The next generation of automated tube and pipe packing

To get tube or pipe from a mill line to a bundler, a conventional method is to lift the workpieces with forks and drop them, which is a forceful, noisy process. In redesigning this process, Fives developed Robopack, a pick-and-place system that uses a robot's chief capabilities to provide a dexterous, deliberate handling and bundling process.

Making a tube or a pipe requires a large amount of equipment, always laid out in a linear fashion. So, when addressing tube packaging challenges, tube makers must deal with plant- and process-dependent layouts, but this is where the utmost flexibility is needed. Tube diameters and cut-off lengths vary, so material handling flexibility is the key to efficiency. Modern technology offers a new way to conceive the tube packing process, smart and simple. Welcome to the age of anthropomorphic robots.

Dedicated to lateral applications for profiles and tubes, a robotically based, versatile system named Robopack from Fives replaces the traditional forks with anthropomorphic robots to pick and place tube to pack hexagonal, square, or rectangular bundles. Because it uses a modular design concept, this system increases flexibility and production, takes less space, improves safety, speeds up changeovers, reduces maintenance costs, reduces noise, and offers fast commissioning, and it does so without compromising quality.

Although robot technology once was novel, niche, and expensive, it has become more widespread, capable, and affordable as it has matured.

The Robopack system comprises modular units arranged according to the customer needs. It is a flexible, versatile packaging system capable of automatically handling profiles and tubes—round and shaped—as small as ¾ in. OD by 10 ft. long (19 mm by 3 m).The system uses an inlet buffer table to store the tubes after being picked up from the runout table. The table is made up of multiple parallel chain units, each one built with ground supports assembled on a large, sturdy frame.

Depending on the layout, a first series of indexing chain receives the tubes unloaded by the cut-off rollway or picks up the tubes directly from the cut-off rollway. For non-round shapes, a sensor located along the indexing chains reads the orientation and, when required, activates a pneumatic tilting device that rotates the tube or profile so that it can be conveyed onto the buffer area horizontally. An additional series of plastic-covered steel chains take the tubes ahead toward the end of the table, creating a storage buffer in front of the robot, properly aligned by a series of product stoppers and pneumatic pushers. Depending on the tube's OD range, a series of additional devices can be installed to prevent overlapping and excessive bending.

The robot moves the tubes from the buffer area to the forming conveyor using a pick-and-place action, picking up the tubes from the upstream chain and placing them into the downstream bundle formation rollway, creating the bundle with the required shape. This operation involves a variety of manipulations, depending on the tube weight and dimensions.

Just after the forming conveyors, the bundles are handled by an additional set of rollways conveying them to storage and unloading chain conveyors. The storage and unloading conveyors are made of arrangeable modules to fit the tube length, covering the needed runout space and storing the required number of bundles. Shutters chain conveyors can be applied when timber pieces are used.

The interface is user-friendly and easy to customize, providing several features:

Depending on the tube size and length, package type, and dimension, the production capacity can reach up to 40 tubes per minute in a fully automatic cycle. Compared to a fork-based system, Robopack offers an overall 15% improved performance. This is based on the system's adaptability to varying operating conditions:

Because it is constructed from small modules, the Robopack system can take up 25% less space than traditional fork-style designs. It can fit easily into normally unused plant spaces, such as the areas between pillars.

For the fastest possible changeovers, the Robopack system from Fives uses a single clamp that can adapt to a variety of tube shapes and sizes.

Beyond space and placement, flexibility is key. The modular design allows the system to be tuned to match any tube format and length with minimal engineering. When necessary, depending on the tube length and storage buffer needed, additional modules can be combined to form a larger buffer table. Moreover, two robots can be put side by side and programmed with coordinated motions to work simultaneously when handling long tubes. The robot payload also can be chosen based on the tube weight, size, and package's dimensions according to the desired throughput. Beyond these considerations, the system can be integrated with third-party equipment, such as blowing stations, strapping machines, film wrappers, draining and weighing stations, and ticket printers.

Any line upgrade in terms of tube size, tube length, and layout modification can be achieved by adding new modules or increasing the robot size, number of robots, or both. For the same reason, the system effectively lends itself to be redeployed in different lines or configurations by rearranging the existing modules or upgrading them to new ones.

First, the small, lightweight modules make the installation easier, quicker, and safer than that of a conventional system made from large, bulky components. The time saved in installing and commissioning a system can be as much as 30%.Second, these systems use fewer moving parts than conventional material handling systems. The minimized number of moving parts helps lower maintenance costs compared to a traditional system. And because the design is modular, it comprises a large number of common components, which reduces the variety of spares needed for repairs.

Third, although robots have many moving parts, they come with maintenance plans with known and limited costs, providing the assurances of a mature technology and a standardized product. Finally, parts that require maintenance are easily accessible, reducing the need for skilled labor.

Using a robot as the central element provides a fundamental change in how tube is handled. A fork-based system lifts and drops the tube, which is a forceful, noisy process. Because a robot's motions can be dexterous and deliberate rather than forceful, the system doesn't generate as much noise as typical systems, a benefit to the operators. Also, because robots come with a full set of integrated and certified safety modules, the system supports workplace safety goals.

Of course, any new manufacturing technology has to provide processes that maintain the product's integrity. Regarding material handling of tube, among the most critical points is the aesthetic appearance. This system is suitable for stainless steel, automotive, and other applications in which product quality preservation is paramount. The anthropomorphic technology means that the bundle-loading process is carried out in a carefully coordinated pick-and-place process, rather than the more common lift-and-drop fashion.

Furthermore, all tubes’ contact surfaces can be coated by plastic or rubber to prevent scratches, blemishes, and smudging.

Because robot technology is infinitely flexible, this packing system can pick up and place tube, pipe, or profiles into essentially any bundle shape.