Robot Automation
Automated Depalletizing, Laser Marking & Storage
AMR-fed trays, RFID tracking, robotic 2D-code laser marking and automatic buffer storage in one two-machine system.
CLIENT
INDUSTRY
SOLUTION
DURATION
The Challenge
Molded products leave the molding line on heavy metal trays carried by an autonomous mobile robot (AMR). Each molded product had to come off its tray, be permanently marked with a 2D product code for traceability, and move on to the next process, and when downstream was full there was nowhere to put it. The plant needed one automated system to receive trays from the AMR, track every part, mark it, and either send it on or buffer it until the line could take it.
Key Requirements
- Receive loaded molded product trays from an AMR and return empty trays
- Lift and transfer trays with molded products of about 250 lb
- Read each tray’s RFID tag for part tracking
- Robot pick and place of each molded product
- Laser mark a 2D product code on every part
- Send parts outbound, or to buffer storage when outbound is full
- Guarded robot cell with safety-rated controls
The ICR Solution
ICR built a two-machine automated depalletizing system with its own control panels: a tray conveyance machine and a robot cell. The AMR delivers loaded trays to the infeed, and powered roller zones, a pneumatic tray lift, transfer chains and a 90-degree turntable carry each tray to the robot pick point while empty trays return to the AMR. At the pick point an Omron RFID controller reads the tray tag, and a FANUC robot with ICR-manufactured EOAT picks the molded product and places it in a laser marking machine that marks its 2D product code. The robot then places the molded product on the outbound conveyor or, if outbound is full, in a buffer storage shelf (ASRS) until it can be released. Safety PLCs and area scanners guard both machines.
Equipment & Technology
- FANUC robot with ICR-manufactured EOAT
- Omron RFID controller
- Laser marking machine (2D product code)
- Buffer storage shelf (ASRS)
- Tray conveyance with lift, transfer chains and 90° turntable
- VFD-driven conveyor zones
- Safety PLCs and area scanners
- 2 control panels with PLC/HMI
Scope of Work
- Up-Front Engineering
- Robot Reach Study
- Mechanical Design
- Controls Design
- Fabrication and Assembly
- Panel Build (2)
- Robot Programming
- PLC/HMI Programming
- AMR and RFID Integration
- Installation
- Commissioning
Results
Molded products now go from AMR tray to outbound without a hand on them. Every part is tracked by RFID and carries a permanent 2D code, so it can be traced through the rest of the plant. When downstream backs up, the robot buffers parts in storage instead of stopping the line, keeping the molding line running 24/7 and making full use of the AMR fleet.