Fully automated process control system for a tyre palletizing plant — SAP integration, robot palletizing with Rick-Rack/Stove-Pipe patterns, collision control, and integrated safety zone management.
The process control system (PCS) manages the production handover from a major tyre manufacturer to logistics. Tyre information is fed from the plant's SAP system to the PCS. Tyres are identified via scanner systems and routed to multiple palletizing robots — fully automated according to prescribed stacking patterns.
Robot palletizing with Rick-Rack and Stove-Pipe stacking patterns.
Master data, production plans and transport orders via SAP REST.
Zone-based safety concept with an operator access request system.
Automated collision prevention for robots and transfer carriages.
Tyre information is provided by the plant's SAP system and the production SOAP interface. Scanners identify each tyre and the PCS determines the target — diversion, intermediate buffer, or final pallet — then controls the conveyor accordingly.
Original Equipment (OE) tyres receive a marking, which is quality-checked and positioned so it always faces outward on the finished pallet.
The plant is divided into safety zones. Operators can request access to a zone via the PCS — the system clears all open orders for the zone before granting access.
Both transfer carriages and robots have overlapping movement ranges. Dedicated collision control in the PCS prevents conflicts automatically, without manual intervention.
The PCS communicates with SAP, production systems, robots, and hardware components across multiple protocols.
Master data, production plans, transport orders. KPIs and pallet contents fed back to SAP.
Tyre data from production to palletizing plant via SOAP.
Control commands to conveyor components via OPC UA.
Direct communication with palletizing robots via TCP/IP datagrams.
Pallet logistics control of transfer carriages via OPC UA.
Tyre tracking via barcode scans and light barrier signals.
From SAP integration to robot control — we build complete control solutions for fully automated palletizing and production plants.
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