Automated Bag Loading Application Solved with Pearson’s RTL-MX

Bag Loading Application

• Application: Loading 2x 8lb bags of powdered building products into a case
• Speed: 16 bags/min with capacity for 20
• ROI Justification: Replacement of  6 workers (3 shifts with each 2 workers) and avoidance of 6 more workers to double the output speed
• Unique challenges: Highly dusty environment
• What was important to customer: A highly reliable, proven solution, minimal maintenance, flexibility to accommodate different products/product variations

Solved with Pearson’s RTL-MX

Optimized for Demanding 24/7 Operations

To address the dusty production environment, an IP67 rated FANUC Foundry Pro robot was selected with additional seals to limit dust ingress. The integration of FANUC robots with proven uptime of over 80,000 hrs MTBF provide the reliability the customer was looking for. A series of servo metering belts receive the product and group them by load count. Once grouped, products are accelerated off the end of the product belt where they will be received by an articulated bucket mounted on the end of the robot. The robot moves the bucket as each product is received to complete a case pattern. Once completed, the pattern is being compressed as the robot moves towards the case, descending into it and releasing the load.

RTL-MX Specs

• Application: Top Load Case Packing
• Case Support: chipboard cartons, corrugated cases, bliss boxes, trays, and warehouse totes
• Supported Pack Patterns: vertical, horizontal, interleaved, stacked, on edge, on end, rainbow or variety packs, bulk and shelf-ready
• Speed: Application specific up to 1,500 products/min
• Controls: FANUC PMC | AB CompactLogix PLC | PanelView Color HMI
• Operation:
  • Robotically using multi-axis articulated robot with MTBF of over 80,000 hours and
    flexibility to accommodate product changes or variations
  • Application specific product handling and transfer including servo-collating, diverting, tabletop, mat top and independent cart technology
  • Vision guidance and line tracking to inspect, detect, sort and manipulate products on the fly or balance the load between robots
  • Continuous case motion design for higher speed applications and reduced wear
  • Application-specific end-of-arm tool with optional automatic tool changeover
• Programming Language: PackML

Minimized Total Cost of Ownership

• Robotic Operation takes advantage of high mean between failure of 80,000 hrs, reduced parts count and wear
• Standard remote access capability for efficient technical support and extensive service cost savings
• HMI models web experience for quick familiarity, intuitive operation, reduced training needs and better upkeep of the equipment
• Tune-Up Plus Program ensures optimal uptime and controlled parts and service expenses year over year

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