Automated solution for efficient and precise lid stacking
In modern industry, speed and reliability are paramount. Our automated lid stacking line, equipped with synchronized transport systems and pneumatic mechanisms, enables an efficient, safe, and consistent process of stacking lids into columns for further processing or packaging.
Initial challenge - The client sought a solution for stacking lids of various sizes that would reduce manual labor while ensuring precise positioning and secure transport. Flexible operation and synchronization of individual line segments without stoppages were also critical.
Result - We implemented a flexible line featuring belt and roller conveyors along with lifting and pushing devices for the lids. The system supports full automation, occupancy monitoring, and manual control if needed. The solution is robust, user-friendly, and enhances both productivity and safety.
Solution description
The lid stacking line is fully supported by inductive sensors, photoelectric sensors, and pneumatic actuators, ensuring accurate detection and positioning of lids as well as synchronized operation of all components.
The line consists of three main parts:
Belt conveyor
Transports lids to the lifting device.
Lid lifting device
A linear unit with a pneumatic cylinder that stacks lids vertically from bottom to top.
Roller conveyor
Receives stacked lid columns, moves them synchronously, and alerts the operator when the line is full.
Line operation steps
1. Lid delivery to the belt conveyor
The lid arrives on the existing line and is moved by the belt conveyor to the lifting station.
2. Stopping the lid and preparing the lifting device
An inductive switch detects the lid position and stops the conveyor using a stopper. The lifting device prepares to lift the lid.
3. Lifting the lid onto the block
The pneumatic cylinder lifts the lid and places it on a block that enables further transport.
4. Pushing the stacked column onto the roller conveyor
After lifting, a second pneumatic cylinder pushes the column of lids onto the roller conveyor.
5. Synchronized transport and stacking of columns
The roller conveyor operates stepwise, stopping and moving columns upon photoelectric sensor detection until full occupancy is reached.
6. Alert for manual removal
When the roller conveyor is full, a signal light notifies the operator to manually remove the stacked columns, allowing the process to continue.
