Pallet collar Hinge Riveting Machine

We would like to introduce our hinge riveting machine for boards intended for pallet collars. Our product stands out not only for its attention to detail but also for the durability of its components and reliability, allowing us to achieve the expected performance.

Technical Specification

  1. Cycle Time: 6.3 seconds
  2. Production Rate: 3,500 units per shift (8 hours)
    This is the average cycle time calculated based on experience. Changing the operator during their break or having a second operator assist in production may result in a higher number of units. Production efficiency may be affected by the type of hinges or boards used.
  3. Board production capability: from 600 to 1200 mm
  4. Extended rivet head operation: Head durability: 1 million cycles. Approximately 1 year of operation. Annual maintenance involves bearing replacement.
  5. Automatic spacing adjustment: It is possible to save different references within the range of 600 to 1200 mm. Changeover time: < 1 minute
  6. Stable and rigid construction.
  7. Oversized working mechanisms provide a significantly extended time of trouble-free machine operation.
  8. Number of operators required: 1 operator responsible for:
    Loading boards (first station ST1)
    Refilling rivets in the hopper (station ST2)
    Refilling hinges (station ST4)
    Transferring the full pallet of products to an empty one (last station ST6)
  9. Maximum number of boards at the loading station: 50 boards
  10. Maximum number of rivets in the hopper: approx. 2,000 rivets
  11. Maximum number of hinges in the feeder at the hinge application station: 150 hinges
  12. Scissor lift for pallet pickup in C-shape, allowing pallets to be picked up with a manual pallet truck. Recommended truck with a minimum lifting height of 300mm.
  13. Time required to transfer the pallet without stopping the cycle: 42 seconds
  14. Monitoring of rivet insertion into pre-drilled holes in the board. The machine stops in case of a rivet jam, preventing defects or prolonged downtime.
  15. Dimensions:
    Length = 7 m
    Width = 4 m
    Height = 2.3 m
  16. Automatic hot stamping included.
  17. Option to add Ink Jet printing. Additional cost option.

Program Information

  1. The machine’s program detects potential errors and indicates the location of the defect. For example, a message may appear indicating a damaged sensor in a specific area.
    It allows manual control of each component (motor, actuator) for diagnostics or servicing.
  2. Remote Service – Enables the programmer to connect to the program and detect faults remotely without the need to wait for a technician to arrive. Diagnostics and technical support can be provided on the same day. It also allows for software updates.
  3. Automatic Mode Screen – Displays the current status of the machine and the number of units produced.
  4. Manual Mode Screens – Allows manual control of each device in the machine with visualization of the current status of the device.
    It also provides the option to disable certain components for servicing and operate the machine in emergency mode. For example, in the event of an actuator sensor malfunction, it is possible to simulate its operation and continue running the machine. The machine operates at a slower pace, but production can continue until the faulty part is replaced.

Electrical Components

  1. PLC Controller: Siemens S7-1500
  2. I/O: Weidmüller UR20
  3. Pneumatic Manifold: MetalWork
  4. Pneumatic Cylinders: SMC
  5. Servo Drives: Schneider Lexium 32

Health and Safety and Ergonomics

  1. The workstations comply with the requirements of Directive 2006/42/EC.
  2. The supplier can provide access to the risk assessment for the machines based on the applicable standards EN ISO 13849 and EN ISO 12100.
  3. All documentation, as well as all descriptions, warnings, and messages on the HMI panel, are provided in English and the native language of the country to which the machine is being shipped.
  4. Each station is equipped with an emergency stop switch within the operator’s reach.
  5. The machine has the capability to implement a Lockout-Tagout system.

Documentation

  1. Operating Manual.
  2. Service Manual, including a description of maintenance tasks for each station,
  3. Drawings and models of wear parts,
  4. A list of purchased components that may fail, along with estimated service life and failure probability,
  5. Electrical schematic, markings according to standard PN-EN-81346-2 2009E,
  6. A list of electrical, pneumatic, and mechanical parts,
  7. Electronic versions of all documents in PDF format.
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Frequently Asked Questions and Answers

What would be the production capacity in boards per hour?

The cycle time is 6.3 seconds per board riveting. Based on our customers’ experience, the machine’s efficiency during an 8-hour shift, including operator breaks and short downtimes, is 3,500 riveted boards per 8-hour shift. On average, this equates to approximately 500 boards per hour.

Is this only for standard dimensions, or can it be customized to the required length? What is the maximum possible board length?

It is possible to produce pallet collars in sizes ranging from 600 to 1400 mm. We can also accommodate custom projects for larger dimensions.

Is it possible to produce pallet collars with double boards?

Unfortunately, no. Customers often ask us about this, but stapling double boards with an automatic machine can be quite challenging.

How many people are required to operate this machine?

One experienced operator can produce 3,500 boards in an 8-hour shift. They are responsible for loading the boards, loading the hinges and rivets, and replacing the pallet at the unloading point for finished boards. 3,500 boards is the maximum quantity for one person; exceeding this amount would require a second person.

What sets your machine apart from the competition?

In designing this machine, we focused on achieving the highest possible reliability, which translates into high efficiency.

We also concentrated on ensuring seamless operation with second-grade boards, such as those that are warped or have defects.

Additionally, we emphasized the durability of the riveting heads and their quick and cost-effective refurbishment. We anticipate that refurbishment will be needed only once a year. The machine is equipped with adjustments to accommodate hinges of different lengths and varying hole distances from the end of the board.