MIXED CASE PALLETIZING WITH MXRP HOW IT WORKS

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MIXED CASE PALLETIZING WITH MXRP
HOW IT WORKS
MXRP
MXRP (Mixed Case Palletizing solution)
MXRP combines RSW’s revolutionary, adjustable-finger gripper and stateof-the-art robotics and control system to streamline the building of pallets
with mixed products and/or packaging at distribution centers. True mixed
pallets usually are comprised of uneven layers. Conventional mixed case
palletizing cells can load no more than one or two cases at a time,
whereas an MCS gripper with four sets of adjustable fingers, or forks, can
stack up to four cases at a time with great accuracy. Such an MXRP cell
with its single robot can handle up to 1,400 cases per hour, depending on
package type and size. Conventional cells employ two robots and yet still
can only manage 1,000 cases per hour at most.
This MXRP concept is easily the most innovative breakthrough in mixed
case palletizing over the past decade and will truly revolutionize the way
warehouses approach sequencing, palletizing and delivery to stores
The MCS gripper technology enlarges the application spectrum for mixed
palletizing. The gripper works in tandem with a load station that groups
cases in the proper sequence and then elevates the product, allowing the
gripper forks to gently lift the packages from the bottom. The design
allows RSW to handle various package types, including open top cases,
multi-drop & nesting.
A recent evaluation of a beverage system proved that five MXRP cells
could produce the same volume as nine convention palletizing cells that
use current case gripper technology. This resulted in not only a significant
cost savings, but also over 3,000 square feet in floor savings. The new
gripper technology also provides a much denser pallet providing the
customer a more store-friendly pallet.
RSW BV I Marcel van Schijndel I 20.02.2014 I page 2
www.mixedpalletizing.com
MXRP – SYSTEM COMPONENTS
FULL 1 SKU PALLET
INFEED
LAYER DE-PALLETIZING & DESCRAMBLING
AUTOMATIC ORDERPICK SYSTEM
SCOPE SUPPLY RSW – EXCL ROBOT
SEQUENCING
TURN, ALIGN & PICKUP
MIXED PALLETIZING
SEQUENCING
TURN-ALIGN-PICKUP
MIXED PALLETIZING
OUTFEED MIXED
PALLET
SEQUENCING – SPIRAL SEQUENCER
SEQUENCING
TURN-ALIGN-PICKUP
OUTFEED MIXED
PALLET
MXRP – PICKUP CONVEYOR
ALIGN
TURN
ROW FORMING
PICKUP
MXRP – GRIPPER & ROBOT
MXRP – SOFTWARE
IPS - ALGORITHM SOFTWARE
MCS EOAT TEST SOFTWARE
PICK-CONTROL SOFTWARE
MXRP – CELL CONTROL
WMS
Visualisation
KMC
ParaGen
PickControl
Warehouse Management System delivers palletizing
orders.
Parameter data base „ParaGen“:
Data base with product specific stored gripper
parameters.
Visualization:
To run and monitor the gripper parameter data base.
Gripper process control „PickContol“:
The software generates running and moving programs
for the robot. They are based on WMS orders, ParaGen
parameter and robot data.
KCP
KRC
WMS:
KRC:
Kuka Robot Control carries out the running and moving
programs for the robot.
KMC:
Kuka Motion Control carries out the running and
moving programs of the additional robot axes on the
gripper.
KCP:
Kuka Control Panel for programming and operation of
the robot.
SCOPE SUPPLY ROBOTIC INTEGRATOR
FUNCTIONS OF THE MODULES
IPS
The Intelligent Palletizing Software (IPS) calculates the optimum number of load
units which can be created out of a dispatch group. The IPS takes all kinds of
business rules into account to create stable stackable load units. The result of
the calculation is returned to PCS, including sequence and stacking (gripper)
information.
PCS
The Palletizing Control System (PCS) controls the modules of the palletizing
system. It has an interface with the control system of DS for exchanging order
information. Via the interface with the modules PCS sends the settings and
coordinates. The modules give status information of the packages processed to
PCS. Via the UI of PCS the exchange of messages between the modules can be
monitored.
ALIGN CONVEYOR
The align conveyor receives packages from the sequencer. The align conveyor
aligns the packages to one side. A turning device on the align conveyor turns
the packages 90 degrees when required. PCS provides the turning settings for
each package.
PICKUP CONVEYOR
The end of line conveyor receives packages from the align conveyor and
accumulates a number of packages together. When ready a pick-up table moves
up so that the MCS gripper can move the forks under the packages for picking
up.
ROBOT
The robot puts the MCS gripper in position for picking up the row of packages. After
picking up the row of packages the robot moves to the stack. The robot gets it x, y
and z-coordinates for each position on the stack from PCS. The robot with gripper
can place the complete line of packages at once or in more than one part on
different positions on the stack. The robot control controls the conveyors and the
turning unit and passes the coordinates to the MCS gripper. For a MCS gripper
with 4 gripper forks we advise to use a robot that can handle 240 Kg (160kg
for the gripper plus 80 Kg for the 4 products).
MCS EOAT GRIPPER
The MCS gripper has one line of forks, which can be positioned in 2 directions
horizontal and in a vertical direction. Before picking up packages the forks are
moved in between the plates of the pick-up table. The robot moves up and lifts the
packages from the pick-up table. The gripper has a clamping mechanism to prevent
packages falling from the forks during movement of the robot towards the stack.
Before placing on the stack the packages are positioned in the gripper by moving the
forks in horizontal and vertical position based on the coordinates given by PCS. The
gripper lays the packages down by quickly moving away the forks. The gripper can
put down the row of packages at once or in multiple parts on different places on a
stack.
CUI
The Central User Interface is intended for 2 types of users namely: the operator and
the service man. The CUI offers the following main functions:
•
•
•
•
•
•
Starting/stopping the MCS-system
Manual operation for each module.
Display/logging of errors
Error recovery
Reading inputs and setting outputs of each module.
Changing module settings and data.
ALTERNATIVE MXRP SYSTEM SETUP WITH MULTIPLE ROBOTCELLS
CUSTOMER WMS and MFC (Material Flow Control): are the high level
system from which the order information come from. MFC corresponds
with the PCS/CUI in the previous system overview drawing.
CUSTOMER ROBOT, IPS and RSW MCS Gripper corresponds also with
the modules shown in the previous system overview. The CUSTOMER
INFEED represents the sequencer, align conveyor with turning unit and
the end of line conveyor.
In this setup IPS receives the orders from the WMS and returns the
stacking information (coordinates and sequence). The high level WMS
passes the order information, box orientation and stacking coordinates
to the MFC. .MFC determines which robot cell handles the order. Then it
transports the boxes in the right sequence to the robot cell.
MXRP – 3D SIMULATION
Endcustomer – Project data analyse
Import & Optimize in IPS
Present in 3D Simulation
Computer screens for generate different tasks
(full automatic quotation, ROI calculation, System layout, Validation ect.)
MXRP – REFERENCE PROJECT
CCR - Grand Rapids USA - Operational April 2014
In cooperation with
FOR MORE INFORMATION
WWW.MIXEDPALLETIZING.COM

MIXED CASE PALLETIZING WITH MXRP HOW IT WORKS

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