Power Packed: A High-Energy Palletizing Solution

The Problem

 

A large battery manufacturer needed a robotic palletizing system to automate the machine-to-pallet transfer of stacks of metallic plates, a process duplicated across multiple facilities. The manual process created ergonomic and safety concerns due to repetitive handling and lead dust exposure. Tight cycle-time requirements and multiple SKUs added complexity to the application.

Key Challenges:

• Footprint Constraints: As a retrofit on an existing line, the system had to fit within tight working conditions near major footpaths, which required a compact, safety-optimized design without impact to upstream and downstream processes.
• Continuous Flow: No product buffering; the system had to palletize a constant stream of metallic plates without disrupting production, as upstream equipment was restart sensitive. Completing cycles in sub-four seconds was required.
• Product Orientation & Variability: The metallic plates exited in a vertical orientation and needed to be palletized horizontally while accounting for product shifting and variability.

The Solution

Concept Systems designed and integrated a modular robotic palletizing system to address these challenges. The implementation involved:

• Custom Tooling: Leveraging experience, iterated and designed the robot’s end-of-arm tool (EOAT) capable of both vacuum-picking divider boards and gripping metallic plates.
• Safety Mitigation: Safety integration included MFAB interlocks, sliding doors, and high-resolution light curtains to mitigate identified risks and ensure compliance with safety standards.
• High-Efficiency Robotic Handling: Integrated a Fanuc M-20iD/35 6-axis industrial robot capable of multi-pick palletizing to meet cycle time demands.
• Standardized Human-Machine Interface (HMI): Implemented a customizable palletizing wizard with a common layout, module-level settings, and standardized alarming to streamline operations, training, and troubleshooting.
• Seamless System Integration: Collaborated with upstream OEM and client engineers to ensure optimal upstream and downstream process integration with minimal disruption.

The Results

The modular robotic system successfully automated palletizing while exceeding performance and efficiency requirements.

Key Benefits:

• Increased Safety & Ergonomics: Removed manual handling in a lead dust environment, improving workplace safety.
• Enhanced Productivity: Automated the placement of both metallic plates and divider boards while meeting demanding cycle-time requirements, handling five parts every 15 seconds through multi-pick robotic palletizing.
• Improved Operator Training & Maintenance: The intuitive HMI reduced onboarding time, while maintenance personnel benefited from clear system diagnostics.
• Future Expansion Opportunities: The modular design allows for easy replication across 30+ facilities, each with unique layouts, across the Americas.

Project Details

By combining a standardized yet customizable approach with application-specific engineering, Concept Systems delivered a scalable robotic palletizing solution that improved safety and efficiency while creating a foundation for future automation expansion.

Control Engineering Article: Using a modular robotic platform to enhance safety, efficiency for battery manufacturer – Control Engineering