Automatic uncoiling of sheet metal to laser cutting and robotic palletizing
The process of sheet metal from uncoiling to palletizing is highly automated. It starts with uncoiling and leveling the metal sheets to ensure they are flat and ready for processing. These sheets are then precisely cut by a laser cutting machine, which can handle complex shapes with high accuracy. After cutting, the pieces are sorted, with finished parts being neatly stacked by a palletizing robot. This system is efficient, flexible, and reduces labor costs while improving product quality and safety.
I. Process Description
(1) Uncoiling and Leveling
- Uncoiling: The operator places the coil material onto the uncoiler, which secures the coil with pressure rollers to ensure stable unwinding. After manually removing the coil’s packaging straps, the sheet metal is fed into the leading mechanism.
- Leveling: The leading mechanism, equipped with guide rollers and sensors, smoothly delivers the sheet metal into the leveling unit. The leveling unit, featuring a multi-roll structure, eliminates any warping or twisting of the sheet metal through pressure adjustment to ensure accurate dimensions for subsequent processing.
(2) Laser Cutting
- Conveying: The leveled sheet metal is conveyed to the laser cutting machine via a conveyor belt.
- Cutting: The laser cutting system performs high-precision cutting according to the pre-set program. Its advantages include the ability to process complex shapes with smooth, burr-free cuts. After cutting is completed, the production line automatically activates the rolling platform to synchronously transport the cut pieces and scrap material to the sorting area.
(3) Sorting and Palletizing
- Sorting: In the sorting area, equipment such as a suction-fork combination machine can be used. This machine is equipped with a dual-function module of vacuum suction cups and mechanical forks. The suction cups are responsible for picking up the finished pieces, while the mechanical forks lift the scrap material and transport it to the scrap box on the exchange platform.
- Palletizing: For the finished pieces that need to be palletized, the robot palletizing system stacks the pieces neatly according to the pre-set palletizing method and stack pattern. Robot palletizing is characterized by high flexibility, fast speed, and high precision, and it can adapt to the palletizing needs of workpieces of different shapes and sizes.
(4) Working Principle of Palletizing Robot System
- Receiving Task Commands: The control system receives task commands to determine the specific requirements of the palletizing task.
- Position Detection: Sensors detect the position and status of the objects to be transported. Commonly used sensors include photoelectric sensors, ultrasonic sensors, laser sensors, force sensors, etc.
- Grasping Objects: The robotic arm picks up the objects using specific grasping tools. The grasping tools can be vacuum suction cups, grippers, etc., chosen according to the shape and material of the workpieces.
- Moving and Stacking: The robotic arm moves the objects to the designated positions and stacks them. During the movement, the control system precisely controls the path and speed according to the pre-set parameters.
- Feedback and Monitoring: After palletizing is completed, the results are fed back to the upper-level computer or monitoring system via a communication system for subsequent management and scheduling.
(5) Control System
- Hardware Composition: The main hardware of the palletizing robot control system includes programmable logic controllers (PLCs), servo drivers and motors, sensors, solenoid valves, buzzers, etc.
- Software Design: The control system software includes continuous operation programs and home search programs. The continuous operation program controls the robot to perform palletizing operations in a loop, while the home search program is used to bring each axis to the home position before entering the continuous motion mode.
(6) Advantages
- Increased Efficiency: The entire process is automated, reducing manual intervention and significantly improving production efficiency.
- Cost Reduction: Labor costs are reduced, and the high precision of laser cutting and high material utilization rate further lower production costs.
- Quality Improvement: The high precision of laser cutting and the high stability of robot palletizing ensure the processing quality of the products and the quality of palletizing.
- High Flexibility: When the size or shape of the product changes, only minor modifications are needed in the control system.
- Strong Safety: The system is equipped with emergency stop buttons and safety protection devices to ensure the safety of operators.
II. Equipment Configuration Table
| Equipment Name | Model Specification | Quantity | Country of Origin | Configuration Description |
|---|---|---|---|---|
| Uncoiler | Customized according to coil size | 1 | Domestic | For uncoiling sheet metal, equipped with pressure rollers to secure the coil and ensure stable unwinding |
| Leveler | Customized according to sheet size | 1 | Domestic | Multi-roll structure, eliminates warping or twisting of sheet metal through pressure adjustment to ensure accurate dimensions for subsequent processing |
| Laser Cutting Machine Main Unit | Effective processing size ≥ 3700mm × 1300mm, maximum average power ≥ 6000W | 1 | Domestic | Fiber laser, fine cutting head, automatic focus control, anti-vibration, collision protection |
| Cooling System | High-temperature and low-temperature dual-temperature control water circuits | 1 | Domestic | For cooling the laser and cutting head to ensure stable operation of the equipment |
| Dust Extraction and Ventilation System | Meets dust extraction requirements | 1 | Domestic | For dust extraction and ventilation to improve working environment |
| Palletizing Robot | Collaborative robot, load capacity ≥ 20kg, working range ≥ 1350mm | 1 | Domestic | For grasping and palletizing workpieces, with high flexibility and precision |
| Mobile Base | Mobile base with optional lifting column | 1 | Domestic | For robot movement to adapt to different working positions |
| End Effector | Customized according to workpiece shape | 1 | Domestic | For grasping workpieces, suitable grasping tools can be selected according to the shape and material of the workpieces |
| Teaching Pendant | 11.2-inch screen, 2560×1536 resolution | 1 | Domestic | For robot programming and operation, equipped with an intuitive user interface |
| Mobile Base with Load Capacity | Customized according to robot model, maximum load capacity ≥ 200kg | 1 | Domestic | For supporting the robot, equipped with mobile wheels for easy position adjustment |
By following the above processes and equipment configurations, the entire process of sheet metal from uncoiling to palletizing is realized with efficient, precise, and automated production, significantly improving production efficiency and product quality.