When one of Pneutech’s customers in the food packaging industry came calling for help for their palletiser, the company found a solution in the VMECA magic gripper system.
Due to the customer’s diverse product range, the exisiting robot system needed to handle a number of different sized boxes at different weights. However, the capabilities of the existing pump and cups limited the product lines that could be facilitated on this pack out line.
The original setup could not run larger boxes because the original OEM cups and pump were not capable of consistently lifting and shifting the target pick. In addition to this, the existing pump was in continuous operation to deliver the required vacuum flow to ensure safe and effective palletising, which created an expensive on-going operating and servicing cost.
The challenging surface of the shippers showed that the cups also required replacement due to premature wear, which takes a considerable amount of time to replace.
The constant servicing and cup replacement were only adding to the expensive operating costs.
Using VMECA's new magic gripper technology, Pneutech was able to deliver a solution for the palletiser system: a complete vacuum robot head assembly featuring MAC control valves to allow 18 different zone combinations, which only added to the palletiser's flexibility.
The MAC valve system, which is a plug-and-play solution, has delivered improved performance, reliability and repeatability.
The VMECA magic gripper system was able to help the customer in four major ways:
Flexibility: The increased vacuum capabilities that VMECA provided allowed for more flexibility, which eliminated the customers’ problem with handling larger boxes. And, with VMECA's improvements in valve control and zoning, there was greater flexibility in packaging patterns. The slotted mounts also allow future changes in cup positions if required, which makes the magic gripper system even more flexible.
Reliability: The independent vacuum generators ensured that there was no loss of vacuum if one or more cups did not achieve contact with the product, which allowed for more reliable vacuum. In most recent times, the need for shelf-ready cartons from retail outlets have only highlighted the challenges of vacuum levels when cups are in contact with pre-punched holes and or perforations.
Decreased servicing maintenance costs: The magic gripper system also has a built-in cleanable filter element in each suction cup coupled with a blow off system, to prevent further losses of suction from fibre build up and extend the intervals between servicing. The cups are also made up of a modular construction, and individual components can be swapped without complete disassembly, saving significant amounts of time.
Minimal downtime at installation & commissioning: Customer was provided with the complete head already coupled to the robot hood, which allowed for the installation process to be completed in less than one shift. Pre-delivery testing also ensured trouble-free installation. Design parameters required the new head to be dimensionally the same, so no programming mods for the robot were required.
