Automated Can Palletizing System

Intro:

We have developed a complete automated system for can palletizing, installed at the final stage of the production line, before packaging and storage.
The goal of the project was to optimize the process of loading and stacking cans onto pallets, ensuring fast, safe, and fully automated handling.

General Overview

The system operates through two independent yet fully integrated functions within the overall line logic:

1. Pallet Feeding Zone
   Empty pallets are delivered by a forklift and placed onto a conveyor.
   A mechanism with movable rods lifts most of the pallets, leaving only the bottom pallet free, which is automatically sent to the palletizing line.
   When only 2–3 pallets remain in the stack, a signal lamp alerts operators to bring more pallets — preventing production stoppages.
2. Can Palletizing Zone
   Cans arrive on an accumulation conveyor, where they are monitored by sensors.
   When sufficient accumulation is detected, the system allows controlled placement of cans onto the pallet, within a metal guiding frame that prevents shifting or falling of packages.
   After each layer, the system checks correct positioning, and by pressing the Start button, the pallet automatically lowers to prepare for the next layer.
   From the HMI interface, the operator can select:

• the desired number of layers per pallet,
• total pallet height,
• operation mode (automatic/manual).

Based on these settings, the PLC calculates the precise lowering distance for each layer and determines when the completed pallet is sent to the wrapping and storage area.