INTEGRAL SOLUTIONS FOR PALLET RACKS MANUFACTURING

AUTOMATION OF THE MANUFACTURE OF PALLET RACKS FOR INDUSTRIAL SHELVING

More than 25 year of experience integrating automated solutions for storage system manufacturers.


We have developed robotic solutions for the different manufacturing operations::
- Welding of beams and connectors.
- Hanging up on the painting line.
- Unhanging from the painting line.
- Stacking.
- Wrapping.
- Strapping.
- Transport.

All the solutions are flexible, so they can work with the different models and dimensions only making very few mechanical adjustments.

INTELLIGENT AUTOMATION

- Great flexibility.
- Quality improvement of the final product.
- Optimization of the occupied area.
- Manufacturing waste reduction.
- Manpower costs reduction.
- Better utilization of the manufacturing consumables.
- More than 90% of availability.

- Process management through propietary software.
- Remote connection via web.

ROBOTIC RACK BEAMS WELDING

We have different levels of automation:
- Welding cells with manual load and unload.
- Welding cells with manual load and automatic unload.
- Fully automatic welding cells and 1 single welding station.
- Fully automatic welding cells and 2 welding stations.
- Fully automatic welding cells and 4 welding stations.

We have supplied this type of solutions to manufacturers of different sizes in European and North American countries, using robots and welding machines from the most prestigious brands on the market.

The satisfaction of our customers is the best indicator of the quality and reliability of our solutions.

WELDING PATH CALCULATION SOFTWARE

This application for PC is what makes the difference between our solutions and the rest.
We have developed an application that facilitates the generation of the trajectories that welding robots will follow.
It is a digital twin of the real installation, capable of calculating everything necessary to weld profiles and connectors.
The end user will only need to choose the family of beams and the type and position of connector using a really friendly screen.
You can view every aspect of the configuration, before requesting the system, to perform the welding.
You can also edit the path suggested by the software to achieve the finish you need.

These modifications can be made both from the application of the computer, as from the robot itself, being always stored safely to be used whenever necessary.

AUTOMATIC CONNECTOR LOAD. BIN PICKING

Manual loading of connectors from "bulk" container is a process that can also be automated using.

We use 3D vision cameras and industrial robots to load the connectors in the beam welding cell.

AUTOMATIC TOOL CALCULATION

The welding torches can be deformed due to the high temperatures they are subjected to during the welding process.
Our solution is able to correct these deviations automatically.

Forget about having to reprogram!
Our systems are always perfectly adjusted.

TOUCH SENSING

This search system is used every time the work reference is changed.
To locate with precision the elements to be welded it uses contact detection between the welding wire and the piece to be welded.

In this way, errors accumulated by manufacturing tolerances of the tools and the parts to be welded are eliminated.

PAINT CONVEYOR AUTOMATIC LOADING

The welded beam arrive to the hanging cell by a conveyor.
A handling robot takes the beam and hangs it up on the paint line conveyor.
Our system is able to hang up on continuous movement or "power and free" paint line conveyors. (Beams up to 4,500mm)

The cycle time is always less than 8 seconds, whatever the length of the beam.

ROBOTIC UNHANGING AND STACKING

Once the beam is painted and dry, a robot unhangs it automatically.

Flexible stacking operation, with or without wooden spacers between layers.

It can also make bundles of 4, 6 or 8 beams and transport them to a strapping and wrapping cell before the final palletizing.

BEAM / UPRIGHT PALLETIZING, STRAPPING AND WRAPPING CELLS

Once the beams are unhanged and stacked, they can be wrapped horizontally, strapped and palletized.

We can also palletize uprights, using one or two synchronized robots working simultaneously depending on the length of the upright.

INTEGRAL SYSTEMS

All these individual manufacturing processes and robotic systems can be linked in an integral solution.
We have developed a range of robotic cells with high technological content to link all the manufacturing operations from the roll forming or profiling machine to the final palletizing, passing through the welding and painting processes.
This way, the technology developed by Inser Robotica allows the whole production line to work with light manpower.

Inser Robótica can help our customers design the complete manufacturing line, integrate all the machines and program the robotic systems.