Kawasaki Robotics’ Ian Hensman, who sold the original robot to Ball Packaging almost 20 years ago, observed: “It was clear from the start of our discussion with Impact Air Systems and L-A-C that a combination of robot payload, speed and durability was being taken as a given, based on Ball Packaging’s previous 20 years of fault-free service from our ZD130S robot. What they needed to be certain of was that the new robot we recommended could cope with new demands brought by rapid growth, lifting anything up to 320 bales on each shift, with each bale weighing around 30kg”.
For the new system, the scrap brightwork bales, typically sized at 440x440x280mm, had to be rotated to the required position for stacking whilst in the transit arc, and needed to be placed into the appropriate stacking position with a precision guaranteed to be within 1mm first time, every time. Further, to cope with increased production levels (and also make provision for further future growth), an extremely fast full-cycle time was specified for each individual movement. This also provided an assurance that the new system could absorb peaks in the event of potential spikes occurring in can making production, such as those seen as a result of lockdown”. Kawasaki’s engineers recommended the company’s CP180L robot for the application. It is approved and certified to carry a payload of up to 180kg at its maximum reach of 3255mm, and at this reach the unit operates with a guaranteed positional accuracy of +/- 0.5mm.
Impact Air Systems’ Dave Lansdell oversaw the project “We identified early on that greater speed and precision were clear requirements as far as the robot element was concerned. Our chosen bale handling integrator, L-A-C, has a long history of successful problem solving in partnership with Kawasaki Robotics, and the solution they provided with their CP180L robot for this application was perfect. From our viewpoint, we were impressed with the approach demonstrated by the entire robot and integration team, who provided us with excellent support and delivered first class teaching and training on installation”.
Chris Unwin, CEO at L-A-C Logistics Automation Systems added “Fundamentally, our brief was to reduce labour costs, maximise the recycling opportunities and help minimise transportation costs. In this case, we needed to look beyond the normal points of reference and make our engineering match each clearly defined stage of a waste recycling process. The engineers from Impact Air Systems, Kawasaki Robotics and L-A-C made a great team and between us we met every objective that was agreed at the start of this interesting project”.
In conclusion, Kawasaki’s Ian Hensman says “Sound application skills coupled with our ability to provide both Impact and L-A-C with the latest simulation package was pivotal to all concerned. Our robot simulation software allows customers to add 3D models of Kawasaki robots, peripheral equipment, robot tools, and workpieces into a virtual environment and build multi-robot automation work cells. It allows us to design the perfect installation for a customer and to prove that it works long before any metal is cut”.
