The Customer

“Optimal” is a service provider in the media industry that produces and distributes CDs, DVDs, vinyl records, and much more for the European market from its facility in Röbel.

Optimal is a wholly owned subsidiary of “edel AG” and was founded in 1990.

Technical Specifications

• Material to be conveyed: Metal transport box (Schäfer)
• Capacity: up to 20 paper containers per hour
• Travel distance: 10,000 mm
• Rotation angle: 360°
• Lifting height: 700 mm
• Communication with: AGVs, press containers, high-speed doors
• Drives: SEW Geared Motors
• Control System: S7-312C

Function

Various production processes generate paper waste throughout the company’s printing area, which is collected in designated paper bins. The paper bins are transported by the facility’s existing automated guided vehicles (AGVs) to a transfer station in a personnel-free area.

The three-axis handling device (DAH) we supplied, suspended from the warehouse ceiling, automatically picks up the container and empties it into one of the two compactor containers using a rotational motion—adapted to the bulk material—combined with vibration cycles. After emptying, the container is returned to the transfer station and released for pickup by an AGV.

Design Details

The system can be used without any problems in the event of an AGV malfunction. In this case, the paper containers are moved to the transfer station using a hand pallet truck or forklift. Once the danger zone has been cleared, staff confirm from outside that the area is clear of personnel. The emptying process begins automatically after the high-speed door has closed. To prevent finished goods—which are also transported by the AGVs—from being accidentally emptied into the baling containers, the waste paper containers are checked for a unique identifying feature.

The Control System

A Simatic S7-312C PLC is operated via a simple plain-text display (OP3) and several illuminated pushbuttons. All linear and rotary drives are controlled by SEW Movitrac or MoviMot inverters. All necessary information regarding the AGV, press containers, and high-speed doors is exchanged between the relevant control systems via potential-free contacts. Any safety loopholes that exist when the AGV enters the area are closed by appropriate sensor systems.