This technology is based on the use of anthropomorphic robots equipped with special tools and designed specifically for handling packages. The robot is part of a fully integrated system that incorporates a series of machines and special devices.
The main advantage offered by this solution derives from the robot’s multi-purposeness and operational flexibility. Indeed, the robot replaces a series of dedicated machines used in traditional systems, thereby reducing drastically the costs per unit transported.
Technologically, this solution stands out for its high running speed, complete positioning accuracy and maximum reliability.

Autopacking systems – complete systems for draw-twisted yarn packages – exemplify perfectly this new technological trend.

These systems handle packages plucked from transportation carriages. The packages, once identified through special ID disks that a special machine applies to the tube collar, pass through quality control stations, before being automatically bagged and packed in cardboard boxes, which are then sealed and labelled.

The system comprises three main areas:
* Transportation carriage line
* Package transportation disk line
* Empty/full box line

The packages, in the various production areas, are loaded manually onto single-side carriages with 72 slightly angled pegs. These carriages are moved manually to the carriage line entry point. Once they have been fed into the line, the carriages advance automatically until they reach the package picking up point.

Here, there is a hydraulically-operated overturning platform, equipped with carriage anchoring devices. When the carriage is in position, the platform rotates through 85 degrees, positioning the packages so that they are perfectly horizontal and can be gripped from above by grippers located on the head of the robot.

The robot is a six-axis machine with its own control system.

When the packages are in picking position, the head grips 4 packages contemporaneously and then ascends, sliding the packages off their respective pegs.

The robot then carries out rapidly a pre-programmed cycle, depositing the 4 packages on as many transportation disks (on the disk line).

Fig. 1 – View of the handling and packaging robot

The cycle is repeated until the carriage is completely empty.
At this point, the platform returns to its rest position; the empty carriage is released and the carriage line starts to move again, pulling the carriage towards the exit from the line.
Should there be another, full carriage already present, this is immediately placed on the platform and the robot starts the unloading cycle again.
The disk line is a group of motorised rollers arranged in a closed circuit. The disks, carrying the packages, are transported around the circuit, passing through the various operating stations.

In the first of these, each package is given a product ID disk. This is applied, by pressure, to the tube collar of the package by means of a special, pneumatically-driven automatic machine. The machine has an 8-chamber rotating drum, and each chamber can contain a different type of disk.
Once the disks have been applied, the packages proceed to the visual inspection stations, where an operator enters the relevant data into a terminal linked up with the management system.

In the next station, the packages are passed through a special bagging machine, which slips a protective HDPE (high-density polyethylene) bag over each one.
Once this operation is complete, the packages are ready to be packed. The disk line forwards them to the packing station. Here, the robot transfers the packages from the transportation disks into cardboard boxes supplied by the box line. These boxes are made up, upstream of the box line, by a special box assembler.
The other packing materials (moulded plastic bottom and top plates) are fed by two separate lines to the positions ready for plucking by the robot, which inserts them into the packing boxes in the correct order.
The filled boxes are transported by the box line to a labelling station, and subsequently to a station in which they are automatically closed and sealed.

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