ROBOTIC PALLETIZING IN THE DISTRIBUTION CENTRE

Implementation of a large and sophisticated conveyor system with a high level of robotization for one of the largest logistics centers of ALZA.cz in Chrášt’any.

The main part of the project is robotic palletizing, where four robots simultaneously prepare up to 60 pallets per hour at 32 independent positions. A conveyor system is installed for handling the pallets to the robots and subsequent dispatch.

ROBOTIC PALLETIZING OF KLT BOXES

Divided into separate safety zones: 4x robotic workstations + 32 palletizing positions

• Line capacity: 1 500 KLT/hr, 60 EPAL/hr.
• 0,1 – 0,3 m/s
• Speed of rail carriages: 0.6 m/s
• Transported goods: EPAL, KLT boxes with lids

ROBOTIC WORKSTATION:

• Output 375 KLT/hr.
• 8 pallet stacking points for KLT boxes
• EPAL/1 pcs = 28 KLT (7 layers of 4 KLT)
• FANUC R-1000iA/80F robot with pneumatic gripper
• Travel of the 7th axis of the robot – 1 m/s

DESCRIPTION:

KLT (box containers) enter the system after the infeed roller conveyor. After reading the barcode, the parent system determines the direction to one of the four workstations. The KLTs turn off the main line and arrive at the picking point, where they are automatically centred. The KLT boxes are ready for collection by the robot.

The robot removes the KLTs and places them on one of the eight pallet locations of the robot workstation. Up to 28 KLTs can be stacked on a pallet (7 layers of 4 KLTs). Once the pallet is fully stacked (EPAL), it is connected to the conveyor system for dispatch using a roller conveyor.

PALLET CONVEYOR SYSTEM WITH KLT BOXES

The conveyor system is a key element in the supply of empty pallets (EPAL) to the loading points, on which the KLT boxes are then stacked by robots. The full pallet is then flattened by a centering device, wrapped with packaging material using a wrapping machine and then transported to the outfeed conveyors for dispatch.

DESCRIPTION:

Our line is designed for efficient processing of pallets and KLT boxes. It starts with an infeed conveyor where a stack of 10 pallets (EPAL) is loaded. This stack is then transported along a roller conveyor to the infeed section, which lifts the pallets from a height of 150mm to 500mm. After the lifting section, the stack is separated into individual pallets in the depalletiser.

The individual pallets travel along roller conveyors, roller-chain transporters and rail carts to the loading conveyors, where a robotic arm stacks the KLT boxes onto the pallets. Once the KLT boxes are stacked, the full pallet proceeds through the roller conveyors, chain-roller transloaders and railcars to the centering device.

The centering device can align the stack of KLT boxes with the outline of the pallet. Then the pallet with the aligned stack of KLT boxes is driven onto the wrapper, which wraps the entire stack with protective material. Behind the wrapper is a lifting section which again lowers the full pallet from a height of 500 mm to 150 mm.

Finally, the pallet passes onto a low rail carriage which distributes it to five roller take-off conveyors. From there, the operator uses a manual low lift trolley to manipulate it further. This complex system enables efficient and reliable processing of pallets and KLT boxes with minimal loss of time and energy.

Servise

We provide both regular and emergency service to the line in 24/7 mode.

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