Abstract:
Purp ose – In this paper, we detail the design and prototyping of a smart automa-
tion solution for de-strapping plastic bonding straps on shipping pallets, which are
loaded with multiple containers secured by a top-cover as they move on a conveyor
belt.
Design/metho dology/approach – The adopted design methodology to have
the system perform its function entails using the least number of sensors and ac-
tuators to arrive at an economic solution from a system design viewpoint. Two
prototypes of the robotic structure are designed and built, one in a research labora-
tory and another in an industrial plant, to perform localized cutting and grabbing
of the plastic straps, with the help of a custom-designed passive localizing struc-
ture. The proposed structure is engineered to locate the plastic straps using one
degree-of-freedom only. An additional strap removal mechanism is designed to
collect the straps and prevent them from interfering with the conveyor.
Findings – The functionality of the system is validated by performing full-process
tests on the developed prototypes in a laboratory setting and under real-life operat-
ing conditions at an automotive original equipment manufacturer (OEM) assembly
facility. Testing showed that the proposed localization system meets the specified
requirements and can be generalized and adapted to other industrial processes
with similar requirements.
Practical implications – The proposed automated system for de-strapping pal-
lets can be deployed in assembly or manufacturing facilities that receive parts in
standard shipping pallets that are used worldwide.
Originality/value – To the authors’ best knowledge, this is the first mechanically-
smart system that is used for the automated removal of straps from shipping pallets
used in assembly facilities. The two main novelties of the proposed design are the
robustness of the strap localization without the need for computer vision and a
large number of degrees-of-freedom, and the critical placement and choice of the
cutting and gripping tools to minimize the number of needed actuators.
