Krones has developed the modular Robobox SynFlow system for container distribution in the section upstream of the packer. According to the description, it is the first use of robotic technology to reliably and gently distribute containers into designated lanes. The company has previously used robotics to group packs into pallet layers, and with Robobox SynFlow the same principle has been adapted to handling individual containers approaching the packaging stage.
In typical infeed layouts, containers are guided into the packer by guide systems that operate according to predefined patterns. In practice, this can result in inconsistent filling of individual lanes, for example when gaps occur in the container flow. As a consequence, during a production batch operators may be forced to intervene manually to keep the packaging process running smoothly through to the end of the run.
Robobox SynFlow applies a different concept: incoming containers are deliberately grouped by a tripod (delta) robot. According to the manufacturer, intelligent robotics identifies exactly how many containers are present on the line and makes on-the-fly adjustments to close gaps in the flow. The objective is to maintain a stable supply of the required number of containers to the packer at all times.
Two capacity versions and application range
Robobox SynFlow is available in two variants. The smaller version, designed for throughputs of up to 55,000 containers per hour, uses a single tripod robot and is intended for layouts where a single container flow is fed into the packer. The second, larger variant targets more complex lines, for example with two labellers, and uses two tripod robots to handle up to 105,000 containers per hour. Both configurations can serve three to nine lanes in the Variopac Pro packer.
The solution is intended to be suitable for common container types, including glass and PET bottles as well as cans, across diameters from 40 to 125 mm. The manufacturer indicates that it is particularly effective when handling specially shaped containers. Positive-fit precision grippers are used to guide containers gently, consistently and accurately to the target position. The system can also rotate containers to orient labels to the desired position within the pack.
Parallel kinematics, drives and safety features
The delta robot operates based on parallel kinematics, with all axes working simultaneously. The robot model used is designed for comparatively lightweight containers, with a focus on precise movement and grouping. Drives are installed in a fixed position, meaning they do not have to be moved along with the rest of the system. Conveyors inside the machine are driven by high-performance permanent-magnet motors, which according to the declaration require up to 50% less power than conventional asynchronous motors.
If disruptions occur, such as fallen containers, the system is designed to detect the changed circumstances and trigger an immediate emergency stop to reduce the risk of damage to the machine or the containers. The paddles used for the gripper guides are attached to the tripod by magnets, intended to act as collision protection, in the event of an impact the part is designed to come off, limiting the risk of mechanical damage.
Reducing the line footprint
Although Robobox SynFlow is a complete machine rather than the guide rails used previously, the solution is intended to reduce the overall footprint of the line. In the smaller version, robotics can adjust container speed variably, down to 16% of the actual line speed. This flexibility is intended to eliminate the need for conveyors to achieve the same effect.
The larger version does not provide variable speed control, but according to the description it requires less space because it does not need an Inliner, allowing labellers, the distribution system and the packer to be connected directly. On average, Robobox SynFlow is stated to reduce a line’s footprint by around 10%.
