Avantar - the digital twin of the Avanti Conveyors Pegasus separator and palletiser

Avantar is the digital twin of the Avanti Conveyors Pegasus separator and palletiser.

A digital twin is a virtual representation of a physical object or process. The concept of digital twins is attributed to Michael Grieves, then of the University of Michigan, in 2002, but the first practical digital twin originated from NASA to try to improve their spacecraft simulation in 2010. Avanti Conveyors’ software engineers worked in conjunction with Autologic to create Avantar using Emulate 3D from Rockwell Automation.

Palletising and separating is a complex process to optimise the configuration of the die with the configuration of the load on the pallet, which affects the die-cutter’s performance. Historically this has been addressed by using tables or operator experience. This approach can be a bit erratic in understanding a palletiser’s performance. Estimated job run times can therefore be widely off the mark and scheduling workload is unpredictable.

Avanti Conveyors has developed a system called Avantar, which is the digital twin of the Pegasus separator and palletiser. A digital mimic of every action of the separator and palletiser has been created. The PLC code emulates all of the actions on Pegasus and can calculate the performance of the line. Line performance can also be emulated prior to installation, which results in faster start-up times.

The Pegasus Separator Palletiser was launched at FEFCO in 2017 to overcome the problem whereby converting machines were unable to run at full capacity due to constraints with existing separators or palletisers. Bottlenecks in the production flow have been beaten by Pegasus.

Avanti Conveyors are able to use this 3D virtual environment to demonstrate that Pegasus is the fastest separator palletiser in the market. Customers will be able to see how product flows through the machine and where time can be saved and manual handling can be avoided. A complete walk-through of the machine allows for our customers to see the full functionality of Pegasus and to see how it could cope with their product mix.

Much like learning to fly a spacecraft before going into space, Pegasus operators will be able to learn how to run Pegasus before the physical machine is on site. Emulators are a proven tool in training as changes can be made to stock, sizes and environment. The real-time responses of the trainees can then be monitored and training requirements modified. This process avoids the costly, time-heavy use of stock and machine, which is often running 24/7 and an interruption to production is not possible. This digital twin also allows operators to repeat tasks until they are comfortable knowing that they have fully understood the functionality of Pegasus. Individuals learn in different ways and having a virtual 3D environment will be another element in the trainer’s toolkit. Testing can also be integrated as a part of a continuous development training programme or as part of the interview process.

Click here to hear more about Avantar.

Please contact us to find out more about this innovative new product.

Video credit: FEFCO

iMPRESS OEE (Overall Equipment Effectiveness) INSITE

Information – the more you have, the more knowledge you gain and the better you will perform. Avanti Conveyors have used their years of experience working in the corrugated packaging industry to develop a new software product, which integrates with materials handling equipment to give detailed performance information to our customers. This information can be used to identify any bottlenecks or weaknesses in the production flow and therefore improve efficiency and reduce costs.

iMPRESS is Avanti Conveyors Finished Goods Central Palletising Control System and iMPRESS OEE (Overall Equipment Effectiveness) INSITE is the Information System which runs alongside. The Finished Goods area of the factory has often been a bit of a black hole and lacked feedback about the performance of all the equipment and flow of product. This area has lots of processes including conveying, strapping, palletising, wrapping, top board loading, top sheet loading, sample boxes and fork truck collection and take-off.

iMPRESS OEE INSITE has been designed to integrate with products from other Original Equipment Manufacturers (OEMs) to give automated feedback to the material handling control system. Each element in the Finished Goods chain has various identifiable issues (e.g. wrapper out of film, bar code misreads, loads waiting for unload by the fork truck). The performance report for the shift can then be drilled down into in detailed reports and graphs. This gives the engineering and maintenance teams specific information to allow them to prioritise their workload to address the equipment which is causing the most breakdowns. Once this engineering work has been completed then the performance report for the next shift can show where next to focus their efforts, making the Finished Goods area as streamlined and efficient as possible. Further, it encourages production teams to analyse throughput, and identify bottlenecks either due to equipment capacity or process, thus highlighting potential areas for future investment. In addition it can allow production teams to question existing practices, while targeting higher outputs or even saving costs, for example “we didn’t realise that we are doing 40% wrapped work, do we need to do that?”

Click here to watch a video explaining more about this new product.

Please contact us to talk about how you can improve efficiency and reduce costs in your plant.

Video credit: FEFCO

ASRS Solutions

Avanti Conveyors, working with our partner DF, can offer state-of-the-art ASRS solutions for WIP and Finished Goods Storage.

Looking for more WIP storage with greater access to different stacks of board to help production flexibility?

Click here to watch our ASRS solution in action.

Why not contact us to talk about what Avanti can do to grow your production and efficiency?

AutoStak Palletising System

The AutoStak Palletising System will increase your host machine output as well as your stack consistency to your customer. In addition, it will eliminate manual labour and decrease operator fatigue and injuries. The AutoStak handles a variety of bundle styles, strapped or unstrapped. No dedicated dunnage or tie sheets. The system uses either an existing, or new, load former.

Click here to watch the AutoStak Palletising System in action.

AutoFeed Robotic Prefeeder

The AutoFeed Robotic Prefeeder is an innovative system that can be used on your rotary and flatbed die cutters, flexo folder gluers and more specifically, will allow you to increase productivity and reduce your manual labour costs. The AutoFeed has the ability to feed a variety of material from micro flute to triple wall. It can also stack pallets, dispose of dunnage sheets, de-stack and more. The AutoFeed can save over 50% floor space when compared to a conventional prefeeder, thus providing your plant with extra space for additional operations. You can expect a quick ROI due to its versatility and speeds that feed at the same productivity as your equipment.

Click here to watch the AutoFeed Robotic Prefeeder in action.

Sushi “Finished Goods” Bar

Creates space and organisation after the banding and shrink wrap operations which ultimately minimises fork truck movements within the warehouse area and ensures that fork truck operations do not limit the overall output capabilities of the finished goods area.

Centraliser

Allows for the optimum presentation prior to palletisation process.

Impress and Impress Console

Impress

Provides the automatic control of finished goods strapping, wrapping and palletising lines.

Impress Console

Provides factory floor level control of the finished goods activities.

Fastpal

The Fastpal robot provides automatic pallet selection and transfer to the load palletising device.

Load Palletising Device

Automatic insertion of pallets under stacks, for single or multiple pallets, with a capacity of up to 200 pallets per hour.

Base Pad Inserter

Used for the placement of protection pads prior to palletising and shipping.

Rotating Bi-directional turntables

Rotates and changes load direction but maintains stack orientation (this aids labelling operations).

Machine Out-feed

Stedi Stak dramatically reduces fork truck movements and improves health and safety.

Plastic Bi-directional Out-feeds

All plastic and negates board-walk when in motion; no damage to the bottom of the load unlike chain driven alternatives.

Bundle Doubler

The Avanti Bundle Doubler quickly double stacks bundles on top of each other and then aligns them.

Bundles of cases or die-cut sheets, either tied or untied are conveyed via the entry conveyor, to a pop up blade stop. The stop squares and readies the bundle for entry to the bundle doubler. The first pack enters the bundle doubler and runs to the back stop. The fork lifts the bundle to a set height. The forks action is pneumatic and all other movements by electric motors and gearboxes. The second bundle held at the blade stop then enters the bundle doubler and runs under the raised bundle to the backstop. The pusher actuates pushing both bundles at 90 degrees where they merge together on the tapered forks. There are various PLC controls which ensure that bundles are entered and released under control to empty zones.

The bundle doubler is normally supplied with a desk top panel with processor and PLC controls, with an HMI to allow certain manual operations.

Turntable

The unit will have an HMI (Human Machine interface) station with automatic/manual modes to allow manual movements of the carrier rollers and belts and rotate function. With a suitable PLC program whole unit rotation loads can be turned -90 degrees, +90degrees or run straight on with load orientation kept entry to exit. Loads must be centred on width for entry to the unit and measured on length to the unit.

Machine In-feed

Using Stedi Stak negates board-walk and protects the base sheets of each stack when in transit.

Pivot Cars

Automatic directional change of loads.

APCS Work in Progress Software

Used for automatic stack transfer in work in progress areas.

Corrugator Take-off

The Stedi Stak conveyor is ideal for replacing roller based take-offs and for new out-feeds.

Stedi-Stak Transfer Cars

For automatically transferring loads laterally between conveyor lines; can be built to any size and number of beds.

Bi-Di Roller

Often used in combination with Stedi Stak where extremely heavy loads are carried.

Stedi-Stak Conveyors

At the forefront of materials handling technology, low maintenance, quick replacement parts, maintains stack integrity when in motion and safe to walk on.