Process layout
This solution automates the repalletizing process for Atlas batteries produced by Hankook & Company for export. Due to the diverse import pallet specifications, customer-specific palletizing patterns, and product types, the total number of possible scenarios exceeds 200. The goal is to standardize these scenarios and ensure line stability by supporting a throughput of 10 pallets per minute for medium-sized batteries and 6 pallets per minute for large-sized batteries.
[Pallet Feeder & Pallet Conveyor]
- This solution allows for the use of up to five different pallet types per country, ensuring a smooth 10-stack logistics cycle. Destacked pallets are transported to the battery palletizing position and aligned simultaneously. Completed pallets are transported to the discharge position.
[Battery Sorter]
- Batteries fed inline are automatically sorted into 1st, 2nd (series/parallel), and 3rd layers according to the preset palletizing pattern. The robot then discharges the batteries, repeating the initialization process.
[Robot Palletizer]
- Once aligned, the batteries are picked and placed at the palletizing position on the conveyor, repeating the pick-and-place process according to the specified location and number of layers. Honeycomb feeds are automatically inserted into each layer according to the settings.
[Honeycomb Feeder & Sorter]
- Automatically sorts and inserts honeycombs into each layer of NO-BOX batteries.
Components
| Robot | YASKAWA GP225 |
|---|
Workflow
| STEP 1. | Pallet Feeder & Pallet Conveyor |
|---|---|
| STEP 2. | Battery Sorter |
| STEP 3. | Robot Palletizer |
| STEP 4. | Honeycomb Feeder & Sorter |
Features
- Standardized palletizing for various pallets, patterns, and products.
- Secured daily palletizing capacity of 2,000 large and 4,000 medium-sized pallets, based on a 10-hour daily operation and an 85% safety margin.
- Reduced the number of workers per line from 4 to 1.
- Operator training, manuals, BOM lists, and spare parts lists were created and distributed. Video materials were secured for manager reference. Emergency response was provided in the event of a line shutdown.
Results
| Client Feedback | Palletizing batteries weighing up to 60 kg by hand by four people was a highly shunned task due to the risk of musculoskeletal disorders and even fatalities in the event of a fall. Even with four people working, the logistics cycle was not smooth, resulting in significant labor costs. However, after automating palletizing with Marosol, we were able to reduce the number of workers per line from four to one, ensuring safer work. |
|---|
Unauthorized copying or reproduction of any content on Marosol may violate the Unfair Competition Prevention Act and Copyright Act.
Recommended Solution
From Mixed Box Sorting to Palletizing with Hyundai Robotics' Industrial Robots! Automotive Parts Factory Automation
Real-world Case Study: Automotive Parts Factory Automates Shipping Process with Palletizing Robots | Daedong Door Implementation Story
Silicone Molded Part Palletizing using AIM AIVE System and Delta SCARA Robot
Silicone Molded Part Palletizing using AIM AIVE System and Delta SCARA Robot
Smart Machine Tool Assistant "G-AiD" using Collaborative Robots
This machine tending solution automates the loading and unloading of parts by integrating three G-AiD small-precision (4-axis) machine tools with a Universal Robots UR10e. By arranging multiple machine tools in a compact space, a single robot can manage the entire workflow, significantly boosting operational efficiency and productivity. G-AiD features an Automatic Tool Changer (ATC) and tool wear sensing, enabling efficient task management. Furthermore, its seamless data integration with external systems makes it an ideal candidate for Smart Factory government support projects, helping to reduce initial investment costs. The project was implemented to resolve labor shortages in part machining, reduce personnel costs, and enable real-time quality monitoring and improvement through smart factory integration.
Process layout
This solution automates the repalletizing process for Atlas batteries produced by Hankook & Company for export. Due to the diverse import pallet specifications, customer-specific palletizing patterns, and product types, the total number of possible scenarios exceeds 200. The goal is to standardize these scenarios and ensure line stability by supporting a throughput of 10 pallets per minute for medium-sized batteries and 6 pallets per minute for large-sized batteries.
[Pallet Feeder & Pallet Conveyor]
- This solution allows for the use of up to five different pallet types per country, ensuring a smooth 10-stack logistics cycle. Destacked pallets are transported to the battery palletizing position and aligned simultaneously. Completed pallets are transported to the discharge position.
[Battery Sorter]
- Batteries fed inline are automatically sorted into 1st, 2nd (series/parallel), and 3rd layers according to the preset palletizing pattern. The robot then discharges the batteries, repeating the initialization process.
[Robot Palletizer]
- Once aligned, the batteries are picked and placed at the palletizing position on the conveyor, repeating the pick-and-place process according to the specified location and number of layers. Honeycomb feeds are automatically inserted into each layer according to the settings.
[Honeycomb Feeder & Sorter]
- Automatically sorts and inserts honeycombs into each layer of NO-BOX batteries.
Components
| Robot | YASKAWA GP225 |
|---|
Workflow
| STEP 1. | Pallet Feeder & Pallet Conveyor |
|---|---|
| STEP 2. | Battery Sorter |
| STEP 3. | Robot Palletizer |
| STEP 4. | Honeycomb Feeder & Sorter |
Features
- Standardized palletizing for various pallets, patterns, and products.
- Secured daily palletizing capacity of 2,000 large and 4,000 medium-sized pallets, based on a 10-hour daily operation and an 85% safety margin.
- Reduced the number of workers per line from 4 to 1.
- Operator training, manuals, BOM lists, and spare parts lists were created and distributed. Video materials were secured for manager reference. Emergency response was provided in the event of a line shutdown.
Results
| Client Feedback | Palletizing batteries weighing up to 60 kg by hand by four people was a highly shunned task due to the risk of musculoskeletal disorders and even fatalities in the event of a fall. Even with four people working, the logistics cycle was not smooth, resulting in significant labor costs. However, after automating palletizing with Marosol, we were able to reduce the number of workers per line from four to one, ensuring safer work. |
|---|
Unauthorized copying or reproduction of any content on Marosol may violate the Unfair Competition Prevention Act and Copyright Act.
Recommended Solution
From Mixed Box Sorting to Palletizing with Hyundai Robotics' Industrial Robots! Automotive Parts Factory Automation
Real-world Case Study: Automotive Parts Factory Automates Shipping Process with Palletizing Robots | Daedong Door Implementation Story
Silicone Molded Part Palletizing using AIM AIVE System and Delta SCARA Robot
Silicone Molded Part Palletizing using AIM AIVE System and Delta SCARA Robot
Smart Machine Tool Assistant "G-AiD" using Collaborative Robots
This machine tending solution automates the loading and unloading of parts by integrating three G-AiD small-precision (4-axis) machine tools with a Universal Robots UR10e. By arranging multiple machine tools in a compact space, a single robot can manage the entire workflow, significantly boosting operational efficiency and productivity. G-AiD features an Automatic Tool Changer (ATC) and tool wear sensing, enabling efficient task management. Furthermore, its seamless data integration with external systems makes it an ideal candidate for Smart Factory government support projects, helping to reduce initial investment costs. The project was implemented to resolve labor shortages in part machining, reduce personnel costs, and enable real-time quality monitoring and improvement through smart factory integration.