Automated production line: SmashR® Conv fragments the nickel blocks for smooth emptying

As part of its activity of producing materials for batteries, the client faces challenges related to the handling of big bags containing nickel sulphate. These big bags, stored for long periods of time, tend to form blocks of compacted powder due to the effect of humidity and cold, making them difficult to empty and impacting the fluidity of the production process.

The main objective was to automate the management of big bags to guarantee a continuous flow of raw materials without manual intervention by operators. The client wanted to:

• Break up the blocks of powder before emptying to improve the fluidity of the product.
• Avoid production interruptions caused by obstructions and incomplete emptying.
• Minimise human handling in order to reduce the risks associated with the handling of big bags and improve the safety of operators.
• Ensure a high production rate by integrating robust and efficient equipment into an automated emptying line.
• Adapt the equipment to the different dimensions of big bags while allowing precise adjustment of the massage parameters according to the characteristics of the product.

These requirements meant setting up an integrated system capable of optimised massaging of the big bags before they are emptied, with automatic management of the decompaction cycles and seamless integration into the existing production process.

To meet the customer's needs, Palamatic Process proposed the integration of the SmashR® Conv, an automated big bag massage cage with integrated conveyor. This equipment is designed to effectively decompact powders stored in big bags, ensuring smooth and continuous emptying.

Integration into the conveyor line

The SmashR® Conv is positioned in the middle of a conveyor line, thus enabling the massage of the big bags to be carried out in masked time, without interrupting the process. Thanks to this configuration, the big bags are decompressed during their transport to the emptying station, ensuring optimal fluidisation of the product as soon as it arrives.

Technical characteristics of the SmashR® Conv:

Hydraulic force:

The leaves exert a pressure of more than 16 tonnes (> 156 kN) on the big bags, guaranteeing effective decompaction of even the most compacted powders.

Operating cycle:

The standard cycle consists of four pressures exerted from the bottom to the top of the big bag, followed by a 90° rotation of the table. This process is repeated to ensure a complete massage on the four sides of the big bag.

Duration and rate:

A standard cycle lasts approximately 5 minutes, allowing a rate of approximately 12 big bags per hour.

Automation:

The SmashR® Conv is equipped with a motorised conveyor integrated into a rotating lifting table, enabling the automatic transport of the big bags into the massage cage. The massage cycles, the duration of the cycles and the evacuation of the decompressed big bags are controlled automatically, thus reducing human intervention and optimising production times.

Adaptability

The operating parameters can be adjusted according to the customer's specific needs. The operator can create personalised recipes, in particular by adjusting the number of pressure cycles per height and the number of rotations of the lifting table.

Integration into the customer's process

By integrating the SmashR® Conv into the conveyor line, the big bags are massaged without impacting the overall production flow. This approach makes it possible to reduce waiting times, improve the flow of powders during emptying and ensure a high rate without manual intervention.

The installation set up at the customer's premises is based on several key pieces of equipment enabling the complete automation of the decompaction and emptying of big bags. This equipment guarantees a smooth, secure process that is adapted to the production constraints of chemicals and battery materials.

1. SmashR® Conv big bag massage cage

• Pressure force: > 16 tonnes per hydraulic leaf to effectively break up the blocks of compacted powder.
• Rotating lifting table: allows uniform massage of big bags on all 4 sides and at different heights.
• Automated cycle: 4 successive pressures, 90° rotation, then repetition to ensure optimal decompaction.
• Rate: up to 12 big bags per hour with customisable settings.
• Secure process: safety light curtain with muting to prevent any manual interaction.
• Benefit: Ensures efficient and uniform decompaction of big bags for easy emptying without residue.

2. Motorised conveyor integrated on lifting table

• Automatic control of big bag positioning.
• Smooth and secure transport to the massage cage.
• Maximum load supported: 1500 kg.
• Rotation speed: 4 rpm for even decompaction.
• Advantage: Reduces manual handling and optimises the rate of big bag processing.

3. Rotary hydraulic lifting table

• Dynamic positioning of the big bag: height adjustment and rotation of the big bag to ensure effective massage on all sides.
• Automated control: synchronisation with the SmashR® Conv for an optimised massage cycle.
• Maximum load: 1500 kg.
• Rise time: approx. 25 seconds.
• Fall time: 20 seconds empty, 10 seconds loaded.
• Controlled rotation: the big bag can rotate automatically to allow optimal decompaction over its entire surface.
• Advantage: As the central element of the process, this table allows for effective massage at all heights and positions of the big bag, thus ensuring perfect fluidity of the product during emptying.

4. Control cabinet with Pal'Touch® interface

• SIEMENS S7-1200 PLC controlling the entire process.
• TP9’ touch interface: allows for intuitive and fast configuration.
• Customisation of recipes: adjustment of the number of cycles and massage parameters.
• Advantage: Offers complete traceability of operations and adaptability to the different materials treated.

The SmashR® Conv is the ideal solution for an automated production line, eliminating the need for operator intervention. The big bag is conveyed automatically, massaged from all angles by the hydraulic rotary lifting table, and then emptied without interrupting the production flow.

This automation process guarantees smooth emptying, reduced downtime and a secure and optimised process for continuous, efficient and unconstrained production.