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Welding flux packed into laminated aluminum bags with a weight of 25 kg, deaerated, welded.

Flux main characteristics:

- granulation: from 0.1 to 2.5 mm

- bulk density: from 0.9 to 1.3 kg/dm3

- temperature: 90°C

Purpose of the investment project:

Increased capacity of the packaging and palletizing process while maintaining the products' high quality.

Robot station:

In the line, a four-axial palletizing robot from Fanuc Robotics type M-410iC/185 has been used, with a lifting capacity of 185 kg, equipped with a special gripper.

Work head:

The work head is adjusted to:

  • pick up bags and place them on a pallet according to a sequence programmed
  • pick up spacers from the spacer magazine
  • pick up pallets from the pallet magazine
  • place bags with a weight outside the pre-set tolerance or not sealed, to a separate site

Other devices:

  • A bag sealing system with air aspiration and bag shaping.
  • A bag is shaped in two stages: first the top portion of the bag is being profiled during its collection and transfer to the packaging machine, and then the whole body is shaped by means of special molds during the filling phase.
  • Label applicators together with printers, which may receive varying bag numbers.
  • A bag control automatic system which covers:
    - a static weight which controls the weight of the bags before palletizing
    - a module for identifying the material based on the bar code (industrial scanner with specialized software and a module for communicating with a PLC controller, which ensures integration with the packing machine's control system
    - vision sensors for controlling the presence of labels, which compare the labels with the models.
  • Bag and pallet transport system
  • Pallet and spacer magazine

Description of operation:

The packing machine fills the bags with portions of flux weighting 25 kg. After the packing, the air is sucked out and the bags are sealed, then are transported to the robotized palletizing station. While on the way to the palletizing robot's cell, the bags have unit labels applied on them (two per bag). The bags are also controlled for correct weight, the presence and correctness of the labels, and the type of the material being packed. If any irregularities are detected, the robot places wrong bags outside the workspace. The bags that meet the control criteria are palletized according to the formula programmed.

Additional information:

Due to the special character of the production process, the line has several work modes:

  • automatic operation – normal mode
  • step work – makes it possible for a human to take certain operations over in the course of the line's work, e.g. in the case of a failure of one of the devices
  • manual work – makes it possible to verify the operation of selected work elements of the devices by triggering them manually on the operator's panel
  • test – makes it possible to verify specified operations without interfering in the line's operation, e.g. inspecting the weighing process, during which test bags do not go to the palletizing line
  • service mode (shutdown of particular functions) – enables maintenance works at selected devices by qualified and authorized technical services without the need to stop the line

Particular operation modes have been programmed in order to keep the line running under fully safe conditions for the users.