CUTTING-EDGE TECHNOLOGY ACHIEVEMENTS ARE USED IN WIKPOL’S PALLETIZING AND SECONDARY PACKAGING LINES

In Wikpol’s robot-based palletizing and packaging lines, many solutions are utilized than are based on modern technology advancements. In practice, the level of technical complication in particular projects varies, which results from the principle of adapting the solutions proposed by us to the customers’ actual needs. This customization and exorbitant operational criteria for the devices always make the challenges accompanying subsequent implementations high.

In order to meet them, we use advanced work tools, which upgrade our production workshop.

MODERN DESIGN METHODS AND TOOLS

CAD 3D SOFTWARE

The key work tool for engineers is used to design mechanical elements, create documentation and simulations.

The software makes it possible to represent real working conditions of devices in terms of their mechanical load. The simulations performed with it make it possible to test the model of a device as well as verify its reliability, particularly thanks to strength calibrations with the Finite-Element Method (FEM). The tool also helps verify the choice of the materials applied.

In the case of the key device in a palletizing and packaging line, which is the robot’s gripper, a FEM analysis helps effectively solve the problems crucial for its usefulness and durability, such as:

lightness vs rigidity
the moment of inertia vs. cycle duration
cycle duration vs. strength

The grippers of robots are a good example depicting the multi-dimensional nature of a design assignment. On the one hand, they must perfectly match the features of the product and the work conditions:

the characteristics of the product: the weight, the shape, the dimensions, the material it was made from, the resistance to mechanical damage and deformation
the working conditions: the temperature and its amplitude, air humidity, dustiness, the presence of chemical agents, the work space available, special hygienic requirements associated with sterility efficiency

On the other hand, they are subjected to numerous limitations associated with the physical parameters:

the weight/the dimensions/moment of inertia
strength
rigidity
stability
carrying capacity

In the end, the head structure must be designed in a manner that guarantees the efficiency expected (cycle duration) within the optimal costs of manufacturing and operation, obviously taking into consideration the external factors mentioned above.

SOFTWARE FOR TESTING THE OPERATION OF THE LINE IN VIRTUAL SPACE

For a palletizing and packaging line to meet the efficiency, reliability, ergonomics, safety, effectiveness requirements etc., the operation of the devices as part of the system must be coordinated and optimized. Specialized software, which is used for complex tests of the line in virtual reality, is extremely useful in achieving the parameters assumed.

Robot simulator (Roboguide)

The robot simulator helps model the machine, represent its movement, display and confirm its trajectory, and simulate commands in 3D. With these functions, the robot’s operation is programmed, and then tested, and modified offline, namely before the installation. in practical terms, this means the ability to:

thoroughly analyze the duration of the cycles that determine the efficiency of the system
verify the actual range of the robot and the correctness of its cooperation with other devices, among others for possible collisions
detect nearby objects before production is started

Production Systems Simulator (Visual Components)

It makes it possible to design and visualize manufacturing processes in 3D. The virtual models of palletizing and packaging lines developed with it make it possible to analyze in detail the solutions we use, the flow of products, or the operation of robots jointly on a single platform.
Computer-assisted modelling and virtual operational tests make it possible to optimize the operation of all the devices in the newly designed system and the elimination of possible collisions between them.

Thanks to combining the simulator with other off-line tools, e.g. with the Roboguide, and with the software of PLC controllers, we may control the correctness of the signal exchange, and therefore – the sequence of the activities performed.

The inclusion of 3D simulators in designing translates into long-term benefits for the customers. It is because, under real conditions, a model is being delivered which best matches the needs of the user, and guarantees the system’s reliable operation.

CONTROLLING THE OPERATION OF THE LINE

An important area in terms of smooth, failure-free operation of a palletizing and packaging line is controlling the operation of the devices which cooperate with each other within the system. Modern solutions that we reach for in this regard significantly facilitate and accelerate the course of processes. As a standard e.g. real time drivers are being used, which help the user perform complex calculations within a time shorter than 1 ms, and, as a result, prepare very complex multi-axial control algorithms based on CAMs. A high computational power of this kind of drivers also makes it possible to integrate many systems into a single central system, which ensures a global control and simplifies the communication structure.

DATA EXCHANGE IN PROCESS MANAGEMENT SYSTEMS

We pay a lot of attention to optimizing the communication between the palletizing and packaging line and external IT systems. We are using data exchange protocols, such as e.g. OPC UA, which are much faster than the standard OPC protocol, thanks to the safety certificates they ensure safe exchange of information between the systems.

Communication Standard

OPC UA / Profinet – standard

Controller
External IT systems and devices

DATA EXCHANGE SCOPE

Standard

Pallet/product shift counters
Minute/hourly capacity of particular lines
Main pallet/product counters
Status of the line (automatic, manual, failure, stoppage mode)
Alert bit array

Options

Availability and utilization of the line (OEE)
Status of the devices (automatic, manual, failure, stoppage mode)
Remote parameterization of the line (assortment selection, production start, SSCC)
Cooperation with pallet label system
Sending pallet information (product quantity, date/time,/ pallet type, line no.)

MODERN AUTOMATICS SOLUTIONS

We ensure that our systems are flexible, user-friendly, and provide a wide range of parameter setting options. At the same time we work on simplifying and reducing the material consumption of the structures we create. One of the methods of implementing these goals are distributed input/output systems which have replaced classic solutions in the form of centralized systems. In our lines, sensors and actuators, e.g. solenoid valves, are connected to local input/output modules which communicate with the main controller of the line. The remote modules are in turn installed directly on the machines.

The application of the distributed input/output systems brings along numerous benefits. Apart from the aforementioned greater flexibility of the system, they include extensive diagnostics of the control system. Thanks to abandoning the central connection point for the sensors and actuators, it is also possible to decrease the size of the main control cabinet and the amount of cabling on the machines, and also to shorten the installation and startup time for the devices.

Another example of modern solutions supporting the operation of devices in the line is the deployment of sensors and valve terminals with IO-Link communication in place of ordinary sensors or solenoid valves controlled with on -off and analogue signals. Digital signal transmission associated with the IO-Link data busses has a number of advantages, the most important of which are: the ability to perform extensive diagnostics and remote parametrization of the devices’ operation, and greater reliability in metering data transmission.

MODERN SUB-ASSEMBLIES AND COMPONENTS

While working on subsequent projects, we look for technical novelties which would answer specific needs of our customers. Close cooperation with world-renowned mechanical and electrical component manufacturers and suppliers guarantees quick access to the latest, often innovative, products and solutions that we can then deploy in our devices working in lines.

CLOSE COOPERATION FANUC ROBOTICS

We are the only company in Poland with the Systemic Partner certificate of FANUC Robotics in the scope of robot-based palletizing and packaging. Our close cooperation with one of the top global manufacturers of robots and industrial automation systems is a source of numerous benefits for us, which we can then transfer to our clients. The most important of them is the education of specialists in the field of robotics and access to the state of the art technology.

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