Hybrid Control Optimizes Ice Handling System
Robots and Automated Equipment Services Co. (RAESCO), in Syracuse, N.Y., builds ice-handling equipment, and offers other machines and services. RAESCO’s machines palletize ice at 40 bags per minute. In developing the control system for its machines, RAESCO engaged Applied Automation Controls Inc. (AACI), also in Syracuse, as a control solution consultant. AACI offers machine solutions that use mechatronic and pneumatic technologies.

“We worked together to complete a design based on RAESCO’s concept,” says Tom Swenton, AACI’s president. AACI provided the control components to optimize the machine design.

“The design went through a few changes from prototype to production,” says Swenton. “The present design implements three axes of electric servo control—two from conveyors and another from a gantry mechanism. These axes required higher speed and positioning accuracy than a pneumatic solution could provide. However, there are four motions to align and rotate the ice bags as they’re presented to the collation station from the in-feed conveyor. Moreover, there are various clamps and lockouts implemented with pneumatic solutions. These were legitimate choices for these motions because they provided more than adequate controls and were more cost-effective.”

Rich Huchanski, RAESCO’s president, adds, “A pneumatic solution provides us with an adaptive capability because the ice bag shapes vary so much from bag-to-bag as they enter the collation station. Using air pressure to sense when vacuum cups come in contact with the bags allows the cups to adapt to the bag shape. Using this compliant adaptation, we can align bags uniformly before delivering them to the pallet.” The machine is capable of lifting as much as 150 lbs, but generally palletizes 7-lb. bags in pallet loads of 300.

This application indicates that a hybrid solution not only can optimize the capabilities of many machines, but also can be the most cost-effective solution.