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Understanding the Most Common Parts of Robotic Palletizers
If you're thinking about investing in a robotic palletizer for your food packaging facility, there's a good chance you've got a lot of questions. It's essential for your team to understand how the key components of robotic palletizers work to operate them safely. Let’s break down each part of these machines.
At TDI Packsys, we provide advanced industrial palletizers. While we could tell you all about the advantages of switching to an automated system, it wouldn't mean much unless you knew how these machines function. Keep reading to learn everything you need to know about the different parts of a robotic palletizer.
The 4 Main Components of Robotic Palletizers
Robotic palletizers move boxes, bags, and other types of packages into neatly stacked pallets, allowing you to ship items in bulk. Unlike conventional palletizers, robotic systems rely on a robotic arm to smoothly move various items along pre-set patterns for faster, more efficient, and safer palletizing. Traditional palletizers use conveyor belts to move one item at a time, whereas robotic palletizers can pick up multiple items of different shapes and sizes and place them in their designated spots.
These palletizers can improve manufacturing productivity, product handling, and workplace safety while cutting down on operational costs. So, how exactly do they work? The main components driving robotic palletizers include the following:
The Robotic Arm
The robotic arm gives the palletizer its flexibility, movement, and adaptability. This component moves the end-of-arm tooling to pick up items and place them on the pallet. A robotic arm functions similarly to a crane arm, though some arms can only move back and forth or up and down on two-dimensional planes, while others can move in multiple directions in three-dimensional space, swiveling around freely.
This component comes in various lengths with differing joint layouts, all affecting how the arm moves, functions, and reaches for items.
Key Robotic Arm Components
The robotic arm includes joints, arm links, the wrist, and the end-of-arm tooling (EOAT). The arm links are the main sections of the arm, appearing like columns. Joints connect these arm links together.
Joints can offer multiple ranges of motion between arm links, depending on the machine you buy. Some robotic arms can offer ultimate flexibility, moving across almost any palletizing pattern imaginable. The number of joints on one robotic arm varies, but you may see up to six on devices with unrestricted movement.
The wrist is the joint that connects the arm to the final “hand,†which picks items up. This hand is called the end-of-arm tooling, which we’ll discuss below.
Common Types of Robotic Arms Used in Palletizing
The different types of robotic arms tend to have varying joints and arm link configurations. Some common types of robotic arms for palletizing include the following:
Cartesian: Movement in three directions
SCARA: Movement left, right, forward, and backward
Articulated: Swivel movements in nearly all directions
End-of-Arm Tooling (EOAT)
One of the most crucial parts of robotic palletizers is the end-of-arm tooling. The end-of-arm tool acts as the hand at the end of the robotic arm, picking up items and placing them on the pallet. Many consider this to be the most vital part of the robotic palletizer since it determines what your system can or cannot pick up and how many items it can handle at once.
Types of EOATs
Selecting the right end-of-arm tooling for your facility ensures optimal palletization efficiency. Some popular options include:
Standard mechanical clamping: Clamping systems can pick up most standard-shaped items without damaging them.
Automated tool swaps: Tool swap EOATs can move entire pallets at once for highly efficient operation.
Vacuum tooling: Vacuum tooling uses suction to transport more unique, oddly shaped products like slip sheets.
Adaptability for Various Product Types
Some EOATs can pick up a variety of unique materials, including barrels, bottles, plastic wrappers, slip sheets, and entire pallets of boxes. When choosing your robotic palletizer, ensure that the EOAT can handle the type of products at your facility.
The Conveyor System
While robotic palletizers don't involve the same complex conveyor systems as their conventional counterparts, they usually still require at least one conveyor belt. The conveyor belt delivers products to the palletizing area to automate infeed. This process allows you to pre-condition products in the correct orientation for hoisting by the robotic arm.
Infeed conveyor belts align and rotate products to prepare them for robotic palletizing. Depending on the palletizer you purchase and your product type, the conveyor system may not be as necessary.
Common Types of Conveyors
Conveyors come with numerous add-on technologies to automate portions of your production process while ensuring maximum quality and consistency. For instance, some types of conveyors can weigh and reject products based on quality control sensors as a final line of defense for your manufacturing facility. You may also select conveyors that can align multiple products at once for the most efficient results.
How the Conveyor System Integrates With the Robotic Arm for Efficient Operation
You can integrate your conveyor system with the robotic arm and the rest of the palletizer to create one automated, efficient machine that reduces human errors while boosting output. The no-contact method minimizes liabilities at your facility while ensuring maximum productivity.
The Pallet and Slip Sheet Dispensers
While pallet and slip sheet dispensers may not be the most common parts of robotic palletizers, they can significantly increase efficiency while reducing safety risks. Pallet dispensing involves any method used to pick up, remove, and replace fully loaded pallets so the robotic arm can continue feeding into the next pallet. You can choose from automatic or manual dispensing options:
Manual pallet dispensing: In manual dispensing, your facility staff must manually remove full pallets and replace them with empty ones in the correct position once the robotic arm completes palletizing.
Automatic pallet dispensing: To avoid any manual intervention risks, you can choose systems that automatically discharge pallets through dispensing belts. Your team will still need to load the dispenser with pallets on a semi-regular basis.
The Pallet Magazine Capacity
The pallet magazine contains the pallets waiting to be dispensed for automatic systems. Many pallet magazines can hold approximately 20 pallets, reducing contact for your facility.
Slip Sheet Dispenser Integration Capabilities
Many facilities use slip sheets in between layers on pallets to limit damage to products. Robotic palletizers can integrate with suction cup EOATs to automatically place slip sheets between pallet layers for automated slip sheet dispensing.
Safety Features on Robotic Palletizers
Robotic palletizers inherently reduce risks at your facility by decreasing the number of times your team must interact with heavy machinery. However, these systems can be hazardous without proper safety protocols. So, what are the most common safety features on robotic palletizers?
Essential Safety Components
High-quality robotic palletizers adhere to Category 3 Safety standards by incorporating the following safety features:
Machine safety fencing
Safety lock features with Trapped Key systems and Safe Locks
Light curtains
3D position checks
Integrated software for redundant safety checks
Robotic Palletizer Compliance With Industry Safety Standards
Robotic palletizers must comply with American ANSI/RIA standards and similar standards set by international organizations. These standards outline safety requirements for robots in industrial settings. By selecting equipment that meets ANSI/RIA and Category 3 Safety standards, you can achieve the highest level of safety.
How Robotic Palletizers Can Prevent Accidents
Robotic palletizers can prevent workplace accidents by minimizing human interaction with machinery. Automatic operations eliminate unnecessary risks at your facility while reducing the potential for human error, ultimately helping you keep your workers safe.
Maintaining and Troubleshooting Robotic Palletizers
Now that you know the key components of robotic palletizers, let’s talk about how to maintain them.
Common Maintenance Tasks
Well-maintained robotic palletizers operate more efficiently and can last exceptionally long. We recommend the following tasks on a routine basis:
Cleaning the exhaust fans
Releasing grease from the axis
Removing debris from the system’s sensors
Tightening all external bolts
Checking for component wear
Reviewing alarms in the HMI and controls
Replacing the controller batteries
Performing comprehensive tests on all parts
Troubleshooting Tips for Common Issues
If you're experiencing problems with your robotic palletizer, the solution might be straightforward. Consider the following:
Ensuring that your products meet the correct variance quality
Using the right type of pallets
Loading products onto the conveyor belt correctly
Training your team regularly
Staying on top of maintenance tasks
The Importance of Regular Inspections
Regular inspections can help you identify errors in your production process or malfunctions in your machinery. We recommend conducting comprehensive inspections routinely to address issues before facing significant downtime.
Upgrade Your Palletizing System Today
Now that you know the key components of robotic palletizers, you may have a better understanding of which type of system will suit your facility’s needs. Call TDI Packsys today at (877) 834-6750 to learn more about our state-of-the-art industrial palletizers.