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Linear Actuators: Optimizing Robotic De-Stacking of Heavy Pallets

Linear Actuators for Vertical Robotic Movement

Linear actuators used for vertical movement

Overloaded actuators need customizing for enhanced pivoting alignment

Automation continues to evolve and improve efficiency, especially on the production-line. While the initial system integration can incur higher start-up costs, manufacturing lines that run 24/7 save thousands in annual labor costs.

This was the case for a newly designed bottle cleanser packaging and sorting conveyor that relied on actuating systems in a de-stacker. During the early stages of testing, engineers found their first actuators to become loaded beyond their rating, and would subsequently become damaged when the system was misaligned by out-of-position product pallets. This test revealed potential machine shutdowns and safety concerns.

Components:

Actuators: MTB

Retrofit or OEM:

OEM

Problem:

A newly designed bottle cleanser packaging and sorting conveyor was suffering from linear actuators being loaded beyond their rating, and damaged when the system misaligned by out of position product pallets.

Solution:

PBC Linear installed new linear actuators (same model and size) with dual carriages to absorb higher moments. They also designed and manufactured a special hinged mount to attach the de-stacker to the actuators in order to prevent breakage and machine shutdown.

Linear actuators from PBC Linear, specifically the MT series, revolutionized the robotic de-stacking process for a packaging conveyor system by delivering durable, precise linear motion to handle 272-pound pallets of empty bottle boxes. Positioned at the forefront of the conveyor, the de-stacker cycles through stacked pallets, moving them into position for lowering onto the transfer conveyor. The MT linear actuators were selected for their ability to drive boxes horizontally into the lowering position and vertically raise and lower them, requiring smooth motion, high load tolerance, and control under demanding conditions.

Initially, the MT linear actuators performed well, leveraging their steel-reinforced timing belt for high load capacity, ball-guided rail system for smooth velocity control, and T-slots for versatile mounting. However, excessive moment loads from misaligned boxes strained vertically mounted actuators, causing shutdowns. PBC Linear engineers addressed this by upgrading to dual-carriage MT linear actuators of the same model, paired with a custom spring-loaded, hinged mounting plate. This design absorbed high moment loads by allowing the actuators to pivot during misalignment, preventing breakage and ensuring continuous operation.

The enhanced linear actuators with dual carriages and custom mounts enabled the de-stacker to operate seamlessly, maintaining production uptime. The manufacturer praised the robust packaging system and PBC Linear’s expert support, highlighting the MT linear actuators’ critical role in achieving reliable, efficient de-stacking performance.

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