Haith Robot System for Aggregate Industries Haith Robot System for Aggregate Industries Haith Robot System for Aggregate Industries Haith Robot System for Aggregate Industries

Haith Robot System for Aggregate Industries

24th May 2004

Kawasaki robots have been fulfilling many different production applications in the automotive industry since 1969, with over 32,000 units sold to date around the world. They were the first robot manufacturer in Japan and their robots perform an important role in the production of many new vehicles including the latest S type and X-type Jaguars.

Robots are seen today as an integral part of manufacture performing repetitive tasks on a 24 hour 7 day basis providing accurate and reliable actions in a wide variety of arduous operating conditions.

The car industry was perhaps the first of many industries to make use of robots extensively. Whereas in the early days of car manufacture, thousands of manual workers were used to place and fit all the various components, with the event of robots more efficient manufacture could be achieved with a smaller work force.

Many manufacturing processes are by nature performed in hostile working condition which are uncomfortable, unpleasant, and sometimes present potential risks for workers. Placing a robot in these working conditions provides a solution to this problem.

Being a controlled machine, the robot also has the advantage of performing repetitive tasks without mental boredom effecting the accuracy and speed of performance. Robots are also capable of handling much larger loads than possible by manual labour, with the latest models capable of handling up to 500kg.

Robots are becoming extremely important in palletizing and handling applications because of their ability to consistently handle and stack pallets, bags, crates and boxes in an accurate and repeatable way.

Producers using manual labour are finding that goods that are stacked in an erratic way are unceremoniously rejected by their customers because of the major inefficiency problems that this causes with truck loading and warehouse storage.

Haith Industrial is the preferred systems integrator for Kawasaki in the quarry products market, through their experience and expertise they resolve the problem and supply all design, drawings and install to the customer's specific requirements.

Additionally they also manufacture all conveying roller systems, and magazine installation, in short they supply a complete turnkey system.

Haith were approached by Aggregate Industries to design, build and install a new stone splitting and rumbling system at their Kemney plant in Scotland. The plant is split into three separate production units, split, pitched faced and rumbling systems.

Split and Pitched Product System.

General production feed consists of 900 x 440 mm reconstituted stone blocks. The system is fed by fork lift truck delivering the product directly onto a 1100mm wide hydraulically driven indexing variable speed slat conveyor designed to accommodate whatever product production run is designated. The product is fed from this 10 metre long conveyor into the tippler head which in turn delivers to a pusher where the product is pushed under a spray head which applies ultra violet dye as required to enable designated product to be identified further down the production line.

Passing under the spray heads the block is fed into a block splitter which produces product at 25 cuts per minute; individual product is then fed onto a slat conveyor passing through quality control where it is manually inspected; any rejects removed by hand into an adjacent skip. This operator also has access to the splitter control panel and the adjacent packing line control panel from this central position.

The product then passes under a light detection system which on recognition of any ultra violet dye activates a pusher which moves the product onto transfer rollers which in turn feeds a right angled slat conveyor designated for this alternative flow.

Both the separate products progress directly on their own individual slat conveyors up to the stops where they are then collated and squared up to a half pack layer.

At this stage production is controlled by a Kawasaki ZD 250 palletising robot which works off four axis. This robot is programmed to pick up a half pack layer (eight blocks) off either slat conveyor and place by gripping hand onto a pallet which is fed into position on a powered transfer chain conveyor supplied from a pallet magazine fed by fork lift truck.

Individual pallets are automatically transferred from the chain conveyor onto one of two separate roller conveyors which enables segregation between a single or double split face production run.

The robot stacks layers of blocks dependant on product thickness onto the pallet which is then transferred along either conveyor and into individual lift-up roller systems; the second roller conveyor can also alternate by means of an extension after its lift up system, this allows feed from the adjacent rumbling system.

This allows another palette feed delivered by fork lift truck to enter into the system and progress to the packing line via this route.

Product lifted and fed onto the packing line chain conveyor is then bagged and shrink wrapped manually from a raised platform position either side of the conveyor.

Product coming off this conveyor is then moved by fork lift truck to either the stockyard or taken to the pitch facing plant.

Automatic Pitch Facing Plant.

Product delivered by forklift truck is deposited onto a pallet stand where single blocks are picked by a gripper hand on a Kawasaki ZX130 Pitching Robot working on six axis. This robot is specifically designed to pitch 3-4 blocks per minute up to a maximum size of 440 x 215mm, with a pitch depth of up to 30mm.

The robot picks individual blocks from the incoming pallet stand into a hydraulically driven pitch facer, each individual pitched block is then removed by gripper hand and placed on a further pallet stand where they are stacked and then completed pallets are removed by fork lift truck for transfer to the stockyard.

Any waste from the pitchfacer is conveyed by short transfer conveyor back across and over the splitter conveyor into the waste container.

Rumbling System.

A third adjacent existing system is primarily used for rumbling bricks. This was originally built and installed by Haith Industrial and re-sited to enable an interface to be created and provide more availability on the packing line if demand required it.

Material for this third system is again 900 x 440mm reconstituted blocks, this is delivered by fork lift truck onto a 10m long slat conveyor which feeds into a tippler head where it is pushed into a splitter which in turn feeds onto an incline conveyor into a brick rumbler which discharges onto an outfeed conveyor where it is manually sorted and stacked onto palettes.

This material if required can then be manually transferred onto a scissors lift which provides a further feed via conveyor and lift-up system to the packing line.