Hella Innenleuchten-Systeme GmbH

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Task

The company Hella Innenleuchten-Systeme GmbH (Interior Light Systems) had built a new assembly centre for the automatic assembly of interior lights. Material should be supplied to and removed from this assembly centre via new conveyor line. For this reason a new conveyor system for bins was installed with connection to a robot which automatically palletizes the empty bins and caps.

Solution

The assembly centre which consists of eight assembly cells, is automatically supplied with the material. Large-volume parts are delivered directly to the assembly cells via pallets. Small-volume parts are conveyed to the assembly cells in plastic bins of the dimensions 600 x 400 x 320 mm and 300 x 400 x 200 mm. Three of the assembly cells are permanently connected with the conveyor system. They are supplied with full bins, empty bins are removed. All other assembly cells are manually supplied with bins at two determined stations. The empty bins are manually placed on the return line.

The bins which were requested from the assembly centre are automatically removed from the small parts stock and transferred to the new conveyor system „ feed assembly cell“ via existing conveyors. During this process the bins are scanned in order to convey them to the places of destination. In case of big bins the caps are automatically removed for palletizing by robot. Subsequently the bins are transported to the corresponding assembly cell via conveyor section. At the three connected assembly cells the bins are removed and accumulated. The material being destined for the other assembly cells is provided at the two determined stations and manually removed. At the connected assembly cells the empty bins are automatically transferred to the return line, whereas this has to be done manually at the other assembly cells. The bins are delivered to the palletizing robot via return line. Prior to palletizing, the bins are turned about-face in order to put the opening down. Thereafter the uni-type palletizing of both bins takes place.

Since there is a small number of minor bins and low-volume caps, palletizing of those is realized at determined places and change of pallets is done manually. Due to the volume of the large bins, change of pallets must take place more frequently. The empty pallets are separated via pallet magazine and conveyed to the palletizing place. After palletizing has finished the pallets are automatically conveyed to an accumulating section. Removal of the finished and palletized goods takes place via manual lift truck at the end of the accumulation section.

Material to be conveyed

Plastic bins

600x400x320mm, max. weight 30 kg

300x400x200mm, max. weight 20 kg

Euro-pallets, 1.200 x 800 x 600/2.000 mm (LxWxH), max. weight 300 kg

Conveying capacity

approx. 200 bins /shift, thereof approx. 80% large bins

Palletizing capacity

160 caps /shift (1 pallet /shift)

160 large bins /shift (7 pallets /shift)

40 small bins /shift (1,5 pallets /shift)

Incorporated components

Roller conveyors, accumulating roller conveyors, transfer units, turning station, palletizing robot, protective guarding, empty pallet magazine, chain transfer unit, roller conveyor for pallets

Control unit

Siemens S7-300

References

Beewen GmbH & Co. KG

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Task Due to the varying requirements in the automotive industry, the company Hella has to provide different types of packaging and shipping for different customers. Therefore an ...

Task With the company Roth & Rau AG, general contractor and supplier for complete cell lines, an order was placed by the company Millinet for delivery of a compl...

Multy-Storey Magazine Equipment + Storage for EURO-Pallets Task In a previous planning contract Förster & Krause determined the performance details for a new Spare Parts Storage - Europe and th...

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ABB AG

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Task The company Wigo-Werk built a new storage for dangerous goods on its existing site. Due to the high pallet turnover per day the storage ought to be c...

Task The company Medice extended its range of products through purchase. As a consequence the whole order picking system had to be redesigned and order picking ought...

Beewen GmbH & Co. KG

ebm-papst St. Georgen GmbH & Co. KG

Geha German Hardcopy AG

Bonfiglioli Deutschland GmbH

Steinhaus GmbH

Roth+Rau AG - Hyundai Heavy Industries C

Plastal GmbH

Hella Fahrzeugkomponenten GmbH

Roth+Rau AG - Millinet Solar Co. Ltd.

Bürstner GmbH

Beewen GmbH & Co. KG

ABB AG

PPS P.E.T. Packaging Solution AG

Wigo-Werk Kreuznach Chemische Fabrik Gmb

Medice Arzneimittel Pütter GmbH & Co. KG