Palletizing using KUKA robots and final processing of aluminum profiles.

Project – Software for PLC – Software for KUKA Robot – Installation – Commissioning

In November, the complete delivery of safe automation for the grinding and palletizing line of aluminum profiles using two KUKA robots was successfully completed for a target customer in Norway. The Allen Bradley GuardLogix 5580 control system from Rockwell Automation communicates with decentralized Point I/O 1734 modules via Ethernet/IP, as well as with PowerFlex 527 frequency converters, KINETIX 5500 servo drivers, KUKA KR 470 robots, and process visualization HMI FactoryTalk View SE.

A system of 4 cameras is used to check the length of the aluminum profiles on the input conveyors and to calculate the offset of the profiles relative to the theoretical center for robot picking. The input robot handles 9 profiles at once, and the subsequent grinding is equipped with automatic pressure regulation of the grinding brushes. The output robot stacks layers of processed profiles on a Euro pallet using a sophisticated gripper that rotates the odd profiles. For some customers or profile types, the output robot inserts spacers between individual layers. The robot control program is designed so that by changing a parameter through process visualization, it is possible to modify the set of parameters according to the type of processed profiles or correct positions.

The equipment is designed according to EN 13849-1 with a defined performance level of PL e. The entire production line is divided into 3 safety zones, and the service doors are equipped with Allen Bradley safety door systems, as well as five light barriers for safe loading and unloading of pallets.