TopTier RoboTier controls consist of a Fanuc robot controller functioning as an electronic slave to an Allen Bradley PLC and AB 12" color touchscreen PC HMI. The control interface is easy to use and eliminates any requirement for robot programming by the end user. The robot functions as a component in a comprehensive palletizing solution.
The Fanuc M-710 robot with Fanuc controller provides exceptional reliability and speed capabilities. The robot arm is used only in its most advantageous form: a highly reliable pick and place device running a very brief operating instruction set that never changes. The robot program establishes the work envelope, move profiles, and interface with the PLC master controller. Teach pendant processing, complicated robot program touch-up, and specialized robot programming skills are not required.
The AB CompactLogix PLC master controller using RSLogix 5000 software interfaces with the PC HMI to provide seamless real-time robot movement instructions via a dedicated Ethernet connection. The electronic slave relationship between the PLC master and robot controller facilitates all robot actions including automatic operations, manual moves, and any error recovery. All relevant robot-generated messages for maintenance, errors, and other robot specific information are displayed on the HMI.
The PLC master controller includes CAPE PACK enhanced EasyStack®, TopTier's industry leading palletizer PLC code. TopTier standards such as networked VFD's, advanced diagnostics, and Ethernet communications are all integrated into RoboTier palletizers. RoboTier palletizers include all TopTier comprehensive safety features, including full Category III safety cage frame, muting light curtain load exit protection, redundant hoist fall protection, fiber optic breach detection circuit, and integration with Fanuc's robot safety system. TopTier's safety features meet or exceed all industry requirements.
The touchscreen HMI provides user interface to all palletizer functions. Running on the PC HMI, AB FactoryTalk® View, CAPE PACK pallet load development software, and EasyStack provides access to all robot functions via the PLC. New patterns can be programmed at the HMI quickly and easily. The PC also collects performance data that can be interfaced to a host. All maintenance manuals, exploded view drawings, operator manuals, and OEM manuals are accessible at the touchscreen. Factory support via remote access to the PLC is available at the discretion of the end user.
CAPEPACK
TopTier RoboTier Palletizers include a 12" PC color touchscreen HMI from Allen Bradley running industry standard CAPE PACK software for load creation and pattern programming. After the operator performs the simple CAPE PACK load creation steps a new pattern is automatically generated for palletizing. CAPE PACK provides nearly any conceivable pattern option based on case, bag, or tray size allowing selection of column, interlocked, spiral and other industry standard patterns. Different pallet sizes, load overhang or underhang, and pallet-less loads are all standard CAPE PACK load generation capabilities. In the event that none of the pattern configurations generated by CAPE PACK are suitable for the application, the layer editor function provides the option to create any alternative pattern.
TopTier CTP (CAPE PACK To Palletizer) software interprets the CAPE PACK data, optimizes pick and place routines for single or multi pick product handling, and generates a Spread Pattern for palletizer operations. A graphic depiction of the load is presented for operator confirmation after automated error checking. Load build options may be added to a confirmed pattern.
Exclusively from TopTier, Spread Pattern Load Building allows the robot with bottom product support tooling to rapidly pick and place products to loose positions on the RoboTier layer apron. The apron clamps and then deposits the layer in a tight finished condition. The traditional task of tuning the robot program to tighten finished layer condition is eliminated. Spread Pattern Load Building is immune to challenges created by common product irregularities such as bulging, minor height variations, parallelogram cases, and other challenges that often undermine the effectiveness of robot palletizing. Bottom support product picking provides the most secure and flexible method available for product handling, capable of reliably palletizing nearly any sealed, open-top, display, tray or overwrapped tray-less product.
The parameters for optional features such as pallet liner insertion, tie sheet insertion, or concurrent stretch wrap are entered on the HMI touchscreen. Concurrent wrapping options include film stretch, number of bottom wraps or top wraps, film overlap, and other options to build a stabilized fully wrapped load concurrent with load building.
Anyone experienced with CAPE PACK software can program a new pattern for RoboTier in under two minutes. Users unfamiliar with CAPE PACK will quickly understand the intuitive pallet generation program and can comfortably program new patterns using instructions available on the HMI touchscreen. The combination of CAPE PACK and TopTier CTP provides a simple yet comprehensive pallet load programming solution - all without robot programming. Additional CAPEPACK information...
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