performance beyond expectations

IN-LOGMAILROOM TECHNOLOGIES GMBH

palletizing

Contents

Flexible automation by use of robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Pallet conveyor systems with pallet dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Pallet conveyor technics with pallet store . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Peripheral assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Dimension sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Services and partners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Contents

Flexible automation by use of robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Pallet conveyor systems with pallet dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Pallet conveyor technics with pallet store . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Peripheral assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Dimension sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Services and partners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Flexible Automation by use of robots

4

IN-LOG GmbH is one of Austria's leading suppliers of automa-

tion for manufacturing and assembly. Robotic automation, as pre-

sented subsequently, is one of the key competences of our company. No mat-

ter if your application concerns web press, rotogravure or bookbindery,

IN-LOG has the complete solution from one source.

One of our strategic goals consists in expanding the advan-

tages of the company cooperation IN-LOG and Merten Group,

that is: construction, production, assembly and

software development. As a result, our robotic equipments

are flexible and modular and present high availability. In

particular, continuous in-line quality checks complying with

ISO criteria allow to provide the constantly high quality of

our robot equipment.

IN-LOG COMPLETE SOLUTIONS COMPRISE:

q cost-benefit analysis

q conception and planning

q construction and assembly of the necessary gripper and

peripheral technology

q software development and control cabinet construction

q installation and startup

q training

5

Flexible Automation by use of robots

4

IN-LOG GmbH is one of Austria's leading suppliers of automa-

tion for manufacturing and assembly. Robotic automation, as pre-

sented subsequently, is one of the key competences of our company. No mat-

ter if your application concerns web press, rotogravure or bookbindery,

IN-LOG has the complete solution from one source.

One of our strategic goals consists in expanding the advan-

tages of the company cooperation IN-LOG and Merten Group,

that is: construction, production, assembly and

software development. As a result, our robotic equipments

are flexible and modular and present high availability. In

particular, continuous in-line quality checks complying with

ISO criteria allow to provide the constantly high quality of

our robot equipment.

IN-LOG COMPLETE SOLUTIONS COMPRISE:

q cost-benefit analysis

q conception and planning

q construction and assembly of the necessary gripper and

peripheral technology

q software development and control cabinet construction

q installation and startup

q training

5

Grippersystems

6

Every day, our high performance grippersystems palletize

thousands of tons, irrespective of the nature of the respective goods.

As a result of our last performance update we can state that our gripper-

systems set a benchmark in palletizing technology. Highlights like CAN-BUS

controlled valves directly integrated in the grippers enable shorter cycles

and eliminate the risk of cable break and damaged pneumatic conducts.

We pay particular attention to the availability of our equipment. First of all

user friendliness, as for example furnished by entirely pluggable sensor tech-

nics and pneumatic devices, helps minimizing maintenance efforts and thus

increases availability.

Of course, multiple products can be handled in one robot cell at any

moment, thanks to fully automated gripper changing system. Just in case,

simple pick-up setting can equally be carried out at any moment by the

operator by integrated EC servomotors.

7

Example of our log gripper handling logs

from 600mm up to 1200mm

Adjustment units of the multipack grip-

pers are regulated by means of Berger

+ Lahr servo drives and intelligent

Feldbus valve clusters.

With IN-LOG technology, even large packing pieces

with up to 250 kg are reliably palletized.

Individual tasks require

individual solutions.

Grippersystems

6

Every day, our high performance grippersystems palletize

thousands of tons, irrespective of the nature of the respective goods.

As a result of our last performance update we can state that our gripper-

systems set a benchmark in palletizing technology. Highlights like CAN-BUS

controlled valves directly integrated in the grippers enable shorter cycles

and eliminate the risk of cable break and damaged pneumatic conducts.

We pay particular attention to the availability of our equipment. First of all

user friendliness, as for example furnished by entirely pluggable sensor tech-

nics and pneumatic devices, helps minimizing maintenance efforts and thus

increases availability.

Of course, multiple products can be handled in one robot cell at any

moment, thanks to fully automated gripper changing system. Just in case,

simple pick-up setting can equally be carried out at any moment by the

operator by integrated EC servomotors.

7

Example of our log gripper handling logs

from 600mm up to 1200mm

Adjustment units of the multipack grip-

pers are regulated by means of Berger

+ Lahr servo drives and intelligent

Feldbus valve clusters.

With IN-LOG technology, even large packing pieces

with up to 250 kg are reliably palletized.

Individual tasks require

individual solutions.

The New Double Gripper

8

Our newly designed high performance double gripper rep-

resents the state of the art in modern gripper technology. Among its spe-

cial highlights let us mention: Servo adjustment with Berger/Lahr Servo

technics, balancer, bus-controlled valve islands for reduced cabling re-

quirements, telescopic fingers, positioned for the individual product length.

The sum of innovations serves as today's reference in gripper technology.

For a trouble-free, smooth three-shift-operation.

9

Massive three-point mounts with impression cylinder

and fixed cabling.

Making use of bus-controlled valve islands, cabling has

been reduced to a minimum; the gripper does not dis-

pose of a terminal box, where clamps could be shaken

loose by vibration.

Individual tasks

require individual solutions.

IRB 6600 with attached double

gripper and wire package for

compressed air, low-voltage

current and bus cabling.

The New Double Gripper

8

Our newly designed high performance double gripper rep-

resents the state of the art in modern gripper technology. Among its spe-

cial highlights let us mention: Servo adjustment with Berger/Lahr Servo

technics, balancer, bus-controlled valve islands for reduced cabling re-

quirements, telescopic fingers, positioned for the individual product length.

The sum of innovations serves as today's reference in gripper technology.

For a trouble-free, smooth three-shift-operation.

9

Massive three-point mounts with impression cylinder

and fixed cabling.

Making use of bus-controlled valve islands, cabling has

been reduced to a minimum; the gripper does not dis-

pose of a terminal box, where clamps could be shaken

loose by vibration.

Individual tasks

require individual solutions.

IRB 6600 with attached double

gripper and wire package for

compressed air, low-voltage

current and bus cabling.

10

As a response to increasing demands for high

capacity palletizers, with an ability to handle

up to 1.800 stacks, we designed the new

polygripper. In order to achieve the required

performance by means of modern robot tech-

nology, it was not necessary to literally start

from zero, yet pickup-station and gripper had

to be re-invented. A combination of robot

technology and „layer palletizer“ has finally

proved as best fit approach. To create a pick-

up station capable of not manipulating un-

strapped stacks, while continuously main-

taining a 2sec/stack performance, was a ma-

jor challenge. Thus, we are particularly glad

to be the first manufacturer able to present

the performance of polygripper technology.

11

Complete palletizer complex with upside

down station, poly-pickup station, poly-

gripper, empty pallet store, slip sheet

and two palletizing stations.

For all productions named „below“ there is an optional

upside down station, capable of turning the stacks by 180°

upside-down.

Displacement of stacks in the pickup station by means of a

patent pending shifting technology making use of a chain

conveyor.

The layer pattern is pre-established by the 90° turning unit.

This way, the polygripper can drop up to six packages simul-

taneously as a palletizing line.

Of course, the polygripper also handles the insert of interme-

diate sheets causing scarcely any cycle loss.

The New Polygripper

10

As a response to increasing demands for high

capacity palletizers, with an ability to handle

up to 1.800 stacks, we designed the new

polygripper. In order to achieve the required

performance by means of modern robot tech-

nology, it was not necessary to literally start

from zero, yet pickup-station and gripper had

to be re-invented. A combination of robot

technology and „layer palletizer“ has finally

proved as best fit approach. To create a pick-

up station capable of not manipulating un-

strapped stacks, while continuously main-

taining a 2sec/stack performance, was a ma-

jor challenge. Thus, we are particularly glad

to be the first manufacturer able to present

the performance of polygripper technology.

11

Complete palletizer complex with upside

down station, poly-pickup station, poly-

gripper, empty pallet store, slip sheet

and two palletizing stations.

For all productions named „below“ there is an optional

upside down station, capable of turning the stacks by 180°

upside-down.

Displacement of stacks in the pickup station by means of a

patent pending shifting technology making use of a chain

conveyor.

The layer pattern is pre-established by the 90° turning unit.

This way, the polygripper can drop up to six packages simul-

taneously as a palletizing line.

Of course, the polygripper also handles the insert of interme-

diate sheets causing scarcely any cycle loss.

The New Polygripper

1312

Software

The graphic operator touch screen of the soft-

ware is the ideal tool for pallet space calcula-

tion, if you want to load pallets with equally large bundles.

Packing plans corresponding to the respective logistics are fast

calculated and documented by the software. This way, the

software is able to generate for example specific layer layouts

for individual application.

The software concept in IN-LOG palletizing systems is based on

state-of-the-art hardware technology, as, for example, bus-

commanded valve terminals and dual – channel security

technology. The visualization is adjusted to the specific client

application and features user friendly operation by means of

symbols. As a matter of course, superordinate command

funct ions as, e.g., processing of various packaging plans, are

standardized by xml-data files.

Optionally, post sort pallets can be assigned to their respective

route. For this feature it does not matter to our ”smart imag-

ing“ camera systems if your delivery information is available

as bar code, data matrix or plain

text. On demand, additional op-

tions like the automated insert of

slip sheets, cover plates or fully au-

tomated foil wrapping or pallet strapping

can be accessed at the push of a button via the

visualization.

Central production data acquisiti-

on via Auto-Count 1000 for detai-

led logging of the exact net

amounts and production stops.

The software we employ for

generating packing plans has stood

thousands of tests and enables

generating a multitude of packing

patterns, as well as manual entering

of well-proven packaging plans.

1312

Software

The graphic operator touch screen of the soft-

ware is the ideal tool for pallet space calcula-

tion, if you want to load pallets with equally large bundles.

Packing plans corresponding to the respective logistics are fast

calculated and documented by the software. This way, the

software is able to generate for example specific layer layouts

for individual application.

The software concept in IN-LOG palletizing systems is based on

state-of-the-art hardware technology, as, for example, bus-

commanded valve terminals and dual – channel security

technology. The visualization is adjusted to the specific client

application and features user friendly operation by means of

symbols. As a matter of course, superordinate command

funct ions as, e.g., processing of various packaging plans, are

standardized by xml-data files.

Optionally, post sort pallets can be assigned to their respective

route. For this feature it does not matter to our ”smart imag-

ing“ camera systems if your delivery information is available

as bar code, data matrix or plain

text. On demand, additional op-

tions like the automated insert of

slip sheets, cover plates or fully au-

tomated foil wrapping or pallet strapping

can be accessed at the push of a button via the

visualization.

Central production data acquisiti-

on via Auto-Count 1000 for detai-

led logging of the exact net

amounts and production stops.

The software we employ for

generating packing plans has stood

thousands of tests and enables

generating a multitude of packing

patterns, as well as manual entering

of well-proven packaging plans.

14

While our software solutions are

based on highly flexible concepts,

our hardware for pallet conveyor applications

and empty pallet dispenser display simular ver-

satile features. No matter if reel conveyors,

chain conveyors, chain transfer or pal-

let turn tables are put to use, the modular

systems integrate sensor technology and drive

engineering. Optimized handling of different pal-

let sizes is a matter of course. The standardized

robot cell developed by IN-LOG GmbH comprises a

storage for empty pallets with a capacity of max.

15 empty pallets, furthermore a waiting station

for empty pallets, a chain transfer for automatic

positioning of the palletizing spot as well as a

waiting position for full pallets. Pallet conveying

height depends on individual needs, starting

with in-ground systems to manual fork-lift pick-

up level height up to waiting stations for auto-

mated transportation by means of driverless

transportation systems.

Needless to say, that safety features of the robotic

cell exceed the actual safety regulations by far. As

integrated „muting system“ it presents

100% operator security.

In-ground pallet conveyor technology for

standardized use of driverless transportation

systems as one of the manifold options of

our technologies

perfect pallets even for sensitive products

and short cycles

Fully automated robot palletizing including pallet dispenser, slip sheet,

buffer space for full pallets, automatic cross strapping and blocking unit.

Pallet Conveyor Technology With Pallet Dispenser

14

While our software solutions are

based on highly flexible concepts,

our hardware for pallet conveyor applications

and empty pallet dispenser display simular ver-

satile features. No matter if reel conveyors,

chain conveyors, chain transfer or pal-

let turn tables are put to use, the modular

systems integrate sensor technology and drive

engineering. Optimized handling of different pal-

let sizes is a matter of course. The standardized

robot cell developed by IN-LOG GmbH comprises a

storage for empty pallets with a capacity of max.

15 empty pallets, furthermore a waiting station

for empty pallets, a chain transfer for automatic

positioning of the palletizing spot as well as a

waiting position for full pallets. Pallet conveying

height depends on individual needs, starting

with in-ground systems to manual fork-lift pick-

up level height up to waiting stations for auto-

mated transportation by means of driverless

transportation systems.

Needless to say, that safety features of the robotic

cell exceed the actual safety regulations by far. As

integrated „muting system“ it presents

100% operator security.

In-ground pallet conveyor technology for

standardized use of driverless transportation

systems as one of the manifold options of

our technologies

perfect pallets even for sensitive products

and short cycles

Fully automated robot palletizing including pallet dispenser, slip sheet,

buffer space for full pallets, automatic cross strapping and blocking unit.

Pallet Conveyor Technology With Pallet Dispenser

Peripheral Assembly

16

The quality of our products is a matter of high importance for us.

Therefore, we adapt our peripheral assembly, like, e.g., buffer conveyor

technology, stabilization modules and pick-up stations to your specif-

ic needs. Your application may concern web press, gravure or book-

bindery, the feed is arranged correspondingly via buffer conveyor technol-

ogy or flection controlled roller buffer conveyors. Additional labeling

devices or barcode capable inkjet printers allow selective cont rolling.

By means of barcode scanners installed directly on the

pick-up stations or, alternatively, by use of „OCR“ capa-

ble image processing systems, the robot receives a com-

mand for pallet change or for new start of the respective

target pallet. Integrated strapping – top sheet or bottom

sheet feeders complete the automated transfer of stacks

on their way to palletizing.

17

The new pick-up-station with six buffer places

is reducing the cycle-rate up to 20 percent.

Pick-up station for double gripper inclu-

ding stack alignment pusher.

Overhead conveyors for flat products for barrier-

free transportation of full pallets.

Schematic representation of a pick-up station for

flexible stack sizes (top view).

Buffer conveyor with integrated

blocking unit, top sheet feeder and

cross strapping.

Peripheral Assembly

16

The quality of our products is a matter of high importance for us.

Therefore, we adapt our peripheral assembly, like, e.g., buffer conveyor

technology, stabilization modules and pick-up stations to your specif-

ic needs. Your application may concern web press, gravure or book-

bindery, the feed is arranged correspondingly via buffer conveyor technol-

ogy or flection controlled roller buffer conveyors. Additional labeling

devices or barcode capable inkjet printers allow selective cont rolling.

By means of barcode scanners installed directly on the

pick-up stations or, alternatively, by use of „OCR“ capa-

ble image processing systems, the robot receives a com-

mand for pallet change or for new start of the respective

target pallet. Integrated strapping – top sheet or bottom

sheet feeders complete the automated transfer of stacks

on their way to palletizing.

17

The new pick-up-station with six buffer places

is reducing the cycle-rate up to 20 percent.

Pick-up station for double gripper inclu-

ding stack alignment pusher.

Overhead conveyors for flat products for barrier-

free transportation of full pallets.

Schematic representation of a pick-up station for

flexible stack sizes (top view).

Buffer conveyor with integrated

blocking unit, top sheet feeder and

cross strapping.

MACHINE DESCRIPTION ROBOT PALLETIZER

TYPE: ABB/SP500

CONTROL: PC control with touchscreen user surface

BUNDLE FORMAT: min: 150 mm – 460 loose or strapped

BUNDLE HEIGHT: min.: 50 mm, max. 300 mm

BUNDLE HEIGHT DIFFERENCE: <30 mm

BUNDLE WEIGHT: max. 25 kg

PAPER WEIGHT: 45 g/m2 up to strongest reel offset printing paper

MACHINE OPERATION: command via touchscreen

PALLET SIZE: 800 x 1200 mm

1000 x 1200 mm (extra sizes on customer request)

PALLETIZING HEIGHT: 1500 mm

PALLET WEIGHT AFTER PALLETIZING: max. 1000 kg

PERFORMANCES:

ABB/SP 500-1 up to 680 stacks/hour (with optimal packing plan, without intermediate sheet, without pallet change)

ABB/SP 500-2 up to 850 stacks/hour (with optimal packing plan, without intermediate sheet, without pallet change)

ABB/SP 500-1S up to 150 logs/hour (with optimal packing plan, without intermediate sheet, without pallet change)

ABB/SP 500-2S up to 150 logs/hour (with optimal packing plan, without intermediate sheet, without pallet change)

ABB/SP 500-1W up to 680 stacks resp. 150 logs/hour (with optimal packing plan, without intermediate sheet, without pallet change)

ABB/SP 500-2W up to 850 stacks resp. 150 logs/hour (with optimal packing plan, without intermediate sheet, without pallet change)

ABB/SP 1000-1 up to 1360 stacks/hour (with optimal packing plan, without intermediate sheet, without pallet change)

AIR CAPACITY: air quantity: 0.9m3/min (depending on machine layout)

AIR PRESSURE: min. 4 bar, max. 6.5 bar

POWER INPUT: depending on electric layout

INPUT SUPPLY VOLTAGE: 3 x 400 V AC + N + PE 50/60 Hz

CONTROL VOLTAGE: 24 Volt

PRE-FUSE PROVIDED BY CUSTOMER: depending on electric layout

INFEED HEIGHT: 850 mm

CONTROL: PC control with touchscreen user interface

PACKING PLAN GENERATION: free generation by the client

ROBOT: ABB IRB6640 – 185/2.8 (ABB IRB660 – 250/3.15)

POSITIONING PRECISION: 0.05 mm

INTERMEDIATE SHEET: paper 80 – 120g/m3 hermetic

TOTAL WEIGHT: robot approx. 1.700 kg palletizing system depending on machine layout

STANDARD COLOUR: ABB orange, RAL 7035

18 19

The new 4-achses ABB

robot with multigripper

MACHINE DESCRIPTION ROBOT PALLETIZER

TYPE: ABB/SP500

CONTROL: PC control with touchscreen user surface

BUNDLE FORMAT: min: 150 mm – 460 loose or strapped

BUNDLE HEIGHT: min.: 50 mm, max. 300 mm

BUNDLE HEIGHT DIFFERENCE: <30 mm

BUNDLE WEIGHT: max. 25 kg

PAPER WEIGHT: 45 g/m2 up to strongest reel offset printing paper

MACHINE OPERATION: command via touchscreen

PALLET SIZE: 800 x 1200 mm

1000 x 1200 mm (extra sizes on customer request)

PALLETIZING HEIGHT: 1500 mm

PALLET WEIGHT AFTER PALLETIZING: max. 1000 kg

PERFORMANCES:

ABB/SP 500-1 up to 680 stacks/hour (with optimal packing plan, without intermediate sheet, without pallet change)

ABB/SP 500-2 up to 850 stacks/hour (with optimal packing plan, without intermediate sheet, without pallet change)

ABB/SP 500-1S up to 150 logs/hour (with optimal packing plan, without intermediate sheet, without pallet change)

ABB/SP 500-2S up to 150 logs/hour (with optimal packing plan, without intermediate sheet, without pallet change)

ABB/SP 500-1W up to 680 stacks resp. 150 logs/hour (with optimal packing plan, without intermediate sheet, without pallet change)

ABB/SP 500-2W up to 850 stacks resp. 150 logs/hour (with optimal packing plan, without intermediate sheet, without pallet change)

ABB/SP 1000-1 up to 1360 stacks/hour (with optimal packing plan, without intermediate sheet, without pallet change)

AIR CAPACITY: air quantity: 0.9m3/min (depending on machine layout)

AIR PRESSURE: min. 4 bar, max. 6.5 bar

POWER INPUT: depending on electric layout

INPUT SUPPLY VOLTAGE: 3 x 400 V AC + N + PE 50/60 Hz

CONTROL VOLTAGE: 24 Volt

PRE-FUSE PROVIDED BY CUSTOMER: depending on electric layout

INFEED HEIGHT: 850 mm

CONTROL: PC control with touchscreen user interface

PACKING PLAN GENERATION: free generation by the client

ROBOT: ABB IRB6640 – 185/2.8 (ABB IRB660 – 250/3.15)

POSITIONING PRECISION: 0.05 mm

INTERMEDIATE SHEET: paper 80 – 120g/m3 hermetic

TOTAL WEIGHT: robot approx. 1.700 kg palletizing system depending on machine layout

STANDARD COLOUR: ABB orange, RAL 7035

18 19

The new 4-achses ABB

robot with multigripper

21

robotic palletizer

162322

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162524

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robotic palletizer

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Services and PartnersPalletizing systems as standardized by IN-LOG Gmbh respond to the

requests of many industrial palletizing tasks. Nevertheless, we are in par-

ticular spezialized in customized solutions, each specific robot cell being

optimized individually with regards to performance and nature of pack-

aging goods. Finally, flexibility and high performance of IN-LOG robotic

configurations are documented by the choice of business partners and

component suppliers, as for instance:

Fotos: Astrid Bartl, IN-LOG; GRAFIK & BILDBEARBEITUNG: MEDIA&GRAFIK, WIEN

Services and PartnersPalletizing systems as standardized by IN-LOG Gmbh respond to the

requests of many industrial palletizing tasks. Nevertheless, we are in par-

ticular spezialized in customized solutions, each specific robot cell being

optimized individually with regards to performance and nature of pack-

aging goods. Finally, flexibility and high performance of IN-LOG robotic

configurations are documented by the choice of business partners and

component suppliers, as for instance:

Fotos: Astrid Bartl, IN-LOG; GRAFIK & BILDBEARBEITUNG: MEDIA&GRAFIK, WIEN

Merten Maschinenbau und Vertriebs GmbH

A-1220 Vienna, Puchgasse 9Phone: +43 1 2594648Fax: +43 1 2594648-25E-Mail: office@merten.in-log.comInternet: www.in-log.com

IN-LOG is a brand name of the Merten Maschinenbau und Vertriebs GmbH