BACKGROUND

Cartons are an essential part of the packaging process in many industries and often involve a "carton forming" process. The traditional manual method is slow, costly and prone to defects in the forming process, making it difficult to guarantee quality. With the rapid development of industrial robotics, fully automatic packing equipment based on advanced vision systems has become an important tool to promote a new round of "machine substitution" and improve the advantages of traditional industries.

SOLUTION ADVANTAGES

Energy saving and reduction of labour costs

The use of collaborative robots to unpack and pack cartons is a complete replacement for manual unpacking, ensuring 24-hour production on the line. Compared to manual labour, each production line can save workers and increase productivity by 30%. At the same time, the average power of the collaborative robot is only 200W, helping customers to achieve "high quality, efficient and low consumption" automated production and effectively reduce labour costs.

Flexible deployment for increased line flexibility

With a wide variety of cartons and large size differences, robotic unpacking can meet multiple carton sizes without the need for repeated manual debugging. The repeat positioning accuracy of the collaborative robot can reach ±0.02mm, and the placement position is accurate and flat. The soft claw gripping method is used for packing. Based on the small size, light weight and flexible deployment of the unpacking and packing system, it can be placed at any work station according to the needs of the site layout, completing a seamless docking of the existing production line and realising automated flexible production.

Safe and reliable partner

The unpacking and packing system supports 10 levels of collision detection, allowing it to share work space with people without the need for fencing. With collaborative robots working in tandem with people, production times are increased by 30%. The placement position is precise, flexible, fast and efficient for high volume production. In addition, the unpacking and packing system is graphically programmed so that employees can master the operation after simple training, allowing them to leave the heavy physical workload and focus on more valuable production processes.

SOLUTION

The SRT fully automatic packing visual inspection solution combines machine vision, flexible gripper jaws and automatic sealing machines to provide a one-stop solution for forming, folding and sealing cartons with high efficiency and consistent quality.

SOLUTION COMPONENTS

1 Visual Inspection System

2 Empty carton placement units

3 Folding bottom cover units

4 Robotic packing system

5 Robotic unpacking system

6 Sealing system

HOW IT WORKS

1.The worker places the product to be inspected on the inspection conveyor and transports it to the inspection system for inspection

2.Once the inspection is complete, the robot drives the end gripper to load the qualified product into the carton

3.The workers place the cartons in the empty carton shelving area and the robot drives the suction cups to pick up the cartons and complete the unpacking

4.The robot folds and assembles the bottom of the carton by cooperating with the bottom cover unit

5.The folded empty cartons are moved to the boxing station, where another robot with flexible grippers carries out the packing operation

6.Once the carton is packed, the collaborative robot uses suction cups to transfer it to the sealing machine.

SOLUTION FEATURES

Modified atmosphere packaging visual inspection

The AI deep learning detection algorithm combined with traditional vision algorithm is used to detect the quality inspection of food products after packaging and to reject defective products. The equipment can achieve accurate detection of foreign objects (various types of hair, etc.) on the sealing edge of food cartons.

At the same time, it has a higher accuracy in detecting the diversity and inconsistency of defective areas such as the characters and pattern changes on the label paper on the surface of the food carton and the reading of 1D codes, with a miss detection rate of ≤ 0.01%.

Straight line automatic lid folding and sealing machine

The machine can automatically fold the top cover of the carton and simultaneously seal the carton in a "straight line" pattern, which is suitable for batch sealing of multi-size cartons. High degree of automation, with automatic correction of the drive belts on both sides, smooth running, adaptable to heavy loads and easy to operate.

The top lid of the carton is automatically folded in, fast and flat pressing without corner folding; the width and height can be adjusted manually according to the carton specification and can be completed quickly within one minute. The sealing of the carton is solid and beautiful, saving labour costs and improving the production efficiency of the enterprise. It can be used either as a stand-alone machine or in conjunction with a series of automatic packaging machines.