Fully Automated Bag Palletizing System: Integrated Robotic Solution Sistema nga Fully Automated Bag Palletizing: Integrated Robotic Solution

2yrs + staff 1000+m² US$300,000,000+ China

I. Pananaw sa Solusyon

Ang solusyon nga ini nanganginahanglan mobigay og labing epektibo ug fully-automated nga sistema para sa pagbalhin sa mga bagged items. Ang tradisyonal nga manual nga operasyon o semi-automated nga robotic methods adunay mga problema sama sa kauban nga mababa nga kahimtang, dako nga panginahanglan sa labor, daghan nga mga panganib sa kalimutan, ug mataas nga mga gasto sa pagpamahagi. Pinaagi sa pag-integrate sa mga inobatibong conveyor lines ug intelligent robot technology, ang solusyon niini nagdisenyo og usa ka seamless nga konektado nga sistema nga gisul-oban sa "Bag Tipping - Flattening - Deceleration Stopping - Queuing for Palletizing - Robot Gripping" stages. Kini nakamit ang fully automated ug intelligent nga pagbalhin sa mga bagged items gikan sa packaging outlet hangtod sa designated stacking point, siguradong mapataas ang efficiency ug kalimutan sa produksyon.

II. Teknikal nga Background & Design Objectives

Teknikal nga Background & Existing Problems

Karon, ang proseso sa pagbalhin sa mga bagged items sa daghang factories gamay pa gihapon ang gi-dependahan sa manual nga labor o semi-automated nga equipment nga may mga inherent flaws. Ang tradisyonal nga proseso kasagaran nanganginahanglan og mga workers aron mopakita sa sealed bags ngadto sa conveyor, ug pagkatapos ang mga workers o robots ang mag-unload ug mag-stack niini sa destinasyon. Ang approach niini adunay sumala nga core deficiencies:

Mababa nga Degree sa Automation: Ang key stages kasagaran giginahanglan og manual nga intervention, naa gihapon ang full-process automation.
Unified Positioning & Posture Lacking: Ang mga bags kasagaran gi-pakita sa conveyor sa random nga anggulo, prone sa deviation, naa gihapon ang precise nga grasping sa subsequent nga robots difficult ug resulta sa messy nga stacking.
Uneven Item Morphology: Ang uneven nga material distribution sa loob sa filled bags mahimong mag-cause og direct nga stacking prone sa collapse. Aron masiguro ang stability, kasagaran giginahanglan og manual arranging sa key stations, naa gihapon ang labor costs ug management difficulty.
Safety & Efficiency Risks: Ang manual nga trabaho malapit sa conveyors ug robotic arms adunay safety risks. Sumala pa, ang production cycle times dili stable, naa gihapon ang pag-improve sa overall nga efficiency.

Design Objectives

Aron matugotan ang uban nga pain points, ang design objectives sa solusyon niini mao kini:

High Automation: Buhaton og rationally structured, fully-automated nga transfer system nga wala na giginahanglan og direct nga manual nga operation.
Precise Positioning & Posture Control: Siguradohon nga ang mga bags moadto sa picking point nga uniform, stable nga posture ug position, nag-lay the foundation para sa precise nga robot operation.
Enhance Efficiency & Safety: Significantly improve transfer efficiency pinaagi sa optimized nga prosesos ug coordinated control, ug completely remove personnel gikan sa hazardous nga work environments.
Reduce Comprehensive Costs: Drastically reduce labor requirements, thereby lowering direct nga labor costs ug subsequent nga management costs.

III. System Structure & Key Components

Ang sistema nag-adopt og modular nga diseno, ang mga komponente gitambokan sequential nga formon usa ka complete nga closed-loop nga workflow.

Overall Layout: Ang sistema sequentially consists of a Bag Tipping Conveyor, Flattening Conveyor, Deceleration Stopping Conveyor, ug Queuing-for-Palletizing Conveyor. Usa ka high-performance nga industrial robot (robotic arm) giconfigure sa end sa Queuing-for-Palletizing Conveyor. Ang process path mao kini: Bag Tipping Conveyor → Flattening Conveyor → Deceleration Stopping Conveyor → Queuing-for-Palletizing Conveyor → Robot Gripping & Stacking.
Component Details:

Bag Tipping Conveyor

Function: Receives upright bagged items gikan sa packaging/sealing mechanism ug completes their posture change gikan sa "upright" hangtod sa "lying flat."
Key Components:

Adjustable Baffle: Installed above the conveyor, set at a preferred 60° angle to the belt surface, height-adjustable, used to contact and guide the bags to tip over.
Support Plate: Located on the side, works with the baffle to receive the tipped bags.
Guide Rollers: Located at the rear of the baffle, assist in adjusting bag direction, ensuring smooth entry into the next stage.

Flattening Conveyor

Function: Rolls the bags to redistribute the internal material, making it even, preventing local bulges, and preparing them for stable stacking.
Key Components & Features:

Square Transmission Rolls: Unique design causes the bags to roll during conveyance, promoting even material distribution and reducing slippage.
Adjustable Guide Edges: Height-adjustable edges on both sides of the conveyor effectively prevent bag deviation.
Low-Speed Operation: Controlled by an independent frequency conversion motor, its speed is significantly lower than the Tipping Conveyor, ensuring sufficient time for flattening.

Deceleration Stopping Conveyor

Function: Buffers and reduces bag transport speed, stabilizes the conveyance cycle, and creates a stable waiting state for robot picking.
Key Components: Also equipped with adjustable guide edges on both sides to prevent deviation.

Queuing-for-Palletizing Conveyor

Function: Serves as the robot's "feeding table," accurately transporting pre-processed bags to the picking station.
Key Components: Equipped with adjustable guide edges to ensure precise centering. Its end connects to the industrial robot.

Industrial Robot (Robotic Arm)

Function: Positioned at the end of the Queuing Conveyor. Uses a custom end-effector (e.g., vacuum suction cups or mechanical grippers) to reliably grip bags and accurately place them at designated locations (e.g., pallets, shelves, or vehicles) according to a preset program.

Drive & Control System

Independent Drives: Each conveyor is equipped with an independent frequency conversion motor drive, enabling precise speed control.
Coordinated Control: A central control system adjusts the frequency of each motor, setting and matching the speeds of each conveyor section and the robot to ensure smooth, coordinated operation without congestion or waiting.

IV. System Workflow

Automatic Loading & Bag Tipping: Sealed upright bags enter the Bag Tipping Conveyor. While moving forward, they contact the adjustable baffle and naturally tip onto the side support plate, transitioning to a lying-flat state.
Material Flattening: Bags enter the Flattening Conveyor. Under the low-speed operation and the rolling action of the square rolls, the internal material is redistributed, becoming flat and even.
Speed Buffering & Positioning: Bags enter the Deceleration Stopping Conveyor, where their speed is further reduced, achieving smooth deceleration and precise positioning.
In Position, Awaiting Pick: Bags enter the Queuing-for-Palletizing Conveyor and move steadily to the designated picking point at its end.
Robot Gripping & Stacking: The industrial robot identifies the bag's position, executes the gripping action, transfers it, and accurately places it onto the preset stacking position or transport vehicle.
Cyclical Operation: The entire process runs continuously and automatically in a cycle until the task is complete.

V. Core Advantages of the Solution

End-to-End Automation, Cost Reduction & Efficiency Gain: Achieves full-process automation from "infeed - arranging - conveying - palletizing," significantly reducing manual input, directly lowering labor and management costs, while ensuring stable production cycles and substantially improving production efficiency.
Precise Process Control, Reliable Quality: Specialized tipping, flattening, and deceleration stopping designs ensure uniform bag posture, even material distribution, and accurate positioning, fundamentally solving grasping difficulties and unstable stacking, thereby improving transfer quality.
Revolutionary Safety Improvement: Completely eliminates the risk of workers operating near mechanical transmission components, providing fundamental protection for personal safety.
High Flexibility, Intelligent Control: Each module is independently driven by frequency conversion motors. Combined with an intelligent control system synchronized with the robot, system operating parameters can be easily adjusted to adapt to different bag specifications or production rhythm requirements, offering strong flexibility.