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.

• 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.