Product size detection
The three-dimensional scanner records the dimensions of the items introduced into the line. A tactile sensor detects the width and length of the items by "tactile" tracking on the edges of the product.
The height of the item is scanned by an optical sensor in the upper part of the infeed area in order to detect the correct values also for items with protruding parts.
To produce the custom-made boxes for shower units, the system has been equipped with a packaging machine Varybox featuring 6 fanfold slots to optimize cardboard consumption. At the outfeed of the machine the box is transferred to the coupling station on a conveyor.
Coupling of Box & Item
The box-item coupling station is equipped with a motorized pin conveyor able position the product onto the open box produced by the packaging machine.
The Coupling Station should simplify the prep operations handled by the operator, and therefore it is equipped with:
- a set of suction pads to hold the box open;
- a special adjustable tool that supports the operator when folding the upper flap;
- a motorized roller unit fitting the maximum available packaging size, to remove the prepared items once the operator has completed all operations.
Glueing and Closing Station
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Glues the upper flap to the preformed bottom containing the items by means of hotmelt glue.
When the box enters the first station, hotmelt glue is applied to the longitudinal flap. The gluing pressure occurs as the box advances in line.
The second station closes the upper front and back flaps with hotmelt glue processing two boxes of different sizes at the same time.
The station is equipped with two labelling devices to print and apply the labels on the sides of the box. One is positioned on the right and one on the left side of the conveyor .
The circular palletizing area includes a palletizing robot with gripper to handle the boxes. The robot removes the boxes from a motorized outbound conveyor and - depending on the type of box and its destination - arranges them in one of the vertical baskets. The boxes are unloaded from 8 vertical palletizing stations. Each station is built with 2 tilted floor guides on which a wheeled cart slides back and forth. The cart is equipped with limit stops and is designed in such a way that it can carry either the wooden pallet or the wheeled trolley.