Innovative, fully automated solution for Paver Block Offline Stacking
Reduced cycle time and labor costs in paver block handling
- At a time 16 Paver blocks in a layer, with gaps maintained for drying
- Clamp all the blocks using 4 jaws of the pneumatic gripper and lift them from the conveyor
- Place the blocks on a Pallet and de-clamp (1 layer of the paver blocks)
- Repeat the process up to 19 times to build a stack of up to 20 levels
- The Paver Blocks are then strapped and the pallet is moved for final dispatch, as required, using a forklift
Challenges and innovations
Variants and weight
There were Seven different types of paver blocks. The sizes ranged from 4”x 4” to 8”x 8” and Pavers blocks also varied in shape. The weights of the blocks ranged from from 60 kg to 120 kg. Weight carrying capacity given to system was 200 kg.
A single gripper was developed to ensure safe and efficient handling of the blocks of different shapes, sizes and weight. The pneumatically operated gripper had 4 jaws to clamp and lift the paver blocks. Additionally, 900 rotation functionality was included for zigzag shaped paver blocks.
When it comes to lifting things, the coefficient of friction is very important. Here coefficient of friction was kept high, which ensured that paver blocks remain intact, without falling, even when the weight is high or contact area between the gripper and paver blocks is relatively less.
Various heights while placing the stack on the conveyor
Pavers are to be stacked in 20 layers on the conveyor. To achieve this 20 proximity sensors were provided to sense 20 different heights and levels. Also limit switches were provided for the telescopic movement of the gripper.
Ensuring highest safety for the Operators and equipment
Limit switches were provided to avoid over-travel of the System during the operation to ensure highest safety for the operator and the equipment.
Earlier the manual process required a minimum of 5 labours and at least 20-30 mins to complete the operation. After installation of the ElbowLIFTTM, the entire task is performed automatically in less than 5 minutes. Additional benefits of the solution included safer operations, lesser product wastage due to damage, lower operational complexity and significantly higher throughput.
Up to 80% reduction in Labor required for the task.
Up to 90% savings in cycle time, as compared to manual handling