UKeyer Intelligent Equipment (Zhejiang) Co., Ltd. (hereinafter referred to as "UKeyer") is a subsidiary of the Ublok Group. It specializes in the research and development of intelligent equipment for AAC products, drawing on the group’s over 20 years of technological experience. UKeyer offers a variety of services such as the "Three 30" one-stop aeration solution, AAC factory technological upgrades (including AAC product packaging systems, AAC steam-saving systems, AAC factory intelligent security systems, and AAC waste recycling systems), as well as project consulting and operational services for AAC factories. This article takes the reciprocating double stack packaging and in-line flipping system as an example to illustrate the application of the AAC product packaging system in the production of autoclaved aerated concrete panels.

Background

There are two common methods of off-line conveying of AAC panels: chain and square pipe conveyor systems, and roller conveyors.

Chain and square pipe conveyor system

This system uses square pipe components mounted on a conveyor chain to transport finished panels, which can be automatically packaged and then flipped for forklift transport. While efficient and simple, it has certain drawbacks. For example, the segmented conveyor chains can cause panel damage during transitions, affecting quality, and the inconsistent alignment of the support points can lead to cracks in the lower stack of panels.

Roller conveyors

In this method, the panels are conveyed by rollers, and while it is simple and cost-effective, this method, too, has its drawbacks. Firstly, it is difficult to maintain consistent support points, which may cause cracks during transportation, and secondly, rollers tend to wear, leading to misalignment and corner damage.

Solution

UKeyer's solution involves using a reciprocating panel conveyor car with a flat surface to increase contact with the panel, resolving issues with cracks caused by inconsistent support points. Fixed packing stations and mobile packing machines are used for automatic packaging. Two reciprocating conveyor cars ensure efficiency, while two robotic arms equipped with grippers handle the automatic collection and placement of support blocks, enhancing safety and automation.

Innovation and advantages of the reciprocating double stack packaging and in-line flipping system

1. Damage prevention: The panels remain static during transportation, preventing damage from sliding friction.

2. Servo-controlled automation: The system allows for rapid transport, automatic length detection, and packaging.

3. Efficiency: The system supports simultaneous packaging, flipping, and forklift transport of two half-stacks of panels.

4. Flexible operation: Both vertical and horizontal stacking and packaging requirements can be handled.

5. High packaging efficiency: The mobile double-layer packaging machine increases efficiency by packaging two half-stacks simultaneously.

6. Capacity: The system is designed for high-capacity production, reducing investment and space requirements.

7. Robotic handling: Intelligent robots automatically handle the support blocks, enhancing safety and automation.

Results

The innovative system, now implemented at the Ublok New Materials (Changxing) factory, significantly improved panel transportation and packaging processes. By introducing robots and mobile packing machines, the system ensures higher efficiency and better safety.

Conclusion

Continuous upgrades to the AAC panel on-line flipping system have demonstrated that smart technologies like sensors, digital programming, and robotics greatly enhance operational efficiency, product quality, and safety while reducing labor intensity and operational costs for businesses.