Recent Projects

What We've Been Up To

2018 is off to a bustling start at PHC. We’ve had the opportunity to work on quite a few compelling projects addressing a wide array of production challenges. We’re happy to share below a handful of the projects we’ve been working so far this year.

Bag Palletizing

Our team created a Robotic Palletizing Cell for accepting closed bags from a conveyor, conveying them into a Palletizing Cell, a robot with end-of-arm-tooling picks them up and places on a pallet. There are be two pallet loading areas. The robot loads one pallet at a time. When that pallet is completed, the robot moves to the second build location. A fork truck operator takes away the full pallet of while the opposite pallet is being loaded. The conveyor at the infeed of the Palletizing cell is Motor Driven Roller (MDR).

A perimeter guard with two entry points is included. Light curtains are included at each entry point. The forklift driver requests access to the cell with a pushbutton, when it is safe to enter the cell, the safety circuits indicates with a signal light and mute the light curtains to allow access to remove the full pallet. If the light curtains are broken when not muted the safety circuits will shut down the robot to protect the operator. The palletizer uses a Kawasaki robot CP180L robot with an E03 Controller. The robot has a maximum payload of 180 kg including the end effector.

The construction of the cell is powder coated mild steel except for the MDR which Stainless Steel rollers mounted in a powder coated mild steel structure.

Bottle Orientation with Vision System

Our team engineered and manufactured bottle rotating equipment to identify labels and orient bottles consistently for label or ink jet application.

Mattop conveyors are used to transport and accumulate the bottles into and out of the bottle orienting equipment and through the vision system. The conveyors feature mattop chain with an open frame design. Mounted to the conveyor is a servo powered belt that spins each bottle to consistently orient the bottles for labeling or ink jet coding. The bottles are indexed into the rotation zone one at a time via a motorized starwheel which can hold back some back pressure while indexing the bottles. The back pressure is allowed to spill onto the accumulation system which is a “bi-flow” style of accumulation.

Stainless Steel Empty Tray/Case Conveyors

Our team engineered and manufactured stainless steel open top conveyors for the transport of empty cases and trays. The conveyors are exposed to a wet and humid environment. The conveyors are used for empty case/tray transport to a palletizing cell. There are multiple lines included and all are capable of transporting the wide variety of cases/trays. All of the conveyors elevated at 150.0” are ceiling hung and placed in a trough. The trough provides the guides for the cases and the trays. Handwheel adjustable product guides are included on the decline conveyors. These rails have an infeed flare in order to center the cases/trays so that they are on center when feeding the existing palletizer infeed conveyors. A single handwheel is included for each decline area. In the area where conveyors are used to decline the cases/trays, friction top belting is used in order to control the cases/trays through the decline.

Also included is a simple pneumatic divert that takes a single stream of cases/trays and evenly divides them into two discharge lanes. A pneumatic pop-up stop is used to assist in the actuation of the gate as it divides the stream into two lanes. The pop-up stop elevates between the drive of one conveyor and the idle of another.

Linear Servo Indexing

Our team engineered and manufacture a quantity of (2) two linear servo indexing stations to be mounted on existing equipment.

The linear servo indexing assembly is controlled by a Linmot linear servo and Ethernet servo drive with Safe Torque Off. The Linmot servo drives are controlled via add-on instruction through the PLC. The servo will be mounted within a “thruster style” pusher assembly which will provide a reliable method of actuation and will be designed with minimal pinch point for operator safety. A frame mounted guard structure is provided to add another layer of safety for operators. Structure consists of bolt-together mild steel powder coated components with bolt on Lexan panels.

A 480V AC electrical enclosure will be provided for each linear servo indexing assembly. Each enclosure will house a main disconnect, power supply, Linmot servo drive, servo cable, fusing, and terminal blocks.

Case Elevation

Our team built an incline conveyor and gravity roller conveyor for loading/unloading of full boxes of supplies. The conveyor’s purpose is to assist with getting boxes of supplies from the main floor to the second floor, and getting additional supplies from the second floor to the main floor.

The conveyor is an incline conveyor that includes a flat section at the base, go up a 6’ radius vertical curve, then a 21 degree incline and nose-over at the top. This incline conveyor is center-driven, and reversible.

On the second floor, after the incline, a gravity roller conveyor is used. A 90 degree curve with tapered rollers, and a straight section with fixed end stop.