UPC/EAN This is the symbol used on items destined for the check-out line. UPC symbols are fixed length, are mandatory in the retail and food industry. They were developed to meet the needs of grocery retailing as it fits 12 digits into a reasonably compact space.
Code 39
Developed because some industries needed to encode the alphabet as well as numbers into a bar code, Code 39 is by far the most popular bar code symbology of choice. It is typically the non-food standard bar code, and is used for ID, inventory, and tracking purposes in various industries such as manufacturing. However, Code 39 produces relatively long bar codes and may not be suitable if label length is a consideration.
Code 128
This bar code came about when the need for a wider selection of characters arose than Code 39 could provide. When label length is a consideration, Code 128 is a good alternative because it’s very compact and results in a dense symbol. This symbology is often used in the shipping industry where label size is an issue.
PDF147
Known as a 2D (two-dimensional) bar code, this is a high-density, non-linear symbology that reminds you of a crossword puzzle. But the difference between this and the other bar codes listed above is that PDF417 is a portable data file (PDF) as opposed to simply being a reference number. In some countries, driver’s license is printed using 2D bar code. There is room enough to encode your name, photo and summary of your driving record, and other important information.
Fixed scanners (hand held or mounted) remain attached to their host computer or terminal, and transmit one data item at a time as the bar code is scanned.
Portable batch scanners are battery operated and store data in memory for later batch transfer to a host computer.
Wireless portable scanners store data in memory. However, data is transmitted to the host in real time. This allows for instant access to all data for management decisions.
Bar codes are read by sweeping a small spot of light across the printed bar code symbol. Human naked eyes can only see a thin red line emitted from the laser scanner.
Barcode is a fast, easy, and accurate way of entering data. A barcode doesn’t contain descriptive data. Just as your social security number doesn’t contain your name or address, a bar code is also a reference number that a computer uses to look up an associated record that contains descriptive data and other important information. In business, the correct use of bar codes can reduce inefficiencies and improve a company’s productivity.
A SCARA robot has a linear vertical axis, two rotary axes that move the two arm linkages in the horizontal plane, and usually one additional axis for the wrist rotation. With a dedicated vertical axis, the vertical motions are smoother and quicker than in a coordinated axis motion. Furthermore, the rigidity of the robot frame is also very high in the vertical axis and the combination of the rotation motions assures a high compliance in the horizontal plane, facts very important in an assembly task.
A SCARA robot has a high repeatability (less than 0.025mm), and has also the highest speed of any other robot configuration (2000 to 5000mm/s). The robot structure is compact, such that the working envelopes are limited (ranges less than 1000mm). The payloads range from 10 to 100kg.
Due to its characteristics this robot was first used for precision, high-speed, light assembly. Common applications are inserting components on printed circuit boards, assembling small electromechanical devices and assembling computer disk drives. In recent years, the Scara robot has become more frequently used on a larger scale for palletizing applications.
Scara robots are well suited for stacking a single pallet where space is limited. A major "arm" is mounted such that the whole mechanism can move vertically. This arm is also capable of rotational movement. The wrist moves in a rotational manner as well, in order to rotate bags or cases for placement. Scara robots are fast and use little space. They may not be suited for applications that require multiple loading positions or pickup positions.
This robot primarily used in palletizing applications. Other uses such as packaging, welding, gluing, painting and moving heavy parts are also possible. The gantry system is mounted primarily overhead, so it will use little floor space. A gantry system has a very large work envelope and repeatability in the range of 0.1 to 1 mm, which is good considering the large size of the work area. Payloads can vary from a few pounds up to 2000 lbs. Gantry systems are generally slower in both acceleration and deceleration than other types of robotic systems.
Articulating Arm Robot (Vertical Articulating Arm)
This robot has 3 main rotary axes, and additional 2 or 3-axis wrist. The most important characteristic offered by this robot configuration is the excellent maneuverability. The 6-axis articulation allows orientation of the wrist in practically any position.
The repeatability is good (0.1 to 0.5mm); however, large sizes of the robot may not be adequate for precision assembly. The working envelope is large, relative to the size. The maximum payloads are between 5 to 400kg, depending on the robot size. Tool tip speed is quite fast (1000 to 2000mm/s).
This robot is flexible and most widely used. It is capable of a wide range of motion and reach. While it may not be quite as fast as the SCARA type of robot, it can generally do the same type of tasks. Given the task of palletizing, the Articulating Arm robot is capable of palletizing many pallet positions simultaneously, while the Scara is more limited due to its smaller reach.
The following is some example of robots being produce by one company, Automation System Integration. It has been installing industrial robot system for many years and is a leader in the field.
Examples of Material Handling Robots:
1) Articulating Arm Robot (Vertical Articulating Arm) 2) Gantry Pick and Place Robots 3) SCARA (Selective Compliance Assembly Robot Arm) Robots
The following is an example of how the robot is being used in a bakery equipments warehouse. It facilitates precise robotic placement of product and also quiet operation in the warehouse.
Perfect product placement with robotic precision
Integrate robotic Stacking with an Automated Storage/Retrieval System
Orders can be forwarded to the robots from a central order processing station and boxes will be picked from designated storage bins following proper sequencing to permit direct loading into trucks for shipping.
There are case and crate loading packing robots, palletizing robots, pallets feeders, wrapping robots, automatic strapping robots, and control and inspection robotic systems. Packing robots should provide flexibility and versatility for adaptation of a broad range of products and warehouse floor configurations. Packing robots need to be of heavy duty construction, provide fault free, safe operations, and allow for reliability in warehouse automation.
Robots with heavy payload capacities are ideal for packing applications. Packing robots should increase throughput of case packing and provide flexible solutions for applications requiring easy change over capabilities. These robots should be designed for speed and high productivity.
Packing robots use flighted conveyors for indexing or lane conveyors for accumulation of your product. Packing robots also have the ability to load both horizontally and vertically with minimal amount of changeover.
Packing robots are capable of gentle handling or quick throughput. They are able to be flexible and allow for fast output.
Packing Robot at work
Robotic Case Packing
The robots package complex and simple shapes, or combine with a case erector to provide a single solution for packaging and palletizing.
Robotic palletizing technology can help with productivity and profitability. The robotic workcells can be integrated towards any project. The savings of using a robot for longer hours without fatigue is always a consideration for warehouse managers. Robotics have become more affordable in recent years and can be paid off in just a few years worth of work.
A robotic palletizing system allows more flexibility to run more products for longer periods of time. With the advancements in End of Arm Tooling, robot palletizing workcells have been integrated in many warehouses.
Examples of Robotic Palletizing
Multi-Line Palletizing Systems
A Robot at work
Multi-Line Palletizing Systems reduce the space required by conventional palletizing systems. These robotic systems can be fitted with a shuttle car to efficiently combine the unit loads from multiple infeed lines into one discharge stretch wrapper.
2 in – 1 out system
3 in – 1 out system
Single Line Palletizing Systems
A system that provides automation of end-of-line palletizing with small footprint palletizers. Integrated with either manual or automatic pallet handling, these efficient systems will improve the throughput and consistency of the palletizing operations.
Compact footprint with over under conveyor –
Allows a fork truck to drop off an empty pallet and then pick up a full unit load.
Wide working envelopes with small footprints allow for a less bulky system with a reduced interference area.
This single line solution combines an automatic plastic strapping station to stabilize the unit load for shipping.
Bag Palletizing Systems
These systems reduce the risk of back injuries associated with manual bag palletizing of industrial sized bags of product such as grain, feed, chemical, building supply, and many other material types.
As of 2005, the robotic arm business is getting to a mature state, where they can provide enough speed, accuracy and ease of use for most of the applications. Vision guidance (machine vision) is bringing a lot of flexibility to robotic cells. So we have the arm and the eye,
But the part that still has poor flexibility is the hand: the end effector attached to a robot is often a simple pneumatic, 2-position wrench. This doesn't allow the robotic cell to easily handle different parts, in different orientations. (Limitations of robots in warehouse with multiple product lines).
Hand in hand with increasing off-line programmed applications, robot calibration is becoming more and more important in order to guarantee a good positioning accuracy.
Other developments include downsizing industrial arms for consumer applications and using industrial arms in combination with more intelligent automated guided vehicles (AGVs) to make the automation chain more flexible between pick-up and drop-off.
One thing to note is that these robots are usually employed in production plant with limited product lines, but with increase trend towards automation they are starting to be seen in warehouses and DC with multiple product lines.
A simple definition of a robot is “a general purpose, programmable machine possessing certain anthropomorphic characteristics.” (Anthropomorphic means human-like and usually refers to the gripper of the robot that resembles a hand).
The material handling robot is used to build and undo unit loads on a pallet. A material handling robot can work 24 hours a day without worries or fatigue. The consistent output of a robotic system along with quality and repeatability are unmatched.
Material handling robot allows for automation of operations in warehouse and is usually integrated with other material handling equipment e.g. conveyor belt.
Applications include: Palletizing, Packaging, Packing and Order picking.
Advantages: Reduced Cycle Time, Increased Throughput, Handling of Hazardous Chemical goods and Quality Consistency.
Some manufacturers of material handling robots are: Motoman, Panasonic, Fanuc, and ABB.
De-palletizer à "unstacks" and separates a fully formed pallet. The purpose of a de-palletizing system is usually to unstack a homogeneous pallet so the products that make it up can be reformed into a mixed pallet. As you can see in the picture, the robot that is stacking the mixed pallet is also de-palletizing three other pallets. In some situations, the de-palletizing robot is also the palletizing robot, but in an Order Fulfillment system, the de-palletizing robot is most often a dedicated machine, handling only the unstacking of product that goes into creating the mixed pallet.
Currently, there are Four types of robot palletizers used in industry today.
1. Cartesian
Cartesian robots move along 3 axes; x, y and z. Each movement is along a straight line with no cylindrical movement. Usually in palletizing, there is no need to rotate a package at odd angles, say 45 degree. So, it is quite common for the rotational unit to either be at rest 0 degree or to rotate to 90 degree with a mechanical stop to prohibit motion past that point. It is possible however, to graduate the motion so that any angular rotation is possible. This graduated rotation adds to the cost of the unit.
Cartesian robots generally lift mid size loads 50 to 100 lbs adequately, at slower speeds than other types of robots. However, this type of robot is also generally lower priced than the other styles of robots.
SCARA robots have joints in the horizontal plane, which allow the arm to swivel about its base and fold in on itself. Its work envelope is cylindrical. These robots maneuver cartons through four axis movement using a mast and cross arm.
3. Articulating Arm
It is the most flexible robot. It is faster than all other types of robotic palletizers and can accept virtually any type of end effector. It can stack cases, bags or drums equally well. Capable of lifting over 400kg at typically 7 or 8 pick-place cycles per minute, this robotic palletizer can rival even high speed palletizers. Flexibility and speed doesn't come cheap, these palletizers typically have a higher price than either the Cartesian or the SCARA palletizers.
The gantry is the slowest of all the palletizer types, but also the most flexible in the number of pallets it can pick from and place to at the same time.
Gantry systems are commonly used in large OFS (Order Fulfillment Systems) where they can travel to one of the many pallets retrieving cases or layers of cases and place that load onto one or many outbound pallets. Although the speed is slower, it is usually very expensive.
High speed palletizing is an extension of the original dedicated palletizers and unitizers developed in the 50's. When pricing palletizers, speed is usually the primary consideration. However, higher price does not always equal higher speed.
One of the primary rules of palletizing is that the more cases per layer, the higher the speed. So, a machine that handles a 12 case layer at 36 cases per minute, may have a limitation of 12 cases per minute at 4 cases per layer. Or, in other words, the palletizer can do 3 layers per minute, if there are a lot of cases per layer, the palletizer can palletize many cases per minute. However, if there are only a few cases per layer, then the palletizer’s true speed is slower.
Palletizing is actually to store or move by means of pallets. In recent years, robotic palletizes have gained acceptance. Primarily due to their flexibility and size. Size is often a determining factor in picking the type of palletizer that is right for you. Robotic systems can fit into tighter areas than a traditional palletizer.
Overhead conveyors have been and will continue to be the industrial workhorses of our time. Going high up into the rafters of our plants and utilizing hither to unusable space, these conveyors move heavy products, provide a buffer of products and in the case of many operations provide drying or cooling time for paint, glue and other wet or hot materials before they get to the next step in the operation. They can carry individual parts or racks full of parts, meandering through our plants, dipping down when needed to deliver or pick up their load and then retreating back up, working unnoticed above our heads.
Chain and Trolley
The I-Beam chain and conveyor system was the first type of overhead conveyor developed. It is, by far the simplest system. An I-Beam is hung from building supports making sure to keep the bottom of the "I" clear of all obstacles. A trolley is designed with roller bearing wheels that ride on each side of the beam. This trolley can have more than the two pictured wheels. Also, there can be wheels mounted perpendicular to the "I" that touch the upper or lower cross member of the "I", for stability. The I-Beam chain and trolley is a very simple type of conveyor that is conceptually easy to install and can handle large amounts of weight per trolley, typically several thousand pounds.
Enclosed Track
The enclosed track overhead conveyor system was developed later than the I-Beam system shown above. The trolley wheels are actually mounted inside the track, with the outer track protecting the chain and wheels from the surrounding environment. Dust, dirt, paint and other debris all accumulate on the outer track instead of the area where the wheels roll. Unlike the chain and trolley system shown above, the enclosed track system does not pick up these contaminants and pass them on to whatever part it is transporting. This can be extremely important in the case of a hot or wet part, where there is dirt or paint in the surroundings. The enclosed track system has a bend radius of approximately 2 feet, so it can more easily negotiate obstacles within the plant than the chain and trolley system, whose bend radius is closer to 4 feet. Also, while the track is slightly more expensive than the I-Beam used above, this cost is more than offset by the relative ease of installation and savings that this brings in installation labor costs. The enclosed track system is not usually used with extremely heavy loads though, typically a few hundred pounds per trolley is the limit.
Slat conveyors are noted for their versatility in handling a multitude of products, from raw materials through finished goods. One of the most rugged and maintenance free of all conveyors, with slats typically made from steel or wood, these conveyors can handle hot, oily and abrasive materials where canvas or belt conveyors would wear out quickly or be impractical.
Both are examples of Spiral Conveyors.
Although slat conveyors have been used more in the past for these hot, oily abrasive tasks, modern slat conveyors are offering more and more functionality. A subset of the slat conveyor (spiral conveyor) is used in warehousing to move products from floor level to mezzanine level (or vice versa). These special spiral conveyors can also be used as a method of buffering product. Spiral conveyor slats are typically made of fiberglass or some other plastic composite material. Spiral conveyors are also very resistant to spills.
This conveyor not only moves product from a high level down to a low level, but also provides quite a bit of buffered space. Even though this conveyor section seems long it still may only be driven by one motor. Some vendors can make a conveyor section as long as 250 feet with only one motor drive unit.
This is a slat conveyor that is capable of high speed rotation of product. The loads can be rotated 180º or 90º in a continuous motion. This new conveyor is used in packing lines where products need to be rotated upside down or to one side without delay or product damage. This conveyor can accommodate a wide range of load sizes without adjustment.
Roller conveyors take in a variety of conveyors, standard roller, skate wheel and ball conveyors. Even though they each look different, what they all have in common is that they all have some type of rolling surface in contact with the unit load being transported.
Ball Transfer Table
Both ball conveyors (or ball transfers) and skate wheel conveyors rely upon gravity or a human operator as the driving force. A ball transfer table is an easy and economical method of moving a part from one conveyor to another or from a conveyor to an inspection table.
Skatewheel Conveyor
The skatewheel conveyor, also a gravity operated conveyor, is most often set at an incline so that material can be given a slight push by a human being and roll to the end of the conveyor. Gravity skatewheel conveyors are used primarily for lightweight packages. They are typically used in shipping departments, stocking areas, assembly lines.
Pallet conveyors are typically either a Roller Conveyor or a Chain Conveyor. Some pallet conveyors can even be a combination of these two types of conveyors.
Roller and chain conveyors are good for transporting heavy loads such as pallets, drums or castings. Both of these conveyors can handle wet or oily loads. Although either type of conveyor can be built to almost any specification; common widths are anywhere from a few inches up to 12 ft, and common lengths are 5ft, 8ft and multiples of 5 ft up to around 40 ft.
Cross Transfer
This unit is used to move a pallet 90 degree from a roller conveyor to a chain conveyor (or vice versa). With the chain section down, the roller section allows the pallet to move from a previous section of roller conveyor onto the cross transfer. Once at the stopping position of the rollers, the chain section raises, lifting the chain section and the pallet on top of it above the rollers. With the chain section raised, the chains transport the pallet onto the next conveyor section.
A belt conveyor as the name implies is comprised of a durable material (the belt) that encircles two or more rollers. One of the rollers has a drive mechanism (usually an electric motor) attached to it either directly or through a gear reducer. The other roller is usually unattached to any type of drive and allowed to roll freely.
Belt Conveyors are the most commonly used in bulk handling. Materials from fine powders to large, lumpy stone or even discrete parts can be handled on a belt conveyor. This type of conveyor can exist as a single wide belt or two or more "V" belts. Usually a single wide belt is used in an application where a single item is to be conveyed, that has little or no chance of separating. For example, you might use a single conveyor belt system to convey a small section of carpet, a tray of parts or other single unit materials from one location to another.
Conveyor belts are available in widths up to 100 inches. It is the most costly part and the component is most prone to damage. The parts that make up the belt are: the covers (top and bottom), and the carcass. The carcass provides: the tensile strength needed to start and move the loaded belt, the transverse and longitudinal flexibility required to allow the belt to both support the load and conform to the shape of the idlers when empty and to wrap around pulleys, the strength to resist impact forces. The cover's main function is simply to protect the carcass from damage.
A wide variety of belt conveyors are used in material handling systems. The most popular types are flat, telescoping, trough, and magnetic belt conveyor.
Accumulation Conveyors are used to transport and accumulate cartons and unit loads. These conveyors are used to hold product for gradual release into a cell or work area. Such a conveyor might be used for instance to release one package at a time to a robotic pickup station.
An example of Minimum Pressure Conveyor, calledLineshaft Conveyor.
There are two major types of conveyors in this category; "Minimum Pressure Conveyors" and "Zero Pressure Conveyors". The term pressure refers to the amount of force exerted from the conveyor onto a package or part. A Minimum Pressure Conveyor releases parts gradually into a work cell, but the parts are touching one another and exerting a slight force on each another. A Zero Pressure Conveyor also releases parts gradually into a work cell, with no part touching any other part.
Zero Pressure Accumulation
Zero pressure accumulation occurs when the driving force is completely removed form the load. This is usually accomplished by way of sensors in combination with various mechanical means such that when a load is stopped on a sensor, the driving force in the zone behind the stopped load is dropped away.
A minimum pressure conveyor is a contiguous conveyor system. There are no zones and the amount of sensors and controls needed is at a minimum. One must be very careful when designing a minimum pressure system because proper operation is highly dependent upon the dimensions and weight of the specific packages involved.
On the other hand, a zero pressure system can be comprised of almost any type of conveyor, roller, chain, belt etc. You need not be so careful with the design because the weight and dimensions are not so critical. A zero pressure system is by definition a zone type of system, where each conveyor section is a zone that will need to be controlled separately. Hence, more sensors and software are involved.
Today, conveyor is driven with an electrical motor through gear reduction, in the earlier times, it was driven by water power, animal power or even manually. This type of conveyor system dates back at least several centuries and was originally used to move grains and flour through mills.
Modern conveying systems began in the 19th century as the industrial revolution demanded more efficient methods for moving components and products through plants. There are two main types of conveying systems; floor conveyors and overhead conveyors.
The term "automated guided vehicle" (AGV) is a general one that encompasses all transport systems capable of functioning without driver operation.
Automated guided vehicles (AGVs) help to reduce costs of manufacturing and increase efficiency in a manufacturing system.
AGVs can tow objects behind them in small trailers which they can autonomously hook up to. These trailers can be used to move raw materials into line to get them ready to be manufactured.
The AGV can also store objects on a bed. The objects can be placed on a set of motorized treads and then pushed off by reversing them. Some AGVs use forklifts to lift objects for storage. Transporting materials such as medicine in a hospital situation is also done.
UPC/EAN
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Barcode is a fast, easy, and accurate way of entering data. A barcode doesn’t contain descriptive data. Just as your social security number doesn’t contain your name or address, a bar code is also a reference number that a computer uses to look up an associated record that contains descriptive data and other important information. In business, the correct use of bar codes can reduce inefficiencies and improve a company’s productivity.+Robots.bmp)
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Roller conveyors take in a variety of conveyors, standard roller, skate wheel and ball conveyors. Even though they each look different, what they all have in common is that they all have some type of rolling surface in contact with the unit load being transported.
Belt Conveyors are the most commonly used in bulk handling. Materials from fine powders to large, lumpy stone or even discrete parts can be handled on a belt conveyor. This type of conveyor can exist as a single wide belt or two or more "V" belts. Usually a single wide belt is used in an application where a single item is to be conveyed, that has little or no chance of separating. For example, you might use a single conveyor belt system to convey a small section of carpet, a tray of parts or other single unit materials from one location to another.
Today, conveyor is driven with an electrical motor through gear reduction, in the earlier times, it was driven by water power, animal power or even manually. This type of conveyor system dates back at least several centuries and was originally used to move grains and flour through mills.
