High-mix, low-volume cobot palletiser at Aerotrim

Challenge

Until now, boxes were stacked by hand according to a set stacking pattern. The main technical and operational challenges in automating this task were:

• Widely varying box dimensions, which have to be stacked without errors and with constant precision. The smallest box measures 136 x 136 x 287 mm, while the largest box measures 406 x 271 x 284 mm. In between are no fewer than 22 different box sizes.
• Small footprint with busy traffic around the set-up, which called for a robust and effective safety solution.
• Various pallet sizes, from 800 x 1,200 mm to 1,140 x 1,140 mm.
• High stacking height of up to 2,150 mm.
• Weight of up to 17 kg per box, combined with a required speed of up to 10 boxes per minute.

Solution: a flexibly adjustable PalCobot

Elenco integrated a cobot palletiser configured specifically for the varied box sizes and Aerotrim's specifications.

Short changeover time thanks to a gripper with interchangeable foam pads and an alignment module

To pick both the smallest and the largest boxes, we provided an interchangeable Piab PiCOBOT vacuum tool. The largest pad is 420 x 260 mm, the smallest 180 x 180 mm. Depending on the box size and stacking pattern, the operator selects the right tool in the software. With a quick-change tool, the foam pad can be swapped in 10 seconds using a sliding lock.

In addition to the quick-change tool, the set-up includes an alignment module that automatically guides boxes into a corner. For this, we provided a powered roller conveyor with angled rollers and a section with straight rollers. Since we perform both single and multi-picks (2 boxes at a time), we also added a stopper and accelerator to separate the boxes from each other.

Hybrid safety concept

Because of the intense operator activity around the installation, we opted for a combination of safety floor scanners to monitor the open areas and detect approaching operators reliably. We combined this with safety fencing to shield an area where many operators pass by.

This set-up allows the cobot to work safely and at optimal speed, without unnecessary stops or delays. This was absolutely necessary to guarantee the desired 10 picks per minute.

User-friendly software

The cobot cell has a touchscreen outside the safe zone running our intuitive PalCobot palletising software. This lets operators create stacking patterns easily, without needing a single line of code. The patterns are shown in a clear 3D view, which makes the software even easier to use. The software has several user levels: operator, maintenance, engineer and administrator.

Specific rights can be assigned per level. For example, operators can only select patterns and not change them, which provides more process reliability and protects the settings.

The interface is available in four languages (Dutch, English, German and French), which simplifies use in multilingual production environments as well.

Remote support and fault analysis

To guarantee the reliability of the cobot palletiser, the software includes a log and error message overview. In the event of a fault, both operators and technical staff can quickly analyse error messages, identify the cause and make adjustments. This also makes remote support by Elenco possible, so any problems are solved quickly, without unnecessary downtime.

Conclusion

This cobot set-up combines flexibility, safety and performance in one installation. Today, the cobot palletiser delivers reliable handling of every box variant, with a very short changeover time, always in a safe and user-friendly way!