Successful start-up of flexible dehacking, pack-forming and packaging plant with integrated grinding machine at Brenner F. Wirth GmbH Brick Factory in St. Andrä, Austria
[January 2007] The increasing requirements of the building industry for bricks having heat insulation properties and accuracy of size persuaded the Brenner Brick Factory to install a new dehacking, pack-forming and packaging equipment as a replacement for the existing pack unloading equipment. This comprehensive investment became necessary in order to automatically dehack the packs set on tunnel kiln cars and to stack them on pallets or shrink wrapped according to the customers’ requirements.
At the same time a grinding machine was installed to grind the bricks to an exact size should it be required.
Taking into consideration the existing conditions – especially the arrangement of tracks and halls with different types of hall supports and beams – an optimum solution was found for the arrangement of the plant in connection with proven robot technology and it was installed in cooperation between Brenner and KELLER HCW.
The chosen machinery arrangement allows the transport of bricks and the grouping of new setting layers in layers, or to separate the layers to single rows to transport them through the grinding machine. Since many products are not ground and are therefore able to be transported in several combinations, the flexible machinery allows for the following:
• to achieve a high output with a minimum of machinery
• careful brick transport with the required output
• to reduce wearing of the plant to a minimum
• the capacity of the plant has been considerably improved.
Stacking of dispatch packs is carried out by a robot with a special gripper, which transfers the setting layers as well as the empty pallets. The stacking and dispatch of packs is done either on EURO pallets with the dimensions 1,200 × 800 mm or one-way pallets with the dimensions 1,000 × 900 mm.
Depending on the type of pallet, the empty wooden pallets are conveyed to the pack-forming plant on two storage conveyors and, if required, automatically transferred to the loading position.
The large sized bricks are stacked with their cut face to the bottom by means of a turn-over device.
A film hood machine with integrated shrinking frame is provided for the packaging of stacked packs on pallets. Two film unwinding trestles for two different film sizes and a double film inlet are provided to handle the different pack sizes without the need to manually change the film. The film is automatically prepared, pulled over and shrunk according to the pack size chosen on the control desk.
After packaging, the stacked dispatch packs are collected in groups on a storage conveyor and are then able to be removed by the fork lift.
Additional car pushing and adjusting devices, as well as a new intermediate platform are installed in the unloading track for the kiln car transport equipment.
The complete machinery is controlled by the proven SIMATIC S7 control system programmed by KELLER HCW. Mechanical changes are not required when changing format sizes or pallet changes. By the corresponding pre-selection of sizes on the control desk, the complete plant is automatically adjusted to the requested programme and operating mode. During operation the actual state of the plant is displayed on the control desk via a visualization system. The control system also allows for manual operation of all functions of the plant.
Further information can be found under the following links:
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