Wikpol’s robot-based palletizing and packaging lines make it possible to obtain measurable savings that positively affect the total cost of ownership (TCO). Many areas where the cost effectiveness is generated could be pointed out. For the users, the following are becoming increasingly more important:
SAVED SPACE OR WORKING SURFACE
Entrepreneurs often face the issue of how to increase the production volume or output without incurring unnecessary expenses for an expensive expansion of the plant. In such a case, robotization is the right solution, especially when it comes to palletizing. Selecting the right palletizing robot model for the characteristics of the site we have is not particularly difficult.
The robots have been designed so that their working space was optimal. In this aspect, several features play an important role: the scope of the arm’s operation (some robots grab upwards and to the back), the vertical stroke (robots might for instance palletize stacks 2 m high), the arm’s range (more than 3.7 m). By adding the precise movement trajectory to the parameters described, we receive a machine, which uses the resources available effectively.
The robots prove themselves in any space, even a very restricted one. A good example is a robot, which packs bottles with alcohol fed from a single production line at a station with a height of 1.2 m. The robot does not use its whole capability, since it was designed for picking up products from two lines. Thanks to the solution applied, the plant has increased its capacity without investing funds into an onerous and expensive expansion of the hall.
ENERGY SAVINGS
The consumption of electricity, which constitutes a significant cost component in the production operations, is a subject of interest for most enterprises. Wikpol also belongs to this group. We can indicate numerous areas in which we implement the energy efficiency idea:
Robot
The robot makes no unnecessary movements. It arrives at the object along the shortest route possible, and never leaves this route. This way, it minimizes the amount of energy necessary to complete the work. When we realize that the shortest route possible is travelled by the robot in thousand cycles (repeats) per day, the scale of the benefits obtained becomes clear.
It is necessary to emphasize that the manufacturers design their robots and their controllers to use energy as best as possible. A good example is FANUC Robotics, which implements state-of-the-art technical solutions in this regard, based on the results of their own, long-term studies. Intelligent energy management systems developed by Japanese specialists make it possible to obtain the maximum efficiency at the lowest energy consumption.
The robots save energy thanks to a package of innovative solutions, such as:
Other devices in the line
We apply similar assumptions when we design all the devices cooperating with the robot. In particular, we emphasize:
- The right selection of electrical drives
The electrical motors and moto-reducers that we use ensure a high power effectiveness within the requirements of the IE3 energy class. The improved efficiency of the drives results in the fact that the amount of energy used to power them is significantly reduced, and thus the operating costs of particular devices are lower. - Vector control inverters and softstart systems
Vector control inverters control electrical drives most efficiently. They precisely control the rotation speed and the torque of the motors, thus they both reduce the starting current and the energy demand during the idling phase. At this level, these are the most efficient elements of the electric energy saving system.
In simple applications, a similar role in saving energy is served by starters, and, in particular, soft start-up systems such as softstart. They are intended to counteract the emergence of high currents which, together with the ability to control the torque, protects the motors not only at the start-up, but also during their operation. - Stand-by feature and economical control systems
The list of our methods of reducing the electric energy demand should include control systems, which make it possible to perform an assumed sequence of task in an optimal way – also in terms of power consumption. Our control systems are normally equipped with the automatic standby mode function which detects inactivity. The deployment of this solution lowers the wear and tear of the components of devices, and extends their service life, and generates measurable energy savings.
MATERIAL SAVINGS
Our engineers optimize the devices being designed in terms of their material consumption. The greatest role in this regard is played by mechanical designers, who, supported by modern analytical tools such as FEM analysis, examine in three dimensions the strength of a structure, by simulating deformations, tension forces, and displacements within the object for each material selected. The involvement of other groups of specialists is also important. For example, solutions proposed by automation system engineers, consisting in applying distributed input/output systems, made it possible to reduce the amount of cabling in the equipment being manufactured, and also to shrink the main control cabinet.
OPERATING THE LINE
Redirecting the operators of the palletizing and packaging process to other positions may solve certain HR problems of enterprises. Particularly if we take into consideration the fact that manufacturing companies increasingly more often are struggling to find people willing to perform onerous physical jobs.
