Overview
The robotic system was developed with conveyor systems as its core element. The primary objective of the system is to merge box flows from four packaging lines and process them using a single palletizing robot.
Empty pallets are delivered to four palletizing positions, and once filled, the pallets are merged into a single flow and pass through a stretch-wrapping machine.
My Role
As a Project Engineer:
Collaborated with the team and the customer's engineers to develop an optimized layout for the robotic system, taking into account the logistical and production process requirements.
As a Mechanical Design Engineer:
Designed the box transport system, which includes:
Conveyors with pick-points for box handling,
A multi-level roller conveyor system,
Inclined conveyors for box elevation,
Modular belt turn conveyors,
Swivel roller conveyors for flow redirection.
Developed the pallet transport system, which includes:
A long-chain conveyor with cross-sections for pallet distribution,
Place-points with precise pallet positioning units.
Designed the filled pallet removal system, which includes:
A shuttle for pallet transport,
A cross-section with an electromechanical drive for flow redirection.
Key Challenges and Solutions
The main challenge of the project was integrating a large number of inbound and outbound conveyors around a single industrial robot.
After multiple iterations and analysis of various layout options, the optimal solution was found:
Boxes are transported via a three-level conveyor system.
The pallet feeding system is placed underneath the robot, which significantly reduced the space requirements and ensured the seamless operation of all lines.