Contents 1 Introduction Purpose and Scope Design Philosophy Track Record Patents Safety Fully Enclosed Palletizer Frames...2

Transcription

1 Palletizer Product Guide

2 Contents 1 Introduction Purpose and Scope Design Philosophy Track Record Patents Safety Fully Enclosed Palletizer Frames Light Curtain Protection Redundant Fail Safe Hoist Protection Touch-Safe Panel Design Controls Control Components Color Touch Screen On-Screen Pattern Load Programming Models Low Infeed High Infeed Oversized Loads Pallet Jack Pallet Handling Models Custom Solutions Loads Product Requirements Loads Built on a Pallet Loads Built on a Slip Sheet Load Build Pallet-less Layer Load Weights Load Heights Restrictions Throughput Rates 7 Product Infeed Conveyor Customer Upstream Conveyor Product Metering Product Turning Row Build Conveyor Electronic Gapping Blade Stop Gapping Row Transfer Pushers and Pullers VFD Controlled Row Pusher and Puller High-Speed Continuous Row Pusher Pneumatic Row Pusher Layer Head Layer Head Frame Construction Layer Head Operations Layer Head Capabilities Roller Floor Construction Palletizer Frame 12 Concurrent Stretch Wrapping 13 Tie Sheet Dispenser Standard Tie Sheet Dispenser Exterior Tie Sheet or Separator Dispenser Slip Sheet or Pallet Liner Dispenser Swing Arm Dispenser Shuttle Dispenser Modified Tie Sheet Dispenser Palletized Load Conveyor Systems Strand Chain Conveyor Powered Roller Conveyor Conveyor for Pallet-less Loads Pallet Dispensers Fixed Size Dispenser for Side Pocket Pallets Sliding Arm Pallet Dispenser for Wing Pallets Forklift Style Pallet Dispenser Layout Options Low Infeed Standard Palletizer High Infeed Standard and Internal Build Low & High Infeed with External Build Accessory Footprints Multi-Line Solutions Legacy Multi-Line Solutions Multi-Line Solutions Freight, Installation & Support Freight Installation Post Sales Support A1 Summary of Requirements A2 Performance Guarantee A3 Warranty A4 Contact Operations Guide

3 Introduction 1 1 FIGURE 1A Purpose and Scope Improved palletizers were developed by to address shortcomings in the options available for the automation of pallet loading. Legacy palletizers had been characteristically bulky and expensive machines that were difficult to program and inflexible to the changing requirements of product and layer patterns. Robotic solutions continued to prove expensive, with program adjustments typically performed by outside vendors. Innovation from has achieved levels of performance never before available at an affordable cost, creating a new standard in palletizing automation. This describes the advantages that separate palletizers from legacy, robotic, and gantry palletizer systems. Design Philosophy The members of the engineering team bring an extensive portfolio of successful machine design for the material handling industry. Based on the principal that simple solutions always work best, our palletizers were developed using evolutionary patented improvements in technology.

4 1 2 Introduction palletizers are designed to meet the following functional requirements: n Capable of handing virtually any load requirement, including cases, bundles and bags n Compact to accommodate restricted production areas n Flexible modular design to accommodate multiple layout requirements n Easy to use, without need for outside support and maintenance n Reliable performance under continuous operations in harsh environments n A full compliment of pallet loading accessories, including stretch wrap and tie sheets n Affordable entry cost with short-term cost justification and low maintenance overhead Track Record palletizers were introduced to the marketplace in 1998, and have been field proven by leading Fortune 500 companies. Applications range from low-speed substitution of manual operations to high-speed production, and include a wide array of products in the food and beverage, health care, commodities, and general manufacturing industries. After five years of field success, has evolved into a leading supplier of palletizers and accessories. A current list of customers and product testimonials is available upon request. Patents Palletizer designs are protected by several issued and pending U.S. Patents.

5 Safety 2 1 Safety is an overriding focus of engineering. The following features are standard on all models. Fully Enclosed Palletizer Frames All palletizers are fully enclosed in a Category Three safety cage (see Figure 2A). Large doors on all sides allow easy access should a jam occur or if maintenance access is required. Each door is protected by a redundant contact that is continually monitored by a safety relay. FIGURE 2A Fully Enclosed FIGURE 2B Light Curtain Protection Redundant contact sensors have two circuits. A safety relay constantly monitors each sensor to confirm the functional status of the sensor. In the condition of either sensor failure or a breach of the enclosure, the safety relay cuts power to all drives. Pneumatic devices that retain hazardous energy are purged when the safety circuit is engaged. Light Curtain Protection Pallet exit openings are protected by a muting light curtain (see Figure 2B). Should an operator break the curtain from the outside, the palletizer will come to a complete stop to preclude injury. Even in the event that an operator should trip and breach the light curtain at full speed, the system will react before the falling operator encounters a moving device. During normal operations, the light curtain functionality is muted and allows a load to exit from inside the palletizer without shutting down operations and negatively impacting rates. Muting is a sequenced event where the load exiting must travel through sensors in a sequential manner before the light curtain is disabled for load exit. The curtain is re-initialized under PLC control and safety relay control when the load clears the curtain.

6 2 2 Safety Should the sequential events occur outside parameters or the load not clear the exit within a preset time, the system will issue an alarm and shut down the palletizer. Redundant Fail Safe Hoist Protection Palletizers are equipped with four-corner lift hoists to raise and lower the layer head without introducing cantilevered loading (see Figure 2C). Some models raise and lower the row build conveyor or layer pre-build table in the same manner. Each corner of the device being lifted is connected to a lift chain with a length adjustor to compensate for differential chain stretch. All chains are driven by separate sprockets, and the chains are held against their sprocket by clamps to assure a chain cannot detach from the drive sprocket. The sprockets are driven by a common drive shaft connected to a drive that includes a fail-safe spring-applied brake that engages when power to the motor is absent. In addition to the fail-safe brake hoist safety system, spring-applied latches are engaged whenever power to the drive removed. The latches engage a serrated vertical guide used for each lift device. FIGURE 2C Redundant Safety Hoist FIGURE 2D Touch-Safe Panel Touch-Safe Panel Design provides an electrical panel utilizing touch-safe components (see Figure 2D). Touch-safe components significantly decrease the potential for electrical shock should maintenance personnel need to access the panel with electrical power connected. All control elements are 24 volt DC.

7 Controls 3 1 PALLET LAYERS HEAD EMPTY LAYER BUILD BOXES ROW BUILD BOXES TURN AREA BOXES CURRENT PATTERN 12-PACK CASE ADJUST COUNT SYSTEM RUNNING PURGE PART PALLET SHOW ALARMS MANUAL SELECT SCREEN SELECT Control Components Standard controls provide functionality and ease of use far superior to any other palletizer solution. The summary below provides an introduction of the standard control capabilities built into every palletizer. Consult the Operations Guide for a complete description of palletizer programming and controls. Allen Bradley control elements are used throughout palletizers. The standard PLC is Allen Bradley CompactLogix, with optional alternatives available. EuroDrive VFDs are used exclusively for hoisting applications and standard for all other applications. uses VFDs on many drives to allow controlled acceleration and deceleration to achieve increased machine longevity, accurate positioning control and gentle product handling. Color Touch Screen All palletizers are equipped with a color touch screen control interface. Interface screens provide dozens of functions including manual control of all devices, simple case count adjustment, alarm messages with corrective actions, timer adjustments, system purge and all other functions required to configure or adjust palletizer operations. Access to functional operations through the screen interface is comprehensive, with no requirement to access the underlying PLC code. On-Screen Pattern Load Programming Layer patterns are created using the touch screen interface. Any pattern can be added in a few minutes using exclusive EasyStack layer programming software. EasyStack includes sophisticated functions such

8 3 2 Controls as labels-out, tie sheet insertion levels, special pallet stretch wrap sequence, and pattern build gap requirements. Each pattern menu instruction is unique to up to 50 patterns. A global pattern menu is not required. Fifty Load Patterns Standard Palletizer controllers store up to fifty separate patterns. Each pattern can be named with a customer selected alphanumeric name consisting of up to 16 symbols. Standard SKU numbers or other pattern names are used to simplify operator selection of new patterns. Programmed patterns are easily selected from a scroll down list for instantaneous load pattern change. Each load pattern menu offers 1 to 40 cases per layer standard, with additional case capability optionally available. Standard programming features include: number of layers per load, load interlocking, column stacking and combination column/interlocking loads. On-Screen Adjustments and Alarms The copy and paste pattern menu feature allows easy creation of new patterns by using another menu as a template. New menus that are closely similar to an existing pattern menu can be added quickly without inputting redundant data. The most common operational fault encountered with any palletizer operation involves cases entering the system out of sequence. In such an event, an alarm message will occur with the interface screen displaying possible corrective actions. The operator simply adjusts case count at the touch screen and automatic operations are resumed. Generally, case jams or miscounts are remedied in seconds. Non-critical alarms such as "PALLET DISPENSER LOW" will display while automatic operations continue. Alarms that require immediate attention will stop the palletizer

9 Models 4 1 Low-Infeed TT-L10/TT-L20 Standard Low-Infeed FIGURE 4A TT-L10/L20 Low-Infeed palletizers accommodate existing low level conveyor and are typically used for replacement of manual palletizing operations. Low- Infeed palletizers build rows at the infeed elevation and transports each row to the layer deposit level. n Infeed from 12" to 72" n 115" x 80" footprint n Multiple infeed and pallet exit options n Finished pallet to 80" tall; optional to 108" Layers are built on the layer head and then delivered to the pallet (see Figure 4A). TT-L50 Low-Infeed with Layer Pre-build Table FIGURE 4B TT-L50 Concurrently built layers on a pre-build table are transported to the level of the layer head and swept onto the layer head (see Figure 4B).

10 4 2 Models High-Infeed TT-H10/TT-H20 Standard High-Infeed FIGURE 4C TT-H10/H20 High-Infeed palletizers are used when the case infeed level is above the tallest finished load. High-Infeed palletizers lower layers to the load so the pallet remains stationary during load build. n Infeed from 72" to 144" standard for short pallets; infeed can be 6" above finished pallet height n Multiple infeed and pallet exit options n Finished pallet to 108" tall Layers are built on the layer head and then delivered to the pallet (see Figure 4C). TT-H50e High-Infeed with External Layer Pre-Build Table FIGURE 4D TT-H50e The external pre-build table allows concurrent layer build operations and layer conditioning and deposit operations for higher throughput rates (see Figure 4D). n High-speed operation n 80" x 120" footprint

11 Models 4 3 TT-H50i High-Infeed with Internal Layer Pre-Build FIGURE 4E TT-H50i A layer is constructed on the internal pre-build table and transferred to a standard layer head nested below the pre-build table. While the layer head transports and conditions the layer for deposit, layer construction continues on the internal pre-build table (see Figure 4E). n High speed operation n 80" x 80" footprint Oversized Loads Options are available to handle higher loads and wider layers. All models are capable of handling loads up to 110" in height and layer widths of up to 60" x 60" (see Figure 4F). FIGURE 4F Oversized Loads

12 4 4 Models Pallet Jack Pallet Handling Models Low and High-Infeed models operating at lower throughput rates are available with pallet jack pallet handling (see Figure 4G). Empty pallets are positioned by the operator, and the operator removes full pallets with a pallet jack. Due to increased pallet change out time, rates of less than a layer every 90 seconds apply. FIGURE 4G Pallet Jack Pallet Handling Custom Solutions Special requirements are accommodated by making modifications to standard components. Modular design allows cost-effective customization with no sacrifice to performance and reliability (see Figures 4H & 4I). All palletizers are available in stainless steel. Suitable for non-caustic wash down or other special environments. FIGURE 4H Stainless

13 Loads 5 1 Product Requirements Cases FIGURE 5A Cases palletizers are capable of building nearly any load on pallets, pallet-less or other industry requirement. Corrugated cases and trays with and without overwrap are the most common application (see Figure 5A). Standard Requirements Width and Depth Minimum: 6" x 6" Maximum: Case Turning: 27" Diagonal No Case Turning: 28" x 50" Height Standard Minimum: 2" Standard Maximum: 18" Weight Standard Minimum: 3 lbs Standard Maximum: 50 lbs Layer Load Standard: 300 lbs Maximum: 1000 lbs Layer Dimensions Standard Maximum: 50" x 50" Special Conditions n Product heights of less than 2" or greater than 18" require engineering review n Product weights of less than 3 lbs or greater than 50 pounds require engineering review Oversized Loads n Oversized layer loads of up to 60" x 60" require engineering review n Diagonal limitation for product is 37" for turned cases n Maximum non-turned case dimension is 38" x 60" n Maximum layer weight is 600 pounds for machines designed to handle oversized loads

14 5 2 Loads Overwrapped Bundles Bundles must be tight to the product and without film tails (see Figure 5B). FIGURE 5B Overwrapped Bundles Bags Palletizers have limited bag handling capabilities. Bags that are firm with limited product flow inside the bag can be handled effectively. Generally infeed conveyor, turning, and row pusher devices must be configured for a specific bag. Engineering review of actual product is required prior to quoting. Buckets, Pails, and Nested Containers Due to the consistency of layer set down accuracy, palletizers effectively handle totes, trays and buckets that nest when stacking (see Figures 5C & 5D). Engineering review of actual product is required prior to quoting. FIGURE 5C Buckets FIGURE 5D Nested Tablock Containers

15 Loads 5 3 Loads Built on a Pallet Loads can be built on pallets of various sizes including CHEP or GMA. Wing pallets or pallets without bottom runners may require special pallet conveyor. Loads Built on a Slip Sheet Loads can be built on slip sheets with or without pallets. Pallet-less loads require close-centered pallet roller conveyor, mesh conveyor or belt conveyor. Loads Built Pallet-less Loads built without a pallet or slip sheet can be built on a turntable and concurrently stretch wrapped, with exit on standard conveyor. Loads built without a pallet that are not concurrently stretch wrapped must be built on a moving floor conveyor such as slat or wire mesh conveyor. Layer Load Weights The palletizers build layers on a layer head, with the load deposited at a stationary load build position. Consequently, total load weight generally does not impact palletizer performance. n Layer weights of 300 pounds are standard. n Layer weights from 300 pounds to 500 pounds require increased hoist drive sizing. n Layers weights from 500 pounds to 1000 pounds require increased hoist drive sizing and close centered rollers on the layer head. n Machines designed to handle oversized layers are generally limited to 600 pound layer weights. Load Heights The palletizers are designed to build loads to any customer requirement. Low-Infeed machines require frame extensions to accommodate loads taller than standard. The cost of modification is modest and the finished machine ships as upper and lower sections inside a standard dry van. Maximum Standard Height n Low or High-Infeed palletizers with pallet jack pallet handling, including the pallet: 84" n Low or High-Infeed palletizer equipped with a stretch wrapper or pallet conveyor, including the pallet: 72" Maximum Special Height n Both Low or High-Infeed palletizers can be equipped with a frame extension and build loads to 110" (see Figure 5E).

16 5 4 Loads FIGURE 5E Overheight Load (110") Restrictions The palletizers are designed to offer the flexibility of handling a wide variety products. Product consistency is critical to the successful operation of the palletizer. Deficiencies that will impact operation include: n Cases erected improperly to create parallelograms can impact case turning and finished layer quality. n Improper taping resulting in two cases joined or attached entering together, or a tape tail that can become stuck on rollers will often cause miss-counts or jams. n Case bottoms that are not flat are difficult to rotate at a case turner due to inconsistent contact with the conveyor roller surface. n The palletizer can accommodate case tops with a slight bulge. Open flaps or excessive bulging can create problems when the next layer is deposited. requires representative product to be delivered to our plant for pre-shipment testing for most orders placed. The resolution of product handling characteristics is critical in achieving successful installations. Should pre-order discussions indicate potential product handling issues, may request samples prior to quoting.

17 Throughput Rates 6 1 Palletizer throughput rates are subject to several considerations. The pattern of each layer is the primary factor in determining ultimate throughput rates. The total numbers of layers per load and the row push direction also influence rates. engineering performs an analysis each layer pattern in order to generate the highest possible throughput rates. Efficient layer patterns begin with the construction of efficient rows. Rates are often significantly impacted by the row push direction. Some patterns are efficiently built pushing 40" rows and others benefit from pushing 48" rows for a typical 40" x 48" pallet pattern. Final determination of anticipated throughput rates can are confirmed after engineering review of layout and pallet patterns. Following are general guidelines of palletizer throughput rates. Rates are not impacted by the number of cases per row. TT-L10 Standard Low-Infeed Model Generally 2 to 5 rows per minute are achieved (1-15 CPM) TT-L20 Low-Infeed Model with High-Speed Lifts Generally 4 to 6 rows per minute are achieved (10 to 20 CPM) TT-L25 Low-Infeed Model with External Row Build A row is constructed external to the palletizer requiring additional floor space. Because row build is concurrent with row transport and push, throughput is increased. Generally 5 to 8 rows per minute are achieved (10 to 25 CPM). Total throughput is usually less than two layers per minute. TT-L50 Low-Infeed Model with Layer Pre-Build Layer pre-build palletizers build a full layer concurrent with layer conditioning and layer deposit. High-speed row pushers reduce the impact of the number of rows per layer. Generally rates are 2 to 4 layers per minute (20 to 50 CPM).

18 6 2 Throughput Rates TT-H10 Standard High-Infeed Model Because vertical row transport is not required when building layers, rates are higher than Low-Infeed palletizers. Rates are generally 8 pushes (2 layers) per minute. TT-H50e High-Infeed Model with External Layer Pre-Build Rates are generally 2 to 4 layers per minute. TT-H50i High-Infeed Model with Internal Layer Pre-Build Rates are generally 2 to 4 layers per minute.

19 Product Infeed Conveyor 7 1 Due to the variety of products handled, offers several standard product infeed systems. Two subsystems make up the palletizer infeed: product metering and product turning. Upstream customer conveyor must be considered in many applications. Customer Upstream Conveyor Palletizers are often located immediately downstream of a taper or product sealer. Due to the inherent surging of palletizer operations caused by the stop and start motions of the meter system feeding the product turner, some gravity conveyor between the product metering system and customer equipment is recommended when rates exceed 8 CPM. Faster systems equipped with a pre-build table require at least 5 feet of gravity conveyor upstream of the metering conveyor. To avoid overrunning the metering system, recommends that customer powered conveyor located immediately upstream of the palletizer be automatically stopped should product begin to accumulate, and automatically restarted once the accumulation is relieved. provides engineering recommendations for customer supplied downstream conveyor on faster systems. Product Infeed Location Products entering the meter belt that are turned by a product bump turner must enter registered against the guardrail side of the infeed system that the product turner is on. If products are not positioned against the turner side, the product can miss the bump turner and enter the palletizer without turning which will cause a jam or incorrect layer pattern. Products entering the meter belt that are turned by a lift and rotate device or differential drive system need to enter on the centerline of the infeed conveyor system. Product must be prevented from entering the system two abreast or turned 90 degrees from normal. Product Metering The standard metering system is a dual meter belt (see Figure 7A). The rough top belt section runs slower than the second conveyor. The high friction surface of the first belt restrains products accumulated upstream. The second belt runs at product turning speed and pulls a gap through the differential speed of the two belts for product counting. Standard speed on the product turning section is 180 FPM.

20 7 2 Product Infeed Conveyor FIGURE 7A Dual Metering Belt Product Turning Bump Turner Bump Turn and Assist Layer building requires product turning. Due to the variety of products handled, several turners are available. The vast majority of products are turned by a bump turner. Products that travel straight do not hit the turn blade. Those that require turning hit the turner face and a combination of inertia and conveyor drive causes the product to rotate 90 degrees around the turner blade. The turner blade has cushioning either through an air cylinder or springs. Products inappropriate for the bump turning method include: n Long narrow products n Products with a diagonal dimension in excess of 24" n Very small or very heavy products Some long products require an assist to turn around a bump turner (see Figure 7B). An assist cylinder extends when the product hits the turn blade and helps start the turn process by pushing the rear of the product. Conveyor drive and inertia completes the product turn cycle. FIGURE 7B Bump Turn & Assist

21 Product Infeed Conveyor 7 3 Lift and Rotate A lift and rotate device raises the product off the conveyor, rotates the product 90 degrees and lowers the product down to the conveyor (see Figure 7C). The device is generally used for products with a diagonal dimension above 24". Lift and rotate devices are also used for soft bottom products where roller drive does not provide reliable turning. Rates are less than 15 CPM. FIGURE 7C Lift & Rotate Lift and Rotate with Labels Out Lift and rotate devices can be equipped with enhanced controls to rotate products 90 degrees right, left or 180 degrees to achieve programmed labels-out finished pallets (see Figure 7D). Labels-out programming is a standard feature of 's EasyStack software provided with each palletizer. Rates are less than 15 CPM. Differential Drive FIGURE 7D Lift & Rotate Labels Out Differential drive consists of two belts that run under product in a product turning section of the infeed conveyor. If the product requires turning, one belt slows down which causes the faster belt to swing one side of the product and causes the product to turn 90 degrees. The motion is similar to the turning method of a tracked vehicle such as a tank. The system is appropriate for larger flat-bottomed products running at high rates. Because motion is continuous, more product can be inducted through the product turner than a lift and rotate or bump turner. Differential drive speeds are unique for each pattern menu allowing instant product changes without manually adjusting speeds after initial setup.

22 7 4 Product Infeed Conveyor Right Angle Product Turning Infeed Right angle infeeds are used only when dictated by layout constraints (see Figure7E). When a product enters the palletizer in the same orientation as it enters the meter belt, product rotates around a turning post. If change of orientation is required, product feeds onto a right angle transfer. FIGURE 7E Right Angle Product Turning Infeed Special Infeed Systems Layout constraints sometimes require special equipment to achieve an effective palletizing solution. Pullers are sometimes used to pull a product onto the palletizer infeed when space is not available for a curve. This method is suitable only for low throughput rates. Sequenced multiple bump turners are used to achieve labels-out if rates exceed the capability of a lift and rotate device. Infeed length must be increased a minimum of 10' and the system is unsuitable for some products. FIGURE 7F Case Puller FIGURE 7G High-speed Labels-out Case Rotator

23 Row Build Conveyor 8 1 Standard palletizers construct rows for transfer to the layer head or layer pre-build table on the row build conveyor. 1.9" roller conveyor with centers of 3" are typical. 2" centers are used with case dimensions less than 9". For case dimensions less than 6", 1 3/8" rollers are provided on 1 1/2" centers. Bags or products not suited for roller conveyor applications require plastic chain or slick top fabric belt conveyors. Electronic Gapping Electronic gapping capability is standard on all palletizers (see Figure 8A). Gap distance configuration is a standard feature of EasyStack software, and allows each pattern to have separate row build gapping instructions. Gapping is achieved with precise VFD control of the row build conveyor speed. VFD control contributes less wear to the equipment because rollers do not continue to drive under a stopped product and because product does not collide abruptly against a row stop. Electronically Gapped Product on a Layer Head FIGURE 8A Product Gapping Blade Stop Gapping Traditional blade row stops are available as a special requirement. Due to the increased abuse of the row build conveyor and abruptness of product stops, blade stops are seldom employed. Special requirements include inconsistencies in the bottom surface of the product that prevent accurate electronic gapping.

24 9 1 Row Transfer Pushers and Pullers Methods of transferring constructed rows to the layer head are based on the product handled and rates required. has several technologies available. VFD Controlled Row Pusher and Puller The standard row transfer device from is a reciprocating row pusher or puller (see Figure 9A). Row pushers are used on all palletizers except Low-Infeed palletizers without a pre-build table (TT- L10/TT-L20). Models TT-L10/TT-L20 transfer rows with a puller. Row pullers are used on all models. Palletizers with external pre-build tables utilize both a row pusher, and a layer puller. FIGURE 9A Row Pusher & Puller All pushers and pullers have wide flat-faced surface that contacts the product to distribute the contact surface load and minimize potential damage. Movement is by controlled acceleration and deceleration VFD, and achieves gentle product handling. Due to the ability to control the motion precisely, the reciprocating motion of the device is nearly as fast as a continuous pusher. Rates are generally not impacted by use of the standard design. High-Speed Continuous Row Pusher Extremely fast applications sometimes require use of a continuous row pusher (see Figure 9B). The device mounts over the row build conveyor in a separate safety enclosure. Two chain loops support a continuous motion pusher bar that pushes the row and returns over the top allowing continual case infeed. By eliminating the retracting stroke characteristic of the standard pusher, continuous pushers are faster in some applications.

25 Row Transfer Pushers and Pullers 9 2 FIGURE 9B Continuous Row Pusher Continuous pusher devices are disadvantaged by the smaller contact surface of the pusher bar. The combination of small contact surface and rapid motion increases the potential for damage to the product. Continuous pushers are not employed on delicate product or product on which case marking is unacceptable. Pneumatic Row Pusher Special handling requirements can be accommodated by a pneumatically operated pusher (see Figure 9C). Generally the pusher motion is less consistent. Pneumatic pushers are appropriate for low throughput applications only. FIGURE 9C Pneumatic Row Pusher

26 10 1 Layer Head uses a layer head to build, condition and transport layers for deposit onto an empty pallet or previously deposited layer. Our universal layer head is used for all models including High-Infeed palletizers. High-Infeed machines build the layer at the infeed level and lower the layer on the layer head for deposit on the pallet. The following features and benefits demonstrate the innovations of 's layer head design. Layer Head Frame Construction The layer head frame is a precision laser cut and formed weldment that is designed to support a 1,000 pound layer standard (see Figure 10A). Each corner is supported by a hoist chain that is attached with an adjustable connector to compensate for chain stretch. The resulting noncantilevered system is guided by oil impregnated nylon vertical travel guides. FIGURE 10A Layer head Frame Weldment FIGURE 10B Layer Head Conditioning Load Layer Head Operations The simplicity of the layer head operation is apparent upon viewing one layer deposit cycle. After a layer is constructed of rows, the layer is conditioned on four sides and the roller floor retracts into the vertical "L" of the layer head. The conditioned layer is then deposited through the open layer head floor (see Figures 10B-10D). Palletizer operations are available for viewing on video by accessing the web site through the navigation tab on the left side of this page. Layer Head Capabilities Layer Size Despite the simplicity of the layer head system, just about any palletizing application can be handled effectively. The layer head allows finished loads to 50" square. Machines designed to handle oversized loads are available with an opening of 60" square.

27 Layer Head 10 2 Layer Build Direction Layer Build with Gap Patterns Layer Conditioning A standard layer head can receive 40" or 48" rows for a standard GMA pallet load in standard configuration. The ability to build a load with either row length increases layout flexibility and allows layers to be built at higher speeds. Layer heads are equipped with 'wings' on both sides of the roller floor that creates a 63" wide row length limit. Thus, gap patterns can be spread out over the available 63" space if required. The wings allow a large layer build area and minimizes the support roller floor tube length for increased strength to the net size of the floor opening. All layer heads are equipped with four-sided layer conditioning (see Figure 10E). Two sides are compressed by centering clamps that always center the load over the floor opening down to 32". Center clamping is pneumatic allowing air pressure adjustment to control clamping force. FIGURE 10E Layer Head One side of the layer is compressed against the layer head backstop by the retracting of the roller floor in combination with layer back-clamp compression. The layer head back-clamp function is achieved with the row puller on slower speed Low-Infeed machines. The VFD that controls the puller transitions into Torque Control Mode when clamping, allowing menubased clamp force adjustment. High-Infeed or Low-Infeed high-speed palletizer layer heads are equipped with a pneumatic-actuated submerged roller that rotates up and compresses the layer on the fourth side. Both back clamp systems can travel to within 32" of the layer head backstop. When combined with 32" side clamping capability of the centering clamps, the clamp systems provides four-side layer conditioning for any load down to 32" square.

28 10 3 Layer Head Load Positioning Relative to the Pallet Layer Pattern Flexibility The layer head backstop is registered to one edge of the pallet. If several loads sizes are handled, an adjustable backstop is available to position the load inside the pallet dimensions on all sides, equally overhanging the pallet dimensions or any combination required. Essentially any pattern can be built provided the finished layer size is less than the opening of the layer head. Maintaining cases at each corner of a layer and spreading gapped cases along any side of the finished layer is a standard capability. Roller Floor Construction The design of the roller floor provides several advantages compared to legacy solutions (see Figure 10F). Roller support tubes have the ability to rotate, providing less resistance to pushed rows. The advantages of a roller surface are most significant when the last row is pushed. During advancement of the final row, all previously assembled rows are pushed as well. On a static platform, the significantly larger force required increases the likelihood of product damage. 's roller floor innovation prevents such potential damage. FIGURE 10F Roller Floor Construction

29 Layer Head 10 4 Other features and benefits include: n Rollers are strong 1" diameter.120" wall tubes supported at each end by extended chain pins. n The hardened chain pins have ½" diameter axles pressed onto them. Pin length and roller tube bushings are over 1" long. Each tube is amply supported and the tubes rotate on lubricated bushings. n The parallel chain loops are driven by large sprockets with 180 degree chain wrap. n Idlers guide the chain loop in an 'L' shape and one idler on each side provides chain take-up. n Sensors at each end of travel in conjunction with tooth counters allow the PLC to accurately register the floor position. n The motor is VFD controlled for fluid acceleration and deceleration. VFD control also allows manipulation of roller floor pullout speed and centering clamp sequences for special layer patterns. Standard roller floor centers are 2 1/2", handling product with a minimum dimension greater than 9". Standard floors handle layer weights up to 500 pounds. Lighter layers with very small products or non-uniform bottom products such as bags require close centered roller floors. Close centered floors are equipped with a roller floor on 1 1/4" centers. The close centers allow layer weights to 1000 pounds. The versatility of the layer head allows stacking techniques generally not available from legacy palletizers. Due to the precise control of roller floor motions through VFD drive and tooth counter combined with manipulation of center clamping motions, layer gaps can be retained on any side of the layer.

30 10 5 Layer Head Special Roller Floor Capabilities palletizers also have the ability to stack freezer loads with uniform gaps around all products. Agriculture or industrial plastic containers with mating interlocking tops and bottoms can also be stacked due to precise repeatability of the layer conditioning and layer deposit technology (see Figures 10G-10H). FIGURE 10G Fold Flat Agriculture Trays 1" gap around each case allows proper air circulation FIGURE 10H Product Gapping

31 Palletizer Frame 11 1 palletizers are designed in 3D CAD Solids and manufactured using the latest laser cut and CNC forming technologies. All frame members are a minimum of ¼" formed mild steel with 8" x 8" corner members (see Figures 11A-11B). Bolted side plate in position with strong moment connection due to flush mount. All corners are smooth radiuses. FIGURE 11A Frame Construction FIGURE 11B Frame Corners Models share common components allowing increased economies to be passed on to end users. By constructing the palletizers from formed steel, conversion to stainless steel is straightforward and cost-efficient. Each welded side and base assembly is powder coated. Final assembly consists of bolting end frames into position and connecting the base frame with welds and bolt connectors. The resulting welded box frame is rigid, square and extremely strong. Base frame assemblies include forklift pockets to allow easy transport and positioning on the production floor during installation (see Figure 11C). Base frame with fork pockets bolted and welded to palletizer sides FIGURE 11C Forklift Pockets

32 12 1 Internal Concurrent Stretch Wrapping All palletizers are available with concurrent stretch wrapping (see Figures 12A-12B), with the exception of models with external prebuild tables. Because the palletizer continues to build layers on the layer head during the wrap process, rates are not impacted by stretch wrapper operations. The load is progressively wrapped as the load is built. FIGURE 12A Stretch Wrapping FIGURE 12B Internal Concurrent Stretch Wrapper After the final layer of the load is deposited only this top layer requires wrapping. Film is cut at the top of the load, so pallet change out is nearly as fast as non-wrapped loads. Stretch Wrapper Features Turntable Construction Turntables are mounted on heavy duty ring bearings integrated into a standard frame base (see Figure 12C). Electrical & pneumatic rotary unions provide utility connection to the turntable deck. Roller conveyor is provided as standard turntable deck. Special decks for pallet-less loads are also available. Rotation is controlled by a VFD drive with tooth counter positioning. Standard load capacity is 2,500 pounds with heavier weights optional. FIGURE 12C Turntable Frame

33 Internal Concurrent Stretch Wrapping 12 2 Stretch Wrapper Construction The stretch wrap head is mounted on a vertical guidepost that is mounted in an enclosure connected to one side of the palletizer. The stretch wrapper enclosure becomes an integrated part of the palletizer enclosure and maintains Category Three safety protection (see Figure 12D). The wrap head is raised and lowered by a VFD controlled drive with position counter. FIGURE 12D Stretch Wrapper Construction Stretch Wrapper Controls The integration of stretch wrapping and palletizing controls is comprehensive. All film handling, cutting and end treatment functions are automatic, and are controlled from the interface screen. Wrapping sequence can be part of the layer pattern menu allowing separate wrap sequences for each load. Other features include: n variable number of base and top wraps n variable wrap density and over wrap n fixed or variable film tension n components manually cycled from the control interface n film brake and other alarms with diagnostics standard Film Specifications Film heads are set for 250% pre-stretch. Good quality film of 80ml thickness is required. If other film pre-stretch is required or thinner film is used in existing operations, a sample roll must be provided for testing. 20" film rolls are standard.

34 13 1 Tie Sheet Dispenser Standard Tie Sheet Dispenser The standard tie sheet dispenser uses a telescoping arm to pick and place a sheet onto the load. Each load build menu can have distinct sheet insertion instructions. Both vertical and horizontal motions of the dispenser are electric with VFD control. Sheets are picked with vacuum cups. All devices can be manually cycled from the touch screen interface. If sheet sizes change with loads, the dispenser magazine can be set with adjustable guides (see Figure 13A). FIGURE 13B Tie Sheet Dispenser Exterior Tie Sheet or Separator Dispenser In the case that 'egg crate' style separators are required for air circulation, an external dispenser is installed on one side of the palletizer (see Figure 13B). The system allows a gripper system to be used suitable for the difficult-to-handle separator sheets. The same device can be used for standard tie sheets if the palletizer builds both load styles. If a separator sheet is required, the load under construction shuttles to the dispenser location while the next layer is constructed on the layer head. Due to the need to shuttle the load between two positions, layer construction time cannot be less than approximately 45 seconds. Concurrent stretch wrapping is not available due to the shuttle time requirements. FIGURE 13B External Tie Sheet Dispenser

35 Slip Sheet or Pallet Liner Dispenser 14 1 Slip sheets can be used as pallet liners that are smaller than the pallet or as slip sheets that overhang the pallet. When the same material is used for both pallet liners and tie or layer sheets, a tie sheet dispenser can handle both requirements. Otherwise, three tie sheet dispenser options are available. Swing Arm Dispenser Swing arm dispensers are positioned between a pallet dispenser and the palletizer (see Figure 14A). Swing arm dispensers require an extended infeed conveyor. The device is simple and inexpensive. FIGURE 14A Swing Arm Dispenser FIGURE 14B Shuttle Dispenser Shuttle Dispenser Shuttle dispensers place a sheet on the pallet after the pallet is positioned for loading (see Figure 14B). The same design is often used for palletless loads. The sheet pick head shuttles between the pick position and set-down position inside the palletizer. The device requires little space outside the basic palletizer footprint. Modified Tie Sheet Dispenser If layout requirements do not allow use of the shuttle dispenser or swing arm dispenser, our standard tie sheet dispenser can be used. To achieve cost savings, the vertical motion of the dispenser is operated by pneumatic lift rather than VFD electric system.

36 15 1 Palletized Load Conveyor Systems The diversity of load support systems handled requires several conveyor options. The bottom board configuration of a pallet or the lack of pallet must be considered when specifying exit conveyors. Strand Chain Conveyor Chain conveyor features #50 chain supported by key stock contacting the chain roller to provide roller support of the load (see Figures 15A - 15C). Center drives have 90 degree wrap and include ample chain takeup. Frames are heavy ¼" material. Optional VFD drives are available for gentle load handling. Pallet jack accessible low profile conveyor with access ramps is available. Standard design accommodates 2,500 pound total load weights. Additional load weight capabilities are available. FIGURE 15C Pallet Jack Accessable Pallet Conveyor FIGURE 15A Two-strand Chain Conveyor FIGURE 15B Three-strand Chain Conveyor Powered Roller Conveyor Powered roller conveyor has the same frame and capacity as chain conveyor (see Figures 15D & 15E). Powered roller conveyors are equipped with 2 7/8" diameter rollers with.90 wall. Through shafts are supported by sealed bearings at each end. The chain-to-chain drive is #40 and the chain guard is mounted flush with top of roller for access from either side. Conveyor is available with rollers installed at either 3" or 6" on center. FIGURE 15D Powered Roller Conveyor 3" Centers FIGURE 15E Powered Roller Conveyor 6" Centers

37 Palletized Load Conveyor Systems 15 2 Conveyor for Pallet-less Loads Roller conveyor, wire mesh conveyor and belt conveyor are available for pallet-less loads (see Figures 15F & 15G). Roller conveyor is equipped with 3" roller centers. Turntables are available for right angle transfer requirements. Concurrent stretch wrapping is available. Wrapped loads without a slip sheet or pallet are effectively handled when concurrently wrapped. FIGURE 15F Wire Mesh Conveyor FIGURE 15G Slip Sheet on Belt Conveyor

38 16 1 Pallet Dispensers Three models are available to provide pallet dispensing solutions for any pallet design. All dispensers are rated for 600 pound pallet stacks. pallet dispensers lift and separate pallets; drag-from-the-bottom designs are characteristic of poor reliability and are not offered. Heavier stack weight capacities are available. Fixed Size Dispenser for Side Pocket Pallets The standard dispenser is used for 40" x 48" pallets (see Figure 16A). Pallets can be loaded with the forklift accessing either the 40" or 48" side, allowing empty pallets to be loaded in either orientation. Loaded pallets exit the palletizer from all directions except from the pallet load side. The dispenser is a lift and separate design where the entire stack is raised above the bottom pallet allowing the empty pallet to discharge on conveyor. Lift is pneumatic with a torque tube connecting the two sides for synchronized lift. Pallet engagement fingers have low force toggle engagement that lock in place when engaged, yet will not jam if misalignment occurs. FIGURE 16A Standard Pallet Dispenser FIGURE 16B Sliding Arm Pallet Dispenser Sliding Arm Pallet Dispenser for Side Pocket of Wing Pallets The sliding arm dispenser is suitable for systems that require different size pallets or systems where queued stacks of pallets are fed into the dispenser on conveyor (see Figure 16B). The system has cantilevered arms that slide horizontally to engage and disengage from the pallet stack. The arms slide on 3" diameter shafts with bushed bearings. The cantilevered arm carriage is supported by cam followers and raised or lowered by an electric brake motor.

39 Pallet Dispensers 16 2 Capacity is 600 pounds of pallet stacks. Due to limited pallet stack conditioning capability of the design, loaded pallet stacks from a forklift or queue conveyor must be uniformly vertical. Loaded pallets exit the palletizer from all directions except from the pallet load side. Forklift Style Pallet Dispenser For winged pallets or other style pallets without side pockets, a fork-style dispenser is appropriate (see Figure 16C). Forks slide horizontally to engage and disengage the stack. The fork assembly also raises and lowers. Capacity is a 600 pound pallet stack. Loaded pallets exit the palletizer in two possible directions. FIGURE 16C Forklift Style Pallet Dispenser

40 17 1 Layout Options All palletizers and accessories are modular in design, providing complete flexibility in the configuration of components and accessories (see Figure 17A). Layout flexibility in combination with the compact nature of the base palletizer overcomes nearly any floor space constraint. INFEED CONVEYOR PALLETIZER FRAME PALLET DISPENSER STRETCH WRAPPER EXIT CONVEYOR FIGURE 17A Layout Flexibility Palletizer frames are four-sided. Generally any accessory can be installed on any side of the frame. The plan view drawings shown in Figures 17B - 17D provide a guide to the flexibility of layout options. Each letter code references the corresponding component or accessory that may be installed at that position. All configurations shown can be mirrored for layout purposes. For additional information, a configuration CAD drawing is available as well as a configuration utility located on the web site.

41 Layout Options 17 2 Low Infeed Standard Palletizer A F E B C n Palletizer Footprint: 80" x 115" n Infeed positions: B & F n Pallet Dispenser, Empty Pallet Infeed Conveyor, Pallet Jack Access or Load Exit Conveyor positions: A, C, D & E n Stretch Wrap or Tie Sheet Dispenser positions: C, D & E D FIGURE 17B Low Infeed Standard Palletizer High Infeed Standard and Internal Pre-Build High-Speed Palletizers D A B n Palletizer Footprint: 80" x 80" n Infeed positions: A, B, C & D n Pallet Dispenser, Empty Pallet Infeed Conveyor, Pallet Jack Access or Load Exit Conveyor positions: A, B, C & D n Stretch Wrap or Tie Sheet Dispenser positions: A, B, C & D C FIGURE 17C High Infeed Palletizer Low and High Infeed Palletizers With External Layer Pre-build A F E D B C n Palletizer Footprint: 80" x 144" n Infeed Position: A, B & F as shown; C, D & E mirrored n Pallet Dispenser, Empty Pallet Infeed Conveyor, Pallet Jack Access or Load Exit Conveyor positions: All sides n Non Concurrent Stretch Wrap: A, B & F as shown; C, D & E mirrored n Tie Sheet Dispenser: C, D & E as shown; A, B & E mirrored FIGURE 17D External Pre-build Palletizers

42 17 3 Layout Options Accessory Footprints Product Infeed Conveyor 84" 30" Standard dimensions of the infeed conveyor are 30" x 84" (see Figure 17E). Alternative lengths and configurations are available as required for special applications. FIGURE 17E Product Infeed Conveyor Pallet Dispenser 63" Dimensions of the standard pallet dispenser is 60" x 63" for delivery of pallets in the narrow (40") orientation (see Figure 17F). FIGURE 17F Pallet Dispenser Tie Sheet Dispenser 73" Dimensions of the standard tie sheet dispenser is 73" x 73" (see Figure 17G). FIGURE 17G Tie Sheet Dispenser Stretch Wrap Tower External To Palletizer 70" The dimensions of the stretch wrap tower that extends beyond the footprint of the base palletizer is 40" x 70" (see Figure 17H). 40" FIGURE 17H Stretch Wrap Tower

43 Multi-Line Solutions 18 1 offers the superior palletizer solution for multiple production lines. palletizers replace existing hand palletizing operations and are installed on new or upgraded multiple production line operations. Legacy palletizing technology offered solutions that are expensive and susceptible to a single point of failure. solutions offer significant improvements and economic advantage over legacy solutions. Legacy Multi-Line Solutions High-Speed Palletizer Fed from Conveyor- Accumulated Pallet Loads The dominant legacy technology required product from multiple production lines to be accumulated on central overhead conveyor and delivered to a single high-speed palletizer. Such systems require extensive space for conveyor that is expensive to purchase and maintain. The high-speed palletizer becomes a single point of failure that potentially impacts all production. The potential for failure is increased because the single palletizer must run at very high speeds to handle all product. Multi-Line Robotic Palletizers Robots can be used to palletize more than one line concurrently. The lines must feed a centralized pickup point and the product must be suitable for top picking. Robots are characterized by high initial purchase cost as well as continuing high cost of support. Either plant personnel must be proficient in the management of complex robotic systems or product changes must be supported by expensive third party technicians. Robots are characteristically less tolerant of inconsistently formed product than are palletizers. Multi-Line Gantry Palletizer Systems Gantry systems have many of the same deficiencies as robot systems. The capability of gantry systems to pick preconstructed full layers can be effective, but similar issues arise as those of legacy high-speed palletizer systems due to the need to accumulate loads on conveyor and exposure to single point of failure.

44 18 2 Multi-Line Solutions Multi-Line Solutions multi-line solutions have higher throughput potential, alleviate single point of failure, require less space and are less expensive to purchase and maintain than legacy solutions. solutions consist of dedicated palletizers for each line. Typical systems employ High-Infeed palletizers configured in a variety of orientations (see Figure 18A). multi-line systems retain all the flexibility and ease of use characteristic of palletizers. systems offer lower purchase cost, higher rates and better reliability than legacy solutions. Future product changeovers are significantly easier than for legacy solutions due to the flexibility of capabilities. Systems from offer lower maintenance cost and are operated and maintained without special training. multi-line solutions often include full and empty load pallet handling and stretch wrapping. Shuttle carts are available for pallet handling when appropriate. Tie sheet systems, slip sheet and multiple pallet style handling are available. FIGURE 18A Dual Palletizers with Common External Stretch Wrap

45 Freight, Installation and Post Sales Support 19 1 Freight Palletizers are shipped in a standard high cube dry van (see Figure 19A). Freight cost is lower than flat bed trailers and the equipment is protected from the elements until arrival for installation. The integrated fork pockets built into all palletizer frames allows easy unloading and equipment placement in the production room. The customer dock must be suitable for high cube vans with a 110" tall by 100" wide door. Most customer forklifts can unload the equipment, but the center distance of the load usually requires dragging the palletizer from the van. Once removed from the van, one end of the palletizer is placed on carts and the forklift guides the palletizer into place. A forklift easily handles all accessories. FIGURE 19A Standard High Cube Dry Van Installation palletizers are designed for installation by customer personnel, with no specialized training required. Palletizers are fully assembled and pretested prior to shipment. Palletizer accessories are reattached to the frame onsite. All accessories attach to the frame in a straightforward manner. Interconnect wiring must be re-terminated in the panel or multistrand connectors reattached. All connections are labeled. Machines designed for palletizing oversized tall loads require on-site placement of the upper assembly on top the base frame; use of two forklifts or a single heavy duty forklift is required. Technicians from are available to perform the installation onsite upon request. It is recommended that technicians provide onsite startup support for high-speed palletizers and for palletizers equipped with stretch wrapping.