The control and operation for packing

叉车用来将包装工位的已包装托盘移走。托盘放置在这个位置。参数在段落2.4。
除标准输送线外还有:
-叉车保护
-信息屏幕
-托盘引导对中装置。需要一个防撞安全支撑。防止叉车在上下料时损坏输送线。

The forklift driver will get the information where to put the pallet of the delivery unit in the warehouse on a screen above the delivery unit.
The temporary label is scanned and the pallet is weighted at the output buffer conveyor, with a link to the already existing warehouse management system. At that point also the final warehouse position is known by the packing line. When this pallet reaches the delivery position, the warehouse position is shown onto the screen to the forklift driver. This is possible because the sequence of pallets does not change.
Final labelling can still be done at warehouse (to keep current way of working).
If the vacuum check failed then the screen will indicate this to the forklift driver (e.g. red screen). The screen will also indicate how many pallets are still on the output buffers.

叉车司机会从一个屏幕上得到把交货工位上的托盘放置到仓库哪个位置的信息。
临时标签被扫描,托盘在出口缓冲区称重,并连接到现有的仓库管理系统。此时包装线也会知道最终的仓库位置。托盘到达交货区后,仓库位置会显示在屏幕上给叉车司机。这是可能的,因为托盘的顺序没有改变。
最后的贴标仍然可在仓库完成(保持现在的工作方式)
如果真空检查有问题,屏幕上也会显示给司机(例如,红色屏幕)。屏幕也会显示出口缓冲区还有多少托盘。

3.9 Plastic Wrapping Unit塑料缠绕膜包装机
This unit is used for the wrapping of the simplified packing.This is an automatic machine with wrapping foil turning around the pallet. The pallet remains stationary while being spirally wrapped. To have a splash proof packing the machine can be equipped with a top sheet applicator. In that case also a top sheet gravitator is needed to keep the top foil in position during wrapping.
用来简易包装。旋臂式自动包装机,包装时货物保持静止。为了防水可配备覆顶装置。这种情况下也需要重力装置来维持顶部膜的位置。

3.10 Electrical cabinet电器柜  
• For the entire installation there is one single control switch cabinet.
• Voltage : 3 x 400 V / 50 Hz – 3 x 460 V / 60 Hz.
• The cabinet is built according to IEC204. It consists of cells set up the one beside the other (2.000 x 600 x 500 mm). Each element has a door, lifting lugs and a removable socle cover. The doors are closed by means of a special-purpose wrench. Protection of the cabinet is IP54.
• The installation is fully PLC-controlled. As PLC Rockwell Controllogic processor must be used,the PLC is provided with :
o CPU processing unit
o Digital input modules (24 VDC)
o Digital output modules : 24 VC (transistor outputs) or 220 VAC (relais contacts).
o Racks and power supplies
o Communication cards
o The necessary software
• On the platform, close to the vacuum unit, there is a control panel installed. This control cabinet is foreseen with a color screen and all necessary push buttons. Push buttons and signal light have a diameter of 22 mm.

整套系统采用一个独立控制柜。
电压:3 x 400 V / 50 Hz – 3 x 460 V / 60赫兹。
电器柜根据IEC204标准制造。 
完全PLC控制。
靠近真空焊接的部分有一个操作面板。该控制柜有彩色屏幕和所有必要的按钮。

General automation for stretch wrapping machine and Pallets with damaged bags

3.4.3 Pallets with damaged bags关于袋子破裂的托盘
If the bag is punctured and thus without vacuum, the operator will not add the cardboard top piece. The strapping belt unit will detect with a color sensor if the cardboard top piece is present or not. If not, the strapping belt (and wrapping unit) will skip the pallet.
The forklift driver will see the pallet is not strapped (and wrapped) and will bring the pallet to the (re)packing area instead of the warehouse. The forklift driver will also get a visual warning. The pallet will not be weighed on the output buffer conveyor.
如果袋子破裂,没有真空,操作员不会覆盖顶部纸板。打包机会通过一个颜色传感器检测是否有顶部纸板。如果没有,打包机(以及缠绕包装机)会跳过此托盘。
叉车司机看到托盘没有被打包(缠绕包装)会把托盘重新放入到包装区域,而不是仓库。叉车司机也会得到一个视觉警告。托盘不会在出口缓冲区被称重。

3.5 Belt Strapping Unit捆扎打包机
3.5.1 Build-up布局
The belt strapping unit consists of an automatic single belt strapper. The strapper straps one belt at the time around the pallet. The pallet is rotated multiple times to apply the different straps. Rotating table is under the strapping unit.The unit has 2 pallet detection sensors for the 2 belt positions. The typical length of the installation is 2000 [mm].Belt specifications are mentioned in 1.4.The strapping head is mounted on a movable (up-down) platform. This platform compresses the pallet before strapping. This guarantees the straps do not come loose when the pallets are placed on to each other in the warehouse. The compressing pressure is adjustable between 200 and 600 kg.
The strap tension is adjustable between 80 and 900 [N].
The strap is sealed by a high strength friction-weld seal.
打包装置包含一个自动单个打包机。打包机在托盘上打一道。托盘旋转数次以实现不同的打包。旋转台在打包机下方。本工位有两个托盘检测传感器。通常的安装长度是2000mm。带子的规格在1.4提及。打包头在一个可移动(上-下)平台上。此平台在打包前会先压缩托盘。这使得托盘在仓库互相叠放时打包带不会变松。压缩压力在200-600kg。

General automation for stretch wrapping machine with packing operator requests

When the plastic bag is clamped the operator pushes a button to start the vacuum-welding sequence. During this cycle the operator checks the vacuum of the previous pallet, see 3.4.2.
当塑料袋夹好后,操作员操作一个按钮开始真空焊接过程。这个环节操作员检查前一个托盘的真空情况,见3.4.2.
• Vacuum cycle begins and when finished the vacuum tube retracts from the plastic bag.
真空过程开始。真空包装结束后真空管从塑料袋上收回。
• Welding bar closes and welding cycle begins.
焊接条闭合,焊接过程开始。
• When sealing cycle is done: clamping bar and welding bar open and VW unit returns to its highest position, making room for the operator.
当封口过程完成,夹杆和焊条打开,焊接机回到最高位置,为操作员提供空间。
• Operator folds plastic bag.
操作员折叠塑料袋。
• Operator adds cardboard sides.
操作员添加纸板
• When done, operator requests next pallet and the cycle restarts. The pallet is transferred to the buffer position for the vacuum check.
以此循环操作。

3.4 Vacuum Check Buffer Position真空检查缓冲区
3.4.1 Build-up布局 
This buffer position is similar to the input and output buffers as described in sections 2.4, 3.2 and 3.6. Additional platform is foreseen.
此缓冲区的位置类似于输入和输出缓冲区如章节2.4,3.2和3.6所述。

3.4.2 Sequence顺序 
Following sequence is done by operator when the automatic vacuum-welding cycle occurs at the vacuum-welding unit.
• Operator checks if the plastic bag still has its vacuum. The check is similar to what is done now: operator checks visual if the plastic bag still sticks to the spools. If not, the vacuum is lost and there must be a puncture somewhere.
• Operator adds top piece cardboard box only when the plastic bag is not punctured.
以下顺序在真空焊接机发生自动真空焊接操作后由操作员完成。
-操作员检查塑料袋是否仍然有真空。检查类似如此:操作员肉眼检查塑料袋师傅哦仍然粘附在线轴上。如果不是,真空已丢失,肯定有一处破损。
-只有在塑料袋没有破损时操作员才添加顶部覆盖纸板。

General automation for stretch wrapping machine with proposal

Proposal X: 建议X:  
Total pallet length: 1100 [mm] 总托盘长度:1100(毫米)  
Roller conveyor length: 1400 [mm] 输送线长度:1400(毫米)
Position pallet detector: 1100mm from beginning conveyor
托盘检测器位置:从起始输送线起1100(mm)
X[s]=(1400 – 1100)(毫米)/167(mm/s)=2[s]
3 Detail unit description详细分项描述
3.1 Supply unit (SU)供应区
A forklift is used to supply the pallets to the packing unit. Pallets are placed on this position. General specifications are listed in paragraph 2.4.
叉车供货(托盘)。托盘放置在此位置。具体参数描述见2.4段。

Additions to the standard conveyor are
• Protection fork lift
• System to guide/place the pallet in the middle of the rollers. Need a safety support to avoid the truck is damaging the conveyor while loading or unloading.
除标准输送线外还有:
叉车保护 
托盘引导对中装置。需要一个防撞安全支撑。
图3: example protection and guide frame supply unit防护和引导装置

When the automation detects a new pallet is supplied to the supply unit, it will wait for 10 [s]before transferring the pallet to the next buffer unit. This gives the forklift driver the time to safely supply the pallet to the supply unit.
The supply unit will indicate to the fork lift driver how full the input buffer is (e.g. light column indicating how many buffer positions are filled).
当系统检测到一个新的托盘放置到供应位时,在把托盘输送到下一个缓冲位之前会先等待10秒。这给了叉车司机安全放置托盘的时间。
供应区会提示叉车司机输入缓冲区的装载状态(例如灯柱提示有多少缓冲区是满的)

3.2 Input buffer (IB)输入缓冲区(IB)   
The buffer units are standard chain driven conveyors as described in 2.4.Each buffer conveyor has a pallet detection system (e.g. sender-receiver with reflector). The pallet is transported to the next position if the next position is free. The motor turns until the pallet is not detected anymore and the motor runs for another 2 seconds (see paragraph 2.4.4).
When the previous buffer position tries to transfer a pallet, the local buffer position also starts to rotate to assure a smooth transfer between the two positions.
The pallet is transferred from the last buffer conveyor to the Vacuum-Welding unit after confirmation by operator–see 3.3.

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[0019]

An apparatus for stretch wrapping a load is provided, according to one aspect of the present invention of horizontal stretch wrapping machine. The apparatus contains a rotatable ring, a packaging materials dispenser for dispensing a film internet, the packaging fabric dispenser simply being attached to the rotatable ring and including an upstream pre-stretch roller and a downstream pre-stretch curler in just a pre-stretch assemblage, a generate device configured to turn the rotatable engagement ring, an input/productivity proportion handle set up to preserve a predetermined percentage of ring rotation pace to pre-stretch velocity during at the very least a principal portion of a wrapping routine, plus a final curler situated a predetermined extended distance from your downstream pre-stretch roller, the predetermined extended distance being in a way that no less than a part of your duration of film increasing between the downstream pre-extended curler along with the final curler acts to reduce variations in forces acting on the pre-stretched packaging substance mainly because it travels from the dispenser towards the stress.

[0020]

An apparatus for stretch wrapping a load comprises a rotatable ring, a packaging material dispenser for dispensing a film web, the packaging material dispenser being mounted on the rotatable ring and including a pre-stretch assembly, a drive mechanism configured to rotate the rotatable ring, an input/output ratio control configured to maintain a predetermined ratio of ring rotation speed to pre-stretch speed during at least a primary portion of a wrapping cycle, and a virtual film accumulator configured to accommodate variations in film demand as the film is dispensed at the predetermined substantially constant length for each revolution, according to another aspect of the present invention of horizontal stretch wrapping machine.

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Traditionally, spinning band style wrappers have suffered from extreme packaging fabric smashes and limitations on the quantity of containment power applied to the burden (as established to some extent by the amount of pre-stretch applied) on account of erratic rate changes necessary to cover “no-sq .” tons, including thin, large tons, simple, broad tons, and brief, narrow loads. The no-square shape of this sort of loads frequently contributes to the availability of excessive packaging materials during the wrapping period, in the course of periods of time wherein the require level for packaging substance by the load is surpassed with the supply rate in the packaging fabric from the packaging substance dispenser. This can lead to freely packaged loads. Additionally, if the desire amount for packaging fabric from the fill is greater than the supply amount in the packaging materials by the packaging material dispenser, breakage of the packaging materials may arise.

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The passageway from the spot causes the power in the packaging materials to improve. This raise pressure is usually transferred to an electronic fill cell, spring-filled dancer interlocked by using a sensing indicates, or by rate switch to a torque handle gadget. Once the area is approved the pressure in the packaging materials lowers since the packaging substance require diminishes. This force or velocity is transferred straight back to some system that therefore decreases the packaging materials offer to try to keep up a fairly constant wrap force.

With all the at any time more quickly wrapping prices desired from the business, the rotation rates of speed of band stretch wrapper have increased considerably to a degree exactly where the thought of sensing need modify and changing supply rate has stopped being efficient. The wait of reply continues to be seen to get started to go away from stage with rotation at roughly 20 RPM. The exact response time for your turning mass of packaging fabric roll and rollers approximating 100 pounds have to change from increase to decelerate 8 periods for every revolution that at 20 RPM can be a shift more than every A sec.

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By driving the stretch wrap packaging-dispenser around a stationary load or rotating the load on a turntable, stretch wrapping machines provide relative rotation between a stretch wrap packaging dispenser and a load either. Upon comparable rotation, packaging material is twisted in the stress. Turning ring type stretch wrappers generally feature a roll of packaging material attached in the dispenser, which rotates about the weight on a turning engagement ring. Wrapping spinning wedding rings are sorted as straight revolving bands or horizontal rotating wedding rings. Vertical spinning wedding rings transfer up and down between an lower and upper position to place packaging fabric close to a load. In the straight turning ring, like in turntable and turning cover arm apparatuses, the 4 vertical edges in the weight are twisted, across the size of the stress. Horizontal spinning wedding rings are stationary supplies along with the weight techniques through the revolving diamond ring, typically over a conveyor, as being the packaging materials dispenser rotates round the weight to cover packaging substance around the weight. From the horizontal rotating engagement ring, the duration of the load is packaged. As the load techniques through the turning engagement ring and away from the conveyor, the packaging materials glides from the conveyor (work surface supporting the load) and into experience of the burden.

[0005]

In the past, spinning ring fashion wrappers have lived with extreme packaging fabric pauses and limitations on the quantity of containment power applied to the stress (as established in part by the volume of pre-stretch employed) due to erratic pace changes expected to place “non-rectangular” loads, for example slim, tall plenty, short, large lots, and brief, filter tons. The non-sq form of these kinds of tons typically leads to the supply of excess packaging materials through the wrapping pattern, in the course of time periods where the need price for packaging materials with the stress is exceeded through the offer amount from the packaging materials from the packaging material dispenser. This may lead to freely packaged plenty. In addition, when the desire rate for packaging materials through the weight is greater than the supply amount of your packaging materials through the packaging fabric dispenser, breakage in the packaging materials could occur.

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As soon as full of the pallets 107, the three-dimensional automatic PALLET WRAPPING MACHINE carriage 108 can begin the build period in the mixed pallets.

Switching to FIG. 3, the 3-dimensional automatic PALLET WRAPPING MACHINE carriage 108 moves horizontally inside the carrier aisle. The robot forearms select the necessary goods from pallets around the shelves 102. The 3-dimensional automatic PALLET WRAPPING MACHINE

carriage 108 moves up and down to service the different rack ranges 104. As soon as every one of the products are picked out in the select pallets at the particular area of the shelves 102, three of the-dimensional automatic PALLET WRAPPING MACHINE carriage 108 movements to the next area of carrier bays 102. As mentioned before, the stretch wrappers 514 on the PALLET WRAPPING MACHINE carriage progressively vertically wrap the various case layers of items 106 on the pallets 107.

The three-dimensional robotic PALLET WRAPPING MACHINE carriage 108 can accelerate and decelerate with lower risk of items 106 falling off of the carriage 502, by progressively stretch wrapping the layers as they are built. The greater number of unstable merchandise is filled near the top of the pallet. For your volatile products, the robot arm 510 can take the things into position because the stretch wrapper wraps the things 106. If required, the turntables 516 reorient the pallets 107 such that the robot arms 510 can easily access a particular location on the pallet 107. The conclusion of arm device of pallet can add a laser beam range detector as well as a eyesight method to be able to ensure that the things are appropriately positioned to the build pallets 1in accordance with three of the-dimensional construct software.

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As soon as the vacuum is driven, one side clamps 912 rotate inwardly up against the object 106 to be able to support it and prevent any kind of slippage. Both of the clamps of stretch wrapping machine shift inwardly, cleaning the no-displaced suction power cups 906 to clamp the piece 106. The shear stress on the suction cup 906 interface with the item 106 is minimized, which in turn facilitates high acceleration of the robotic arm 510 without the risk of items 106 falling off the end of arm tool 702, by clamping the item 106 between the clamps 912. As soon as the end of arm device 702 nears the build pallet 107, the clamps 912 retract in very first the horizontal route after which within the vertical direction to get rid of any items near the place in which the picked product 106 is put. The final of arm instrument 702 can select up several things 106 from the whole layer at the same time. The empty pallet hooks 910, which are utilized to pick bare pallets from the storing holder, keep retracted in a regular deciding on/putting procedure.

The typical functioning of your combined pallet build the program 100 can be explained with guide primarily to FIG. 1. The empty pallet dispenser 116 dispenses pallets on the launching region 112. As portrayed in FIG. 1, person beginner full layers of products 106 may be loaded onto the pallets 107. On the other hand or furthermore, the vacant pallets 107 can be filled to the PALLET WRAPPING MACHINE carriage 502.

The loading of individual layers onto the pallets 107 ahead of time provides higher case throughput and a more stable platform, as mentioned before. The infeed conveyor rss feeds vacant pallets 107 or partially packed beginner pallets 107 to the PALLET WRAPPING MACHINE

carriage 502. The starter pallets 107 are centered onto the turntables 516, typically.