Automated Unloading

Context

The client wanted to automate part of their process to eliminate a task that was both physically demanding and repetitive for their employees. This operation involved manually transferring bins weighing over 25 kg, each containing a product received from one of their suppliers.

Mandate

The mandate was to design a turnkey solution to automate the handling of bins containing 25 kg bags, in order to efficiently separate the contents from the receiving bins while also reducing certain ergonomic risks. The system needed to be capable of supporting a throughput of 300 bins per day.

The solution had to perform the following functions:

o Handling of heavy containers
o Processing of containers
o Palletizing of bags

Task performed

o Develop a solution to automate the process
o Design a custom robotic cell
o Program a PLC to manage the cell sequence
o Program 3 robots to follow the cell sequence
o Program an HMI to support operators during cell operation
o Program 2 vision systems for quality control and cell functionality
o Perform risk analysis and implement appropriate safety measures
o Support the client during installation
o Commission the equipment

Tools and methods used 

o Simulation using FANUC ROBOGUIDE
o Mechanical design using SOLIDWORKS
o Allen-Bradley PLC programming
o HMI programming with FactoryTalk View SE
o Control panel design using SEE Electrical