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Competence

Robotic Section Packaging

We plan, build and commission robotic stacking and packaging for long-product mills — from the analysis of your product list to the finished line.

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The problem

Packaging is the last manual step of the line

In many section mills the bars are still counted, turned and stacked by hand at the end of the line. It is heavy, repetitive work close to moving loads, and the product mix — different sections, lengths, bar counts and bundle heights — makes it hard to automate with a fixed machine.

A robot cell handles that variety from the recipe. Whether it suits your plant depends on your product list, so we start there.

Competence

What we do

1Product data analysis and feasibility

  • We go through the plant’s complete product, length and bundle list line by line and assess thousands of product–length combinations in one tool.
  • For every product we check bundle size, robot payload, pick method and hourly capacity.
  • Products that are hard to pack by robot, and inconsistencies in the customer data, come out at the quotation stage.
  • The capacity reference can be chosen: theoretical, mill, straightening, packaging or cutting speed.

2Magnetic gripper (EOAT) design

  • Switchable permanent-magnet grippers: the load is not released if power or air is lost.
  • Gripper and pole shoes selected for the section and wall thickness; on thin sections a contact face that does not pick the neighbouring bar.
  • Part-present, double-part and gripper open/closed sensing.
  • Gripper mass list, robot payload, centre of gravity and inertia calculation.

3Pitch spreading and nested stacking

  • For asymmetric sections such as bulb flats: alternating upright and inverted layers, with the bulbs sitting in the gaps of the layer below.
  • Servo pitch spreading on the gripper, done while the robot moves — cycle time does not increase.
  • Pitch is set from the recipe; no mechanical adjustment at product change.
  • Layers are turned with the robot wrist; no separate turning mechanism is needed.

4Multi-robot synchronisation

  • Calculation of the number of robots and pick-point spacing to carry long bars within the deflection limit.
  • Several robots carrying one load together, with load sharing between robots.
  • Work with 500 kg class industrial robots.

5Line integration

  • From the straightener exit to bundle discharge: transfer chains, layer separation, alignment to the robot pick position and the bundle roller table.
  • Detection and handling of half bundles at the end of a batch.
  • Manual packaging with the crane, without the robot, if there is a fault.

6Simulation and verification

  • 3D offline simulation of the robot cell, collision analysis and cycle-time verification.
  • Simulation source files are handed over to the customer.

7Electrical, automation and traceability

  • Siemens-based PLC, safety system, drives and robot integration (Siemens Solution Partner).
  • SCADA/MIS: bar count per shift, live weight, per-bundle data and reporting.
  • Panel design and manufacture, site installation and commissioning.

8Complete manufacturing

  • Not only automation: mechanical equipment, grippers and panels are manufactured and the line is installed as one scope.
  • One contact from data analysis to commissioning.

Products

Product groups we pack

  • Equal and unequal angles
  • Flats
  • Squares
  • Rounds
  • Half rounds
  • UPN / UPE / NPU
  • IPE / NPI
  • I sections
  • Bulb flats (HP)
  • Bar lengths of 13–25 m; the same size in different lengths, bar counts, base counts and bundle heights
  • Curved bars: packaging within the standard straightness tolerance and with the total deflection of long lengths

How we work

Six steps from your list to the running line

  1. 1Product list and line dataWe receive the product, length and bundle list and the line data.
  2. 2Data analysis and feasibility reportEvery product–length combination is checked; hard cases are reported.
  3. 3Concept designNumber of robots, gripper and line layout.
  4. 4Simulation3D simulation and cycle-time verification.
  5. 5Engineering, manufacturing, installationDetail design, manufacture and site installation.
  6. 6Commissioning and supportCommissioning, training and up to 10 years of spare-parts support.

Deliverables

What you receive

  • Concept and detail design
  • Drawings as PDF together with DWG/DXF and 3D CAD source files
  • Electrical design, I/O and cable lists
  • Bill of materials (BOM)
  • Simulation source files
  • Operating and maintenance documents

FAQ

Frequently asked questions

Which products can be packed?

Equal and unequal angles, flats, squares, rounds, half rounds, UPN/UPE/NPU, IPE/NPI and I sections and bulb flats, in bar lengths of 13–25 m. Whether each product in your list can be packed by robot is shown in the feasibility analysis.

Can it be added to an existing line?

Yes. We integrate the robot cell between the straightener exit and bundle discharge — transfer chains, layer separation, alignment and the bundle roller table — based on your line data.

What happens if a robot fails?

The line is designed so that bundles can be made manually with the crane, without the robot. Permanent-magnet grippers do not drop the load if power or air is lost.

How long does a product change take?

Pitch and stacking pattern come from the recipe, so a product change needs no mechanical adjustment on the gripper. Gripper or pole-shoe changes for very different sections are planned in the concept phase.

What do you need for a feasibility study?

The product, length and bundle list as an Excel file and basic line data: line speeds, the current packaging method and the available space. We take it from there.

Send your product and bundle list as an Excel file and we will assess feasibility.

info@adeptek.com.tr

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