SETUP UNIT LOAD SCREENS


SETUP UNIT LOAD SCREENS

1. SETUP UNIT LOAD SCREEN

A unit load consists of all the units that are stacked in layers on a pallet. You must set up the unit load before you can run PalletTool. There are two types of unit loads:

  • Standard Load - all layers contain the same product.

  • Mixed Layer Load - each layer can be a separate product.

Table 1.  SETUP Unit Load Screen Items

ITEM DESCRIPTION

ITEM

This item is the row number for each unit load as it appears on screen.

UNIT LOAD

This item indicates the unit load.

ID NAME

This item is a text field that describes each unit load.

Table 2.  Unit Load Setup Items

MENU ITEM DESCRIPTION

Unit Load

This item specifies the number and product ID of the unit load you are setting up.

Unit length (O.D)units: mm

This item specifies the outside dimension of the length of the unit. (mm = in. x 25.4)

Unit width (O.D)units: mm

This item specifies the outside dimension of the width of the unit. (mm = in. x 25.4)

Unit height (O.D)units: mm

This item specifies the outside dimension of the height of the unit. (mm = in. x 25.4)

Unit weight units: kg

This item specifies the weight of one box or bag in the unitload in kilograms. The unit weight is used by PalletTool Turbo to set the proper PAYLOAD during production run. The PAYLOAD is calculated dynamically in conjunction with the gripper weight which is specified in the Gripper Setup menu. When a robot picks and drops multiple parts, the PAYLOAD is automatically calculated. The PAYLOADS that PalletTool Turbo uses are PAYLOAD 1 and PAYLOAD 2. The PAYLOAD instructions and the automatic calculations are integrated with the standard TP programs provided with PalletTool. Setting the proper unit weight will help the robot realize better cycle time and performance from the Collision Guard function. The unit weight property is available only from version V7.70P/20 and higher.

Pallet length units: mm

This item specifies the length of the pallet. (mm = in. x 25.4)

Pallet width units: mm

This item specifies the width of the pallet. (mm = in. x 25.4)

Pallet height units: mm

This item specifies the distance between where the pallet station was taught and where the surface of the pallet will actually be. If P1 is taught on the pallet, the pallet height is zero. If all the pallets are the same height , put the fixture plate on the pallet and teach the station on the pallet; the pallet height is zero. In Unit Load Setup, set the pallet height = 0. (mm = in. x 25.4) If the pallet heights vary for each unit load, or if you cannot teach the station with the pallet in place, put the fixture plate on the floor or conveyor, teach the station on the floor or conveyor, and assign a pallet height for each unit load in Unit Load Setup.

Pattern type :

Note: The following pattern types are only available when you use PalletTool PC to set up the unit load

Column

Interlock

Trilock

Spiral

Brick

Diagonal

Aug-Diag

Unique

Optimal

This item specifies the pattern type of the unit load.

The following items appear when F4, [CHOICE] is pressed:

Unique

The following items appear when DETAIL is pressed:

Layer flips

The following items appear when DETAIL is pressed:

Flip Specifies that the selected layer is flipped

Noflip Specifies that the selected layer is not flipped

Units per layer Specifies the number of units on the layer

Unit load length Specifies the length of the completed unit load , NOT the pallet.

Unit load width Specifies the width of the completed unit load , NOT the pallet

Unit load height Specifies the height of the unit load

Layer spacing: Specifies the spacing between layers

If set to 0 , no slip sheets will be used

If set to any number greater than 0 , number indicates thickness of slip sheet, and enables slip sheet placement. The following items appear when DETAIL is pressed

Spacing Between Pallet top & Layer 1

Spacing Between Layer 1 and 2

If 5 layers are specified, then you get 6 lines for spacing between layers.

Flip type

This item specifies whether or not the selected layer in the unit load is flipped. NOTE: 90° flips are allowed for unique and column patterns only.

Layers high

This item specifies the number of layers that will be in the finished unit load.

2. SETUP UNIT LOAD PATTERNS SCREEN

Table 3.  SETUP Unit Load Pattern Screen Items

ITEM DESCRIPTION

Layer flips

This item displays the Layer flips DETAIL screen from which you can specify whether existing layers are flipped.

Units per layer

This item pecifies the number of units on the layer.

Unit load length

This item specifies the length of the completed unit load , NOT the pallet.

Unit load width

This item specifies the width of the completed unit load , NOT the pallet.

Unit load height

This item specifies the height of the unit load.

Layer spacing

This item specifies the spacing between layers.

Pattern coordinates

This item displays the Pattern coordinates DETAIL screen from which you can enter the x and y coordinates of the center of each unit in the pattern relative to the pattern origin.

3. SETUP UNIT LOAD LAYER SCREEN

Table 4.  SETUP Unit Load LAYER Screen Items

ITEM DESCRIPTION

LAYER

This item identifies each layer on the unit load.

STATUS

This item indicates whether a layer is flipped or normal (unflipped).

4. SETUP UNIT LOAD SPACING SCREEN

Table 5.  SETUP Unit Load Spacing Screen Items

ITEM DESCRIPTION

Pallet top & layer 1

This item indicates the spacing between the top of the pallet and layer 1.

Layer 1 and 2

This item indicates the spacing between two layers.

On Top Layer

This item indicates the spacing of the top layer.

5. SETUP PATTERN COORDINATES DETAIL SCREEN

Table 6.  SETUP Pattern Coordinates DETAIL Screen Items

ITEM DESCRIPTION

UNIT

This item indicates the currently selected unit.

LT_OFFSET

This item is the offset from orientation of the length of the pallet.

WD_OFFSET

This item is the offset from orientation of the width of the pallet.

ORIENTATION

This item is the orientation of the unit on the pallet.