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Industrial Automation



Kimberly Clark Millicent S.A.

Carton Control

Palletisers

Other Details

One of these installations features three palletisers, with a moderate sized pallet conveyor system and an extensive carton conveyor system. The other features a single palletiser, with a small sized pallet conveyor system and a moderate sized carton conveyor systems.

These installations are responsible for the development of the palletiser PLC code and the palletiser operator interface described in the “Palletisers” section. The carton conveyor control algorithms are also of note.

Carton Control

The three palletiser system, is fed from three carton conveyors, with a diverter allowing operations to continue if one or two of the palletisers are being serviced. Before the diverter the three carton conveyors service nine cartoners (three each).

Each cartoner has a dedicated section of conveyor, incorporating a length of zero-pressure conveyor. Cartons would be accumulated on this dedicated section of conveyor until sufficient catrons had been produced to form a pallet load. This pallet load would then be released onto one of the three main trunk conveyors and be conveyed in tact to one of the three palletisers.

The single palletiser system, is fed from a carton conveyor servicing two cartoners. Again, each of these cartoners has its dedicated section of conveyor to accumulate its cartons into pallet loads.

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Palletisers

The palletisers then must palletise the slug using the appropriate pattern, and, while finishing, commence the palletising of the next slug, with usually a different palletising pattern.

Since it takes some considerable of skill on the part of an operator to sort out a palletiser when things go wrong, the operator interface for the palletisers was developed to enable faster recovery from these problems by personel less familiar with the machine. It also incorporates more convenient pattern programming, rather than requiring a PLC programmer to be setting bits in the data table.

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Other Details

The pallet conveyor system incorporates pallet destackers, alignment bars, and stretch wrappers.

Communications between the “Movement Controller” and the host computer system is via FTP/TCP-IP/Ethernet.

All PLCs are Allen-Bradley.

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