Case: OCTOPUS 1 - Robot Unit for Handling and Packing

At KILDE A/S we have been working with various robotic solutions for a long time. Since there has proved to be a need for robot cells for packaging of pre-manufactured parts, we have tried to standardise the robot cells so that it is possible to construct a robot cell fast and easy using the necessary tools for the specific task. This concept is called:

Octopus
Robot Unit for Handling and Packing

We think that this is a very appropriate name considering the many different kinds of tasks, which the robots must be able to handle.

Space – limited space – is an important parameter when choosing a robotic solution for packaging of parts coming from a thermoforming machine, as in this particular case.

Flexibility is an equally important parameter, since the parts may have to be packed in scantainers, gitter boxes or card board cartons stacked on pallets – all of them ready to be put in stock or moved directly to the shipping department.

After having left the thermoforming machine the finished trays are put on a buffer conveyor. Depending on the production the conveyor has room for a buffer stock lasting for a considerable period. This is an important feature ensuring that the production in the thermoforming machine is not stopped during change of pallet, foil or other conditions, which stop the robot cell.

From the collecting shelf the trays can be moved on to:

1. Loose packaging in a large gitter box (the size of a EUR pallet) with/without plastic sealing.

2. Packaging into bags by means of the angle welder. The packages are stacked in a scantainer or a gitter box.

3. Packaging into bags by means of the angle welder. The packages are packed in cardboard cartons which are then stacked on a pallet – EUR or disposable pallet.

In order to be able to perform these tasks the cell requires tools which must be adapted to the specific task. If the parts are to be packed into card board cartons a carton erector as well as a magazine for the cartons are required.

Handling of cartons 

At first the operator adjusts the magazine for the cartons to be used for the specific task and fills up the magazine with the flat cartons.

The carton erector is placed in the cell by means of a lifting truck and is connected to the control and other supplies. It must be set to the nominal size of the carton in question 400 x 400 – 600 mm. Heights from 150 to 450 mm are controlled by the carton erector.

Foil welder

One or more rows of trays are placed in the folded foil in the foil welder.

When the required number of stacks has been placed in the foil welder the boom is closed around the foil and the trays. The foil is welded/cut so that the trays are now inside a closed bag, which the robot then moves on to a cardboard carton, a scantainer or a gitter box – as required.

Finished pallet with cardboard cartons ready to be removed from the robot cell.

Ready to be put in stock or for further distribution.