On both the industrial and retail lines, a robotic case erector equipped with vacuum cups picks a horizontal case from the powered case magazine using articulated motion. It rotates the case vertically and uses the opposing vacuum plate at the erecting station to secure it before pulling the knockdown open. Once erected, the EOAT is inserted into the case. Minor panel vacuum cups hold the case squarely open as plows fold down the minor flaps.
Next, the robot transports the case to the sealing station and guides the case through the major flap plows and across the glue head, applying compression against a base plate to ensure a proper seal.
On the non-retail line, the upstream winding machine detects flawed spools as they exit and sends a reject notification to the erect, pack, seal cell. A belt transfer sends adequate spools toward the pack station, while faulty spools are transported via a reject conveyor for manual rework outside of the cell. On the retail line, a Pearson-provided
detection system equipped with sensors verifies that plastic sleeves are placed properly around spools before they transfer into the downstream heat shrink equipment. A reject pusher discharges inadequate spools out of the cell when necessary.
Reintroduced spools are retrieved by the robot using an end-of-arm gripping tool and placed back onto the infeed conveyor, resuming normal operation thereafter. The robot releases the case at the loading station where it is rotated onto its side for loading. On the non-retail line, a plunger mechanism pushes one or two spools at a time (depending on pack pattern) into the open case. The full case is indexed to the final sealing station where the two minor flaps and one of the major flaps are closed. As the case transfers past a glue applicator, the second major flap is plowed closed. The sealed case is compressed as it moves through a sidebelt conveyor and exits the cell to continue to a downstream labeler and palletizer.
On the retail line, wire spools are wrapped prior to case packing. The robot EOAT is equipped with a gripper designed to securely grasp around the spool body. It picks spools one at a time from one of two discharge positions and places the spool onto a conveyor for transport to a nearby labeling and/or shrink sleeving station. Once the label/
shrink sleeve application is complete, the spools move to be loaded and sealed the same manner as on the non-retail line.