Boxing clever
August 1st 2006

When TM Robotics launches ABOT to the European market this month it will be the first time a robotic system to open boxes has been made generally available. With the logistics and distribution sector already showing huge interest in the system, Charlotte Stonestreet met with TM Robotics' MD, Nigel Smith, to find out more.

Think about the use of robotic machinery in the supply chain and the chances are that one of the areas that springs to mind is packaging. In fact it is not uncommon to find a degree of automation in even the smallest of end-ofline systems, with the food, drinks and pharmaceutical industries standing out as particularly prolific users of the technology.

Robotic systems are widely used to construct cartons, place items inside and then carry out the sealing process.

However, further along the supply chain robots have been somewhat conspicuous by their absence, with box opening remaining firmly in the sphere of manual tasks – until now, that is.

ABOT (Automated Box Opening Technology) has been developed in the US by Texas-based Cornerstone Automation Systems, which specialises in providing solutions to the logistics industry. The system has been launched in the UK and Europe by TM Robotics.

"Up to now robots have been used in the packing process, but there has been no technology developed to open boxes," says TM Robotics managing director, Nigel Smith. "When I first heard about ABOT, it seemed like such a logical progression that I thought surely something similar must have been tried before. When I investigated further though, it became apparent that there were no such systems available."

Any size order Cases, boxes and cartons are fed on a conveyor into the ABOT system, which uses a vision system to measure the exact size of each item. The system then uses this information to tailor the cutting action of the robot to suit the individual case, box or carton. Items ranging in size from 100 x 75 x 50mm to 760 x 600 x 500mm can be fed into the system in any size order or orientation, at a rate of up to 1200 per hour. Available in single or double in-feed versions, ABOT can also cope with any items that may have been damaged in transit.

In addition to the obvious productivity benefits (it is reckoned that operations opening 2500 items per day will achieve a payback period of around six months), ABOT also results in increased levels of safety.

"Often when you go to a goods-in area there is an army of workers wielding knives as they go about manually opening boxes." says Smith. "With ABOT this is eliminated and the chance of accidental injury from knives slipping or being used without appropriate care and attention is no longer an issue.

"Product damage is also greatly reduced as the system is highly accurate, much more so than a human could ever be. It can be programmed to cut just below the box flaps, ensuring that the product inside is never compromised. It is also possible to produce a perforation that can then be ripped by hand, rather than a complete cut." It is possible to vary the type of cut made. For example, as well as a perforated cut the system will make threesided cuts or cuts which produce a display case for point-of-sale use. For the basic operation making cuts to remove the top of the box or carton, the distance from the top can be varied to suit the application.

Proven technology Incorporating standard conveyors, vision systems and robotic devices for the cutting action, ABOT uses proven technology and offers high levels of reliability and accuracy.

According to Smith, Cornerstone Automation is renowned for its human/machine interfaces and as a result ABOT is very user-friendly and intuitive to operate via a touch-screen panel, which can be adapted to suit individual customer needs.

Maintenance requirements are minimal, with the main concern being the sharpness of the blade. For applications processing 600 cases per hour the blade will typically need to be changed once a day. This can be indicated by an optional blade wear monitor and subsequently changed using the automated blade changer, which is also an option. Other options include automated top removal and inner packaging opening.

With a "phenomenal" reaction in the US, where ABOT has been available since the end of last year, Smith has high hopes for the system in Europe.

"As traditional manufacturing markets have moved East, the UK has gained strength in logistics. This sector is typical of the 'new' industries emerging that are beginning to embrace technology of this sort," he says.

Other sectors that have already expressed an interest in ABOT include supermarkets and web-based retailers.

"Companies are always looking for ways to reduce injuries and improve productivity – with ABOT both of these objectives can be achieved," concludes Smith.

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