The first task was to verify the data determined by the logistics planner Würth Logistics. The responsible project managers therefore first developed a measuring station and integrated it on site as a separate element in the existing conveyor system.

Over a longer period of time, the necessary data was verified and the data connection to the existing control system was developed. The data obtained also formed the basis for a simulation of the pallet planning software to be created. The operator Reca Norm, the planner Würth Logistics and the system manufacturer used these findings and the data obtained to gradually adapt the planned system layout, the software concept and the gripper system to the actual conditions. Due to the carton geometry and the snap-on lids, a pneumatically actuated clamping gripper was used, which allows two cartons to be picked up at the same time.

The concept is characterized above all by the special arrangement of the carton conveyor technology and the pallet conveyor technology with the ring wrapper. (Image: Ro-Ber)

Further challenges were the limited space available and the ability to expand the system, which also had to be planned, through the possibility of using additional gantry robot carriages in the existing support frame. Further dispatch destinations were also to be made possible by the possible integration of additional palletizing stations.

The result: Use of a highly dynamic Genix FP150 area gantry robot with telescopic axis, form-fit gripping using a pneumatically actuated double gripper, pallet conveyor technology with an upstream empty pallet magazine and a fully automatic ring wrapper downstream of the palletizing, Carton conveyor technology with measuring station and sorting comb, designed for direct access by the robot system, the control technology for the system by the robot controller itself, the Ro-Pack planning software for online planning of the appropriate layer patterns and the data connection to the in-house ERP system.

The data determined by the measuring station is transmitted to the Ro-Pack system and the target position of the carton in the sorting comb is assigned online. (Image: Ro-Ber)

The implemented system is located in the shipping area of the end customer Reca Norm and only requires an area of around 5.5 by twelve meters. The concept is characterized by the special arrangement of the carton conveyor technology and the pallet conveyor technology with the ring wrapper and enables highly available system operation through consistent division into dedicated safety areas. sw