XHE electronic handle applicator prototype for horizontal application of handles on cardboard boxes
Requests for handle application at low production speeds are less frequent, but involve design challenges comparable to high-speed lines.
Design constraints
The project requirement included strict technical constraints:
- handle application within defined dimensions and positions, with reduced tolerance and high repeatability
- in case of application error, the machine must not mark or damage the box
- Horizontal application
- precise and repeatable positioning of the black mark on the handle
- high adhesion along the full usable length of the adhesive tape on the cardboard box, to ensure secure grip and prevent detachment during transport
These are logical constraints for the final product, but technically demanding from an engineering perspective.
A perfect handle for a special product.
The prototype
After several meetings with our engineering and technical team, the resulting solution is shown in the following video.
Description of the XHE handle applicator prototype
The objective was to develop a solution that is easy to use and, at the same time, effective.
The machine feeds one box at a time through a dosing belt, preventing accumulations and variable pushing forces caused by different box weights (boxes may contain variable internal products).
The box is then transferred individually to the handle-application belt.
Given the low line speed, an intermittent movement profile was chosen, and the handle is applied while the box is stationary to maximize adhesive performance on cardboard. Box position is checked precisely before the gripper applies the handle.
The gripper is powered by a servomotor instead of a pneumatic cylinder, to keep speed under control in the most critical phase: bonding the adhesive tape to the box surface.
The control architecture is based on a Siemens S7-1200 PLC, related expansion modules, and a 7" Siemens HMI display.
As with all our machines, a remote connection module is included to provide remote technical support.
Conveyor belts are controlled by Omron Q2V series inverters via Modbus communication. The machine also provides easy access for box removal when required.
Technical FAQ
Why was this project developed for low production speed?
The requirement was handle application in a low-speed context, while maintaining constraints typical of faster lines: positioning precision, high repeatability, and process control. The solution was engineered to satisfy these constraints without compromising adhesion quality on cardboard surfaces.
How is handle adhesion quality ensured?
The machine uses intermittent advancement and applies the handle with the box in a stationary position. Before gripper action, box position is verified precisely. Gripper motion is managed by a servomotor, allowing speed control in the most critical bonding phase of the adhesive tape.
Which systems support machine control and assistance?
Control is based on a Siemens S7-1200 PLC with expansion modules and a 7" Siemens HMI. Conveyor management uses Omron Q2V inverters in Modbus communication. A remote connection module is also included for remote support activities, with easy physical access for box removal if needed.
