Objectives
The objective of this project was to automate the palletising of plastic totes in a high-throughput logistics environment. The client needed a robust and efficient solution to arrange totes from an infeed conveyor onto pallets, which would then be automatically transported out on an integrated conveyor system. Key goals included increasing throughput, improving stacking accuracy, reducing manual labour, and ensuring reliable system performance to handle large volumes of totes with minimal downtime.
Solution
We implemented an industrial robot integrated with a PLC to automate the palletising of plastic totes from an infeed conveyor onto pallets, which were automatically conveyed out of the palletising cell. The system was programmed and simulated offline to refine robot movements, stacking patterns, and cycle times before deployment. A custom end-of-arm tool securely handled totes of different sizes, while the PLC synchronised all system components. Safety barriers and light curtains ensured operator safety, and the PLC diagnostics provided real-time monitoring for uninterrupted, reliable operation.
Benefits
- Increased Throughput: The high-speed robot and automated workflow reduced bottlenecks and increased processing speed.
- Enhanced Precision: The robot provided consistent tote stacking accuracy, ensuring stable and uniform pallet loads.
- Labour Efficiency: Automation minimized manual handling, reducing labor costs and physical strain on operators.
- Reliable Operation: The PLC offered real-time monitoring, optimizing uptime and allowing for rapid issue resolution.
- Optimised Efficiency: Offline programming and simulation reduced setup time and streamlined robot operations.