Robotic Cart Unload System - Textile Manufacturer

PROBLEM: Operators were manually unloading textile carts, placing the packages on a stretchwrapper, and then manually palletizing the package. Ergonomic issues were a major concern, considering the packages weigh between 40 and 50 pounds. The operators were limited in the number of packages they could lift per shift, which put limits on capacity

SOLUTION: ABCO provided a turnkey solution. We developed robotic work cell concepts and layouts. We wrote functional specifications, flow charts, and subcontractor scope of work. We then specified, procured, tested, installed, and commissioned all required equipment

Installation took place in a manner so that interference with production was minimal. ABCO provided on-site support throughout the installation and startup. ABCO also provided operations and maintenance training as well as complete documentation for the system.

The robotic work cells relieved the ergonomic issues and provided the capacity to meet the plants production needs.

SYSTEM DESCRIPTION: A robot unloads the textile carts that are delivered to the area by AGV. The AGV places the cart on one of four turntables. The turntable then positions itself to the robot for unloading. Textile packages are unloaded from the cart and placed on the stretchwrapper by the robot. After wrapping, they are removed and placed on an ergonomic worktable where an operator uses a lift assist device to palletize. ABCO designed and constructed the worktables and 'built-from-print' the stretchwrappers which included both mechanical and electrical improvements to the existing design.

The control system featured an Allen-Bradley ControlLogix controller (for controlling the stretchwrappers, turntables, and providing an interface to the robot and AGV's), robotics and vision programming, and a SCADA package.