The Totnes company modelled the custom-designed cells on its Cosimir 3D simulation software and employed finite element analysis to perfect the construction of the special vacuum pick-up tool. Each cell incorporates Mitsubishi's latest 12kg class of 6-axis articulated robot, the RV-12SL, to offload the incoming 11kg floor panels and stack them onto pallets, inverting every other one for quality control purposes. The fully integrated material handling cells also feature Interoll powered conveyor rollers, EcoSafe modular protective barriers and interlocked Sick C2000 safety light grids for safeguarding the pallet access apertures.

Kingspan, market leaders in raised access flooring, producing 150,000 panels each week, commissioned the three cells primarily for health and safety reasons, given restrictions on manual lifting, although Engineering Manager, Stephen Williams, also anticipates substantial productivity gains.

The first cell has already been installed by Barr and Paatz, meeting a very demanding eight-week timescale.

It is expected that Kingspan will now explore further applications for robotics technology.

Part of the international Kingspan building group, recognised throughout the construction industry for innovation, design and technical quality, the Access Floors division on Humberside was recently awarded the Specialist Flooring Contractor title, by Building magazine.

The company's modular, raised access floor system is literally an elevated platform above an existing, usually concrete floor, comprising load bearing panels supported by adjustable vertical pedestals.

The underfloor space provides for the housing and distribution of internal services, the readily removable panels providing quick and easy access to power, data, telecoms and HVAC systems.

Normally 600mm square, the industry standard module size, the access floor panels consist of a high density particle board core encapsulated in galvanised steel, their unique wraparound construction making for ready removal and replacement.

Each panel has a decorative upper surface, although a bonded carpet or tile finish is optional, is around 31mm thick, has a Class 0 fire rating and is extremely solid underfoot.

In production, the steel envelope and particle board core are bonded together using high performance adhesives, which take up to two days to become fully cured.

Thus for palletising, previously cured panels, know internally as 'sacrificial' items, are used to top and tail each stack of newly produced product, although in fact the sacrificial panels are perfectly usable.

Alternative floor panels are also inverted to protect their decorative surface and ensure they reach the customer in mint condition.

The Barr and Paatz designed robot cell accepts each new batch of panels from a fork lift, the use of Interoll powered conveyor wheels, rather than full width rollers, allowing the track to move right into the conveyor system for ease of unloading.

This infeed aperture in the EcoSafe barrier system is fringed by Sick safety light guards, which are interlocked with the robot controller for finger and hand protection.

The Mitsubishi RV-12SL articulated arm robot then picks up each panel from the infeed conveyor, inverts every second tile and stacks them on a standard wooden pallet, with 'sacrificial' panels automatically placed top and bottom of each stack.

With a payload of 12kg, a working reach of 1384mm and speeds up to 9500mm/second, as well as six degrees of freedom, the RV-12SL was ideal for this particular application, at a highly affordable price.

Furthermore, since the Cosimir robot simulation system supports the Mitsubishi range and material flow control system, Barr and Paatz was able to model and simulate the entire work cell for Kingspan, enabling the customer to finalise the contract with a high degree of confidence.

The pick-up tooling, incorporating three pneumatic vacuum cups, was designed and manufactured employing FEA software, to apply simulated loads to the design.

The resulting custom-made lightweight aluminium frame is strong enough to support the 11kg panels, yet does not impose unnecessary loads on the robot arm or compromise its 12kg payload capacity, thereby eliminating over-specification and unnecessary extra cost.

Some 20metres of 2.2m high EcoSafe protective barriers, each comprising an aluminium frame and black steel mesh for enhanced visibility, were used to fence off each cell and meet the highest health and safety standards.

This barrier system was coupled with interlocked light guards at the infeed and outfeed apertures, to provide personnel safety without constantly interrupting the robot action.

'Barr and Paatz offered us an effective solution and we took up references with existing clients, so we knew they could deliver,' says Kingspan's Stephen Williams.

'We are very happy with their work and now plan to speed up throughput generally, to take advantage of the improvements in palletising productivity'.

'Certainly, we can foresee more robotics technology being introduced to automate other processes.'