Automation of mineral wool depalletizing for Ruukki
Project
RUUKKI is a company with traditions, with its roots in Scandinavia. One of the company’s branches is the production plant in Oborniki, in the Wielkopolskie Voivodship. As part of activities aimed at expanding the portfolio of manufactured boards and increasing efficiency and safety on the production line, RUUKKI decided to introduce a new system for depalletizing mineral wool sheets. Among the challenges of this project were, among others:
- high efficiency of the depalletizing line
- ensuring an extensive buffer of unloading sheets
- the possibility of simultaneous depalletization of different types of mineral wool
- optimization of the number of unloaded species and the place of depalletization
- adjustment of line capacity to current production needs
- optimization of the wool grade selection process for depalletization
- automatic tracking of transported sheets and transferring them to the right place
Proster solutions used in the depalletizing line
We have designed the new depalletizing line in such a way that the expected tasks are performed by two workstations with robots. This was necessary to ensure the efficiency of the process assumed at the beginning of the project.
Pallets with mineral wool sheets are delivered by roller and chain conveyors. We have placed the conveyors in the production hall in such a way as to ensure an extensive buffer of unloaded sheets. In practice, this means even 33 pallets on conveyors (3 deliveries from a truck).
Stacks of pallets at the entrance to the robotic stations are manually unpacked from the protective foil and then transported to the depalletization process. We have programmed the robots so that they can unload sheets independently from four pick-up points, which allows to increase the efficiency of the process. The wool sheet collected by the industrial robot is placed on a conveyor belt, which transports it to the next stage of the technological process.
Project implementation process
During the implementation period, we designed a comprehensive range of mechanics, automation and robotics, as well as electrics. Then we produced the mechanical components and the power and control switchgear for the depalletizing line.
The implementation process began with the design of a system of roller conveyors, chain conveyors and grippers for robots. Then, the electrical design was developed and the power supply and control switchboards for the depalletizing line were made.
Jarosław Tynka, Senior Project Manager in Proster
One of the most important stages of our engineers’ work was the design and manufacture of two-jaw mechanical grippers. They have three main functions: transport of pallets, transport of mineral wool sheets and transport of sheet strips. Each of these functions, as well as the maintenance of the gripper drive mechanism, are described in detail in the comprehensive line manual.
After the production stage, it was time to test the robotic stations in our assembly hall with the participation of Ruukki employees. After accepting our solution, we took care of transport to the plant in Oborniki, where the depalletizing line was installed.
Commissioning of the depalletizing line
After completing the assembly work, we configured the automation devices and the robots themselves, and then we launched our test line on various formats of the semi-finished product in the form of sheets and strips of mineral wool – which went without major disruptions.
First, we integrated the depalletizing line with the client’s production line, where we focused on the exchange of appropriate signals between them. This made it possible to coordinate their work so as to maintain the condition of continuous feeding of the semi-finished product in the form of sheets of mineral wool. Each break in the depalletizing process stops continuous production on the sandwich panel production line, which in turn results in time and material losses for the customer.
After refining continuous depalletization, we focused on achieving full efficiency of the line with production processes. At this stage, work was mainly carried out on optimizing the movements of the robots in order to reduce the cycle time of feeding the mineral wool sheets to a minimum. After a few corrections in the sequence of work of the robots, the expected results regarding the efficiency of the robotic depalletizing process were obtained. The last stages of the commissioning were training for line operators and maintenance services, and then handing over to the customer with a short production assistance on our part. All these stages lasted about two months, after which the customer could fully use the purchased rope for depalletizing mineral wool sheets.
100%
increase in process efficiency
The entrusted works were carried out fully professionally and in line with Ruukki's expectations. PROSTER is characterized by reliability and proper commitment to the work performed. The order was completed efficiently, accurately and on time. We recommend PROSTER as a competent and trustworthy contractor offering high quality services.
Process Engineer Ruukki Polska Sp. z. o.o.
Benefits for our partner
The mineral wool sheet depalletization line we designed and built provided Ruukki with measurable benefits.
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Line efficiency increase by 100%
directly affects the increase in company profits
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Increased process efficiency
through a system enabling tracking of transported sheets
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Simplicity of retooling
allows you to quickly change the type of wool sheet, while minimizing downtime of the production line
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Comprehensive staff training
ensures occupational health and safety during the operation of the depalletization line
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Easy change of palletizing capacity
increases control over the production process and optimizes the use of resources
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Process flexibility
thanks to the functionality of adaptation to current production needs
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PROSTER warranty and post-warranty service
guarantees quick response and peace of mind in the event of a system failure
Talk to an advisor
Send an inquiry or call +48 513 221 627. We will talk for a few minutes about the challenges you face.
