Fully automatic, cycle time optimised handle automation

Beck Automation AG will be presenting the newly developed Beck Bailer at K 2022, which will take place from 19 to 26 October in Düsseldorf. The system enables the fully automatic assembly of metal handles on buckets with a diameter of 175mm to 380mm. The unit is a self-operating system that can be used autonomously thanks to its own control system.

"The Beck Bailer is a trade fair innovation that we will be presenting to the trade public for the first time at K 2022," explains Nino Zehnder, Marketing and Sales Manager at Beck Automation. The Beck Bailer can be operated autonomously thanks to its own control system and is particularly interesting for producers of industrial plastic buckets. With a cycle time of 3.5s per bucket, the system enables the quick assembly of metal handles on different bucket sizes.

The buckets are fed individually to the Bailer via a conveyor belt. They are then precisely positioned and aligned with the bracket hole. Optionally, the alignment can also take place on an additional feature. Via a magazine, the unshaped metal handles can be fed individually, automatically separated and provided with a handle roll. The grip rolls can be fed into the system as bulk material via a spiral conveyor. After the grip roll has been pushed on, the nubs are formed on the metal rod ends and the ends are bent off by 90°. Subsequently, a forming plate and forming rollers bring the metal rod into the desired handle shape. The shaping rollers can be moved and positioned as required via two servo axes, and the end position can be changed via the HMI while the system is running if necessary. All the individual steps for shaping the handle are carried out sequentially at separate stations. "Because the finished moulded handle has a high level of reproducibility as a result, the process stability of the next steps and the quality of the finished packaging product are increased," says Zehnder.

The fully formed handles are conveyed to the conjunction station for final assembly, where the bucket and the handle are precisely aligned and the ends of the handle are pressed into the holes. The position of the handle ends on the product is monitored. If there is no handle or if it is only pressed in correctly on one side, the bucket is not stacked and is conveyed individually to the exit conveyor. The products that are considered good are stacked after this step and conveyed out of the system via a conveyor belt, where the buckets are available for further processing purposes.

The Beck Bailer can handle a wide range of bucket shapes from round, rectangular, square to oval. It is possible to fit buckets with a diameter of 175mm to 380mm and a height of 100mm to 450mm with a metal handle and therefore cover a large bucket bandwidth of approx. 2L to 40L. The bail specifications that can be processed range from 370mm to 645mm in length and 2.7mm to 4.0mm in diameter. In total, the Beck Bailer can be loaded with 1500 metal rods and 500 grip rollers. " As a result, we enable cycle-time-optimised bailer loading. In the event of a production change, the system can be easily and quickly converted. This also applies to the adjustment of the conveyor belts, which do not have to be adjusted in height in the event of a bucket change. Furthermore, we have paid attention to efficient maintenance with simple and cost-effective wear parts," Zehner continues. Thanks to integrated rollers, the Bailer can also be quickly relocated within a production line and positioned at other lines.  After the market launch, the Beck Bailer can be delivered 10 to 12 weeks after the customer's order.

The Beck Bailer will be on public display for the first time at the Beck Automation booth in Hall 12 B36-05.