Q-SHAPE

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Description of the stationary pallet changer Q-SHAPE

This system guarantees productivity of 50 pallets per hour.

Toppy Q-Shape is a fully automatic pallet changer that allows a very quick pallet change. The lower platform is equipped with a roller conveyor so that the machine can be placed in a logistic line keeping a unidirectional flow.

The Toppy Q Shape is fast and strongly designed for a 24/7 operation. Depending on the product and the particular load/box mosaic configuration Toppy Q Shape can rotate the load at 95°, 120°, 180° exchanging angle.

This fully automatic system is equipped with a centering system in order to allow the system to center the load from a wooden pallet (800×1200 mm) in the center of the receiving plastic pallet (1000×1200 mm).

How does the pallet change operation take place?

Below we describe the logistics system phases needed to replace a wooden pallet with a plastic pallet. Vice versa, the operation can be managed via PLC with the adequate program:

The operating logic of the system is illustrated below:

1. The operator loads on the input roll conveyor the pallet with the load. The wooden pallet with the load passes through the muting body reflector safety barrier, which is then driven by the roll conveyors to the turning table equipped with roll/chain conveyors.

2. The wooden pallet with the load is driven by the system from the exchange roll/chain conveyor to the Q-Shape roll conveyor.

3. The load on the wooden pallet is driven by the roll conveyors towards the Q – Shape. The wooden pallet with the load stops into the Q – Shape frame against the folding bar.

4. During the execution of the cycle, the plastic pallet stacker leaves an empty plastic pallet on the line, ready to be used.
5. The system detects the wooden pallet size that has been loaded. With this info, the system can choose the proper pallet stacker during the pallet changing cycle.

6. The wooden pallet with the load is locked by a holding device equipped on the lower platform of Q – Shape.

7. The Q – Shape turns upside down. After the rotation of 180°, the wooden pallet is now over the load.

8. The lower platform, holding the wooden pallet, turns from 180° to 0°. After the 180° rotation, the wooden pallet is at the height of the roll conveyors. The wooden pallet exits from the Q – Shape and is brought back to the proper pallet stacker.

9. Now, the plastic pallet is driven by the line onto Toppy Q – Shape. The plastic pallet is locked by a holding device equipped on the lower platform of Q – Shape. The PLC automatically centers the pallet with the load. The lower platform turns from 0° to 180° holding the plastic pallet. In this position, the plastic pallet is over the load. The Toppy Q- Shape turns upside down from 180° to 0°. After the rotation of 180 degrees, the plastic pallet is now under the load. The upper compactor lifts up, at the same time the lower platform, holding the plastic pallet with the load, goes down. In this position, the plastic pallet and the load are at the height of the roll conveyors.

10. The plastic pallet with the load exits from the Q – Shape and is driven by the conveyor on the logistic line.

11. The plastic pallet with the load is driven by the line from the Q-Shape conveyor to the exchange roll/chain conveyor.

12. The plastic pallet with the load travels from an exchange roll/ chain conveyor to a roller conveyor.

13. The plastic pallet with the load is driven by the line to the de-dusting cabin, ready to be dust-dried.

14. After the de-dusting cycle, the plastic pallet with the load exit from the dedusting cabin and reaches the output conveyor, where an operator, equipped with a forklift, has to remove it.

SECURITY SYSTEM

The MEKKANO gate combines with the components for the EASY BARRIER perimeter protection overcoming the limits of welded framing.

Using the pre-painted elements and original connecting systems with screw fastening, it is possible to assemble gates of different width in a rapid and clean way, making them ready to be installed. With the same elements, the MEKKANO gate can be prepared in the right or left configuration, with outward or inward opening.

All the configurations of the gate can be obtained either for the version with the upper support or without it. The high strength of the connecting elements makes the structure as rigid as a classic welded frame.

What is your need?

1. FROM WOODEN PALLET TO PLASTIC PALLET: In many companies, there must be a separation between the goods reception area, where the shipping pallet generally made of woods are stopped, to the “white area” of the warehouse, where sanitized pallets (aluminum or plastic) are used. In our range of production there is also multiple dedusting cabins able to decontaminate the products and the air in order to maintain the certified environment.

2. SAVINGS AND AUTOMATIC: For companies with large numbers of pallets to handle, we usually recommend automatic solutions, able to perform with many pallets every hour. Our system reduces the number of operators required for the production process and therefore the cost of labor.

3. STANDARDIZATION OF THE INTERNAL PALLET and CENTERING PRODUCTS: Modern production processes increasingly need to standardize all pallets that move products during the production cycle and often also in warehouse, which are usually automated. Our pallet changers system can suit perfectly because they are able to handle heavy goods and / or fragile products whatever is the incoming pallet, replace it with a used one and center the product. It’s also possible to carry our automatic packaging operations.

4. SHIPPING with SLIP SHEET WITHOUT PALLET: It’s essential to save on the transport cost of the shipment of finished products. The pallet represents an important cost for those with a high flow of outgoing products. In addition, without the use of the pallet in the shipment, companies greatly increase the number of products that can be stowed. Our Inverter pallet changer placed at the end of the production process, are able to insert automatically a slipsheet under the load, which will be ready for shipment without the pallet. The pallet stackers will automatically stack all the pallets removed.

5. SAFETY and WORK REDUCTION FOR OPERATORS: Our Pallet Inverter significantly increase safety within the process, as the manual work of operators is seriously reduced. Our pallet Inverter systems are very safe as they are equipped with advanced safety systems. The access to dangerous areas is controlled by doors with sensors, photocells or laser scanners in order to prevent dangerous cycles.

6. PICKING & AGV: We offer a logistics line able to automate the composition of the load. The pallet management is automated with the AGV system, in order to facilitate the operator in the composition of the load.

7. CLEANING, DEDUSTING AND SANITIZING: In the production range with our pallet inverter can be implemented a sanitization or dedusting system. We usually supply these systems to companies that need to separate the “white” area from the “grey”. Where necessary, there are inserted few particle counters in order to check the cleanliness and sanitization of the air before opening the doors. The main objective is to avoid that too high numbers of particles remain suspended in certified atmospheres of UNI EN ISO 14644-1 certified environments (Federal Standard 209D, 209E in the United States).