Small Case Erecting and Packaging Machine

Project Description:  This system is a fully automated self-contained case erecting and packaging system. 

Operation:  This case erecting/packaging system operates with two asynchronous subsystems. 

Robot 1 - Case Erecting:  Cases are erected automatically by a UR3 6 axis robot utilizing a custom End-of-Arm tool.  These cases are retrieved from a custom magazine by the robot, erected, then moved to a staging station.  The robot waits at the staging station with the case until given the signal to advance by the Case Filling robot. 

Robot 2- Case Filling:  This robot is dedicated to moving product from an automated inspection station where good/bad determinations are made by dedicated barcode readers.  A second barcode reader confirms a barcode on the case itself.  If the barcode readers confirm a match, the Epson Scara robot retrieves the package (using vacuum suction cups) and moves it into the case. 

When a case has been filled, it is pushed forward by the 6 axis robot (which is simultaneously moving the next empty case into position).  The Robot then translates, and moves the full case out of the machine and onto a case sealer (the product is subsequently automatically palletized on a Dynamic Control and Automation robotic palletizer). 

Mechanical Architecture:  The Card Packaging System is constructed using a two-piece powder-coated steel weldment. 

Motion: 

Product Casing:  1ea Epson Scara robot with custom End-of-Arm tooling (EOAT).

Case Erecting:  1ea UR3 6 Axis collaborative robot with custom End-of-Arm tooling. 

Sensors:  Through beam, ultrasonic, proximity capacitive. 

Vision:  Cognex 8000 series and Cognex Dataman

Safety:  Full perimeter 80/20 safety cage with safety interlocked hinged door for maintenance.   Openings provided for operator access to load cases.   

Primary Challenges and Solutions:

1. Case Erecting:  The small size of the cases and poor creasing/consistency prevented the use of standard “Off the Shelf” End-of-Arm tooling. 

Solution:  A custom End-of-Arm tool and custom case erector were designed for this project.  A custom “4th flap” closer for a “Little David” case sealer was also designed to complete the automated process. 

2. Overwrapped Package Movement:  The overwrapped cards were highly variable in terms of thickness, entrapped air, and conformation to the interior product profile.

Solution:  Custom gates, guides, vision algorithms, and sensors were employed to ensure accurate pickup and placement of the product into cases.