guided straight on to another GUF-P 2000 belt conveyor that serves as the buffer area for manual quality control. The stack can also be guided onto an RBS-P 2066 gravity roller conveyor with a fixed stop, which serves as a manual emergency discharge system for multiple stacks if a fault occurs in the robot cell. These stacks are fed back into the process via the GUF-P 2000 for quality control once the robot cell is ready for operation again.
Customer benefits
- Optimum use of space thanks to the space-saving design: The conveying path combines several functions, including a robot handover point, quality control and a buffer area, with a minimal footprint.
- A non-stop material flow: An intelligent sensor system and rapid diverter capabilities allow stacks of cartons to be guided to a buffer zone when necessary, without having to stop the production machine.
- Working in partnership with mk allows for rapid responses: The experts at mk worked with the client to develop a custom solution that is tailored to its needs, while also facilitating quick and flexible adaptation.
Products used
> GUF-P 2000 belt conveyor
> RBS-P 2066 gravity roller conveyor
> ZRF-P 2040 multiple line timing belt conveyor
