Palletising with Layer Cards

The Challenge

For this solution, the customer required a system that could be integrated with their current line with no changes to the factory layout. In addition to this, there were several other specified requirements, including:

• Feeding of very low centre of gravity boxes due to the “bags” of product inside the boxes
• The development of a bespoke end of arm gripper to accommodate the product boxes
• Accommodate sealing tape stretch on the boxes
• Ability to load layer cards from two sides
• Cater for different box/pack sizes
• The ability to pick up different box sizes with no end of arm changes
• Required to be easily reprogrammed to suit future pallet layouts

The Solution

Based around the standard SP-EZPal palletiser platform, the system design also incorporated two layer card load positions.

Product in various box sizes were fed via a conveyor and escaped to a pickup position. Due to the low centre of gravity of the product in the boxes, the head was designed to pull the box top close to a flat plate to create a stable lift.
Depending on the pallet configuration and pack size, up to two boxes were picked using the bespoke gripper and placed onto the waiting pallet. A layer card was then added between layers and on top of the final layer.
Once the pallet was fully loaded, the robot would then populate pallet position two. The three-scanner safety system integrated into the SP-EZPal palletiser means that the operator is always safe when removing pallets.