Design and implementation of a pallet moving system through the gallery between buildings

The system should provide automatic pallets movement from the production area to the warehouse area (and in the opposite direction) through the gallery between the premises.

Rusklimat company produces a large amount of products that are palletized and transported to a storage warehouse prior to shipment on an everyday basis. The main tasks were: implementing a system for automatic pallets movement from palletizers to a warehouse, providing:

• moving pallets weighing up to 800kg;
• system productivity up to 50 pallets/hour;
• round-the-clock operation (24/7);
• loading pallets onto a conveyor at three points;
• line occupancy control;
• automatic pallets stacking.

The first mode provides for the pallets transportation from the production area to the warehouse area through the gallery between the production and warehouse premises.

This mode provides for:

• loading the transport system in three places with Rocla trolleys or a forklift;
• scanning the barcode pre-applied on the pallet in manual mode by the operator (manual scanner is included in the delivery);
• After scanning the barcode, the control system (CS) receives data on the cargo from the database (DB) of the CS (nomenclature position of the product, its weight, type of stacking on a pallet, etc.). The cargo database in the control system is generated by downloading and regularly updating the data file received from the Customer’s WMS system;
• further, according to the data received from the CS database, it determines the total weight of the pallet;
• the checkweigher section weighs the pallet in a stationary mode (the pallet stops at the weighing section for 2-5 seconds) and compares the data obtained after weighing with the data from the database;
• CMS control system determines the total amount of products on the pallet and checks it against the measured weight;
• in case of mismatch, the pallet is unloaded to the loading place, a sound and light alarm is triggered;
• further transportation is carried out through vertical sections with a roller platform installed in attached shafts, equipped with a service door and a ladder for maintenance and repair, along the gallery to the warehouse area;
• at the warehouse, pallets are unloaded using a forklift;
• for transporting pallets that do not meet the requirements in advance, the control-weight and measuring control is switched off.

The second mode provides for the transportation of pallets from the warehouse area to the production area through the gallery between the production and warehouse premises.

This mode provides for:

• loading the transport system in the warehouse area using a forklift;
• further transportation is carried out through vertical sections with a roller platform installed in attached shafts equipped with a service door and a ladder for maintenance and repair, along the gallery to the warehouse area;
• unloading a pallet to one of the pallet-free unloading points in the production area. The unloading pallets from the unloading points is carried out by a Rocla-type trolley or a forklift.

1. Preparing technical specifications;
2. Determining the system’s main components;
3. Determining the required equipment to be installed;
4. System production;
5. Delivery to the place of installation;
6. Installation, testing.
7. Putting the system into operation. Putting the system into operation. Commissioning works are being carried out to set up the interaction of electrical equipment systems in various modes.

These works include:

• ensuring intercouplong, adjusting and setting the characteristics and parameters of individual devices and functional groups in order to ensure the specified operating modes;
• testing equipment at idle speed and under load in all operating modes to prepare for operation.

• Conveyor line;
• Control cabinet (Controller, panel, circuit breakers, frequency converters, etc.);
• Light signaling;
• Sensors;
• Top-level software;
• Computer and monitor.

Rusklimat has implemented an automated system for moving pallets from the production area to the warehouse area (and in the opposite direction) through the gallery between the premises at its warehouse.

Benefits obtained

• Saving warehouse space by reducing technological driveways and aisles;
• Increasing transportation speed of transportation and handling of goods, thereby increasing productivity;
• Reducing financial costs by reducing the number of operators;
• Reducing the human factor, increasing the efficiency of cargo handling;
• Automatic control of the goods quantity and types.

VEKAS and CROS companies installed an automated system for moving pallets through the gallery between the production and warehouse premises for Rusklimat. CROS has developed the conveyor system configuration, supplied and installed conveyor equipment. VEKAS developed a conveyor line control system, supplied automation equipment, carried out installation and commissioning.