First-ever use of robotics for container distribution

Krones has had great success using robotics to group packs into pallet layers for several years.

And now, for the first time, the same principle has been adapted to distribute containers as they approach the packer.

With Robobox SynFlow, Krones has brought to market a new, modular system that is the first to use robotic technology to reliably and gently distribute containers into designated lanes.

Intelligent robotics is the key.

Normally, containers are directed into the packer via guide systems that operate according to preset patterns. However, that can often result in the individual lanes being filled inconsistently, such as when there are gaps in the flow of containers.

And so, at some point in a production batch, operators will inevitably have to intervene manually to keep the packaging process running smoothly right down to the last bottle.

Now, Krones has found a remedy in a completely novel concept for container distribution: the Robobox SynFlow uses a tripod robot to group the incoming containers purposefully. Thanks to intelligent robotics, the system knows exactly how many containers are in the line. It can make on-the-fly adjustments to close gaps, ensuring the packer is reliably supplied with the right number of containers at all times.

Robust delta robot for diverse applications

Robobox SynFlow is available in two designs: The smaller version, for handling up to 55,000 containers per hour, uses a single tripod robot and is appropriate when a single flow of containers is fed into the packer. A second, larger version is suitable for lines with, for instance, two labellers running. With two tripod robots, it can handle up to 105,000 containers per hour. Both setups can serve three to nine lanes in the Variopac Pro.

Although the Robobox SynFlow is suitable for all common container types (glass and PET bottles as well as cans) and diameters (from 40 to 125 millilitres), it really shines when it comes to handling specially-shaped containers. Positive-fit precision grippers guide the containers gently, reliably and precisely to their intended position. They can even turn the containers to orient the labels just right within the pack.

When grouping packs for palletising, the delta robot used here employs parallel kinematics, with all axes operating simultaneously. The robot model used for the Robobox SynFlow is specially designed to handle the comparatively lightweight containers, moving and grouping them with precision. Here, too, drives are installed at fixed positions so they do not have to be moved with the rest of the system. The conveyors within the machine are driven by high-performance permanent-magnet motors, which require up to 50 per cent less power than conventional asynchronous motors.

If there is a problem, such as fallen containers, the intelligent robotics immediately recognises the changed circumstances. It triggers an immediate emergency stop to prevent any damage to the Robobox SynFlow or containers. The paddles used for the gripper guides are attached to the tripod by magnets. In the event of a collision, they come off to prevent mechanical damage to the machine.

Up to 10 per cent space savings in the line

Although the Robobox SynFlow is a complete machine rather than the simple guide rails used up to now, the new system still reduces the line’s overall footprint. On the smaller version of the machine, intelligent robotics can variably adjust the container speed down to 16 per cent of the actual line speed. This sort of flexibility eliminates the need for conveyors to accomplish the same thing.

Although the larger version of the machine does not provide variable-speed control, it requires less space because it does not need an Inliner, so the labellers, distribution system, and packer can be connected directly. On average, the Robobox SynFlow can reduce a line’s footprint by around 10 per cent.