How does a fully automatic block arrangement machine ensure precise gripping and damage-free stacking of film rolls of different specifications during high-speed operation?
Publish Time: 2026-02-18
In modern high-end manufacturing fields, such as lithium battery separators, optical films, and flexible packaging materials, film rolls, as core semi-finished products, place extremely high demands on downstream logistics and warehousing. The fully automatic block arrangement machine was designed to address this challenge—it must process 6 to 10 rolls per minute, compatible with rolls of varying diameters, widths, and hardness, ranging from thin BOPP to high-density PET, while achieving millimeter-level positioning accuracy and zero-damage stacking. This seemingly contradictory goal relies on the deep collaboration of four major systems: sensing, execution, control, and protection.
1. Intelligent Identification: Multi-dimensional Sensing Lays the Foundation for Flexibility
The fully automatic block arrangement machine integrates a 3D laser contour scanner and a high-resolution industrial camera at the entrance. Combined with an RFID or QR code reading module, it completes a comprehensive "check-up" of the incoming film rolls within 0.3–0.5 seconds: accurately measuring the outer diameter, width, and end-face flatness, identifying the label orientation, and reading the material type, tension level, and process parameters. This data is uploaded to the central control system in real time, automatically generating customized gripping and stacking strategies. For example, a low-clamping-force mode is activated for ultra-thin diaphragm rolls, while a reinforced support program is activated for heavy-duty optical film rolls. This flexible identification mechanism, tailored to each roll, is a prerequisite for high-speed compatibility with multiple specifications.
2. Adaptive Non-destructive Gripping: The Core Technology of Flexible Execution
The gripping mechanism generally employs a combination of servo-driven electric cylinder-driven contoured grippers or vacuum adsorption + flexible covering arms. The gripper surface is covered with a high-friction coefficient silicone pad and has a built-in pressure sensor that dynamically adjusts the clamping force to ensure that lightweight rolls are not crushed and heavy-duty rolls do not slip. Some models are also equipped with a floating buffer mechanism to absorb impact energy at the moment of contact, preventing end-face collisions. For optical films with extremely sensitive surfaces, the system even uses non-contact vacuum adsorption, using negative pressure to evenly lift the film, completely eliminating the risk of scratches from physical contact.
3. High-Precision Collaborative Motion: Millimeter-Level Control at High Speeds
Stacking is accomplished by a six-axis collaborative robot or a high-rigidity gantry crane, coupled with a high-response servo system and precision reducers, achieving a repeatability accuracy of ±0.1mm. The control system, based on a preset "block-style" algorithm, calculates the landing point of each roll in real time and eliminates vibration and inertial offset during high-speed movement through forward trajectory planning. Before final placement, the end effector initiates a secondary visual correction: using a bottom camera to compare the target position and fine-tune the posture, ensuring that the gap between rolls is ≤1mm and the overall stacking verticality error is less than 1mm/m, meeting the stability requirements of AGV automated handling.
4. Full-Process Cleanliness Protection: Safeguarding the Integrity of the Film Surface
To prevent electrostatic dust adsorption or friction damage during handling, the fully automatic block arrangement machine deploys ion air bars in key areas to neutralize static electricity and sets up negative pressure dust collectors along the conveying path. All contact surfaces use low-friction, anti-static engineering plastics or rubber-coated rollers, ensuring no exposed metal throughout the handling process. The stacking platform is equipped with a buffer tray and limiting edges, combined with a "soft landing" control strategy—switching to a low-speed, gentle descent 5mm from the tray—to ensure smooth positioning of the film rolls and prevent rebound or misalignment.
In summary, the fully automatic block arrangement machine, through a closed-loop design encompassing "intelligent recognition—flexible gripping—precision motion—cleanliness protection," achieves precise, safe, and efficient stacking of multi-specification film rolls at high speeds. It is not only a key node in logistics automation but also the last line of defense for ensuring the quality of high-value-added film products—protecting the safety of countless rolls with millimeter-level precision.
