Automated weighing and status tracking of plates using a robotic system

Introduction

This application note outlines the integration of a robotic system designed for handling and weighing metal sheets. The system features a vacuum gripper, a carousel with 20 hotels, a barcode scanner, and a loadcell for weight measurement to track the status of the sheets throughout various stages. The process of monitoring and tracking the weight and condition of metal sheets in industrial or laboratory settings requires precise automation for efficiency and accuracy. The system is designed to process metal sheets through a series of steps, recording each sheet’s condition at different stages: initial (empty) weight, soiled weight (after exposure to contaminants), and cleaned weight (after washing). The system compares these weights against predefined thresholds to ensure quality control. 

Application purpose

The robotic arm, equipped with a unique and custom-developed vacuum gripper, picks up metal sheets from the carousel and places them on the load cell for weighing. The gripper ensures secure handling without causing damage. The carousel can hold up to 20 hotels, each containing 20 metal sheets. It rotates to position each hotel in front of the robotic arm, enabling efficient sheet retrieval.

Each sheet is identified by a barcode, which is scanned by an integrated barcode reader. If the barcode is unreadable, the sheet is automatically discarded. If successfully scanned, the system retrieves the corresponding data from the connected database. The load cell records the sheet’s weight at various stages, comparing it with the stored information to ensure accuracy.Once a metal sheet is retrieved, its initial (empty) weight is recorded in the database. At this stage, the system marks the sheet as 'empty,' indicating it has not yet been exposed to contaminants. If the weight is successfully recorded, the process proceeds.

Next, the sheet undergoes contamination exposure and is weighed again. The soiled weight must fall within a predefined range stored in the database. If it falls outside this range, the sheet is flagged as ‘under’ or ‘over spec’ and is automatically discarded, as this suggests improper handling or an abnormal contamination level. If the weight is within the acceptable range, the system updates the database and returns the sheet to its designated hotel position.

The cleaning process is manually performed using a designated cleaning agent. While washing is an essential part of the workflow, its effectiveness is assessed through subsequent weighing. After cleaning, the sheet is weighed again, and its status is updated in the database to reflect its cleaned state. The system then compares the post-wash weight to the pre-wash weight, calculating the degree of cleanliness achieved. This evaluation helps determine whether the cleaning agent has effectively removed contaminants to an acceptable level.

Throughout the process, the system continuously communicates with the database, ensuring real-time updates on each sheet’s status as it progresses through different stages.

The barcode system plays a crucial role in ensuring accurate tracking and identification of each metal sheet throughout the process. Its integration allows for real-time status updates in a centralized database, providing operators with full traceability at every stage. Additionally, weight thresholds and database settings can be adjusted as needed to accommodate variations in contamination levels, making the system adaptable to different operational conditions. 

Why choose this application
The robotic system presented in this application provides an efficient, automated solution for handling, weighing, and tracking metal sheets. By integrating a vacuum gripper, carousel, barcode reader, and load cell, the system ensures precise control over each stage of the process. This automation enhances accuracy and efficiency, making it a reliable solution for industrial and laboratory environments.