Bin picking rethought: Singulation instead of complexity.
The task sounded familiar: automate bulk material, ideally through bin picking. However, after the first consultation, it was clear – we are taking a different path. One that reduces complexity and focuses on cost-effectiveness.
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The Challenge
Over 100,000 components per year had to be individually, manually, and sequentially processed. The process included unpacking the parts, the actual processing step, and subsequent packaging. Additionally, multiple variants of the components complicated the process and increased handling complexity.
A single employee was responsible for all process steps. As a result, the work steps could only be carried out sequentially, with accordingly negative effects on throughput time and efficiency. At the same time, the customer faced an acute shortage of skilled workers and was looking for a solution to automate the monotonous individual part processing and specifically relieve the employees.
The Solution
As early as the first consultation, it was clear: Instead of relying on a classic, complex bin-picking system, we deliberately reduce the complexity of the task.
The core of the concept is a mechanical separation using a Flexibowl from ARS Automation. Through this intelligent feed, the parts can be provided in an oriented manner – eliminating the need for costly 3D image processing. Instead, smart cameras are used, guiding the UR7e from Universal Robots precisely to the right position. The cobot then reliably takes over the handover of the parts to the processing process.
An inclined conveyor with a bunker also ensures sufficient buffering of components and enables stable, efficient system operation. The employee only needs to fill the conveyor and package the finished parts – the monotonous subprocess is omitted.
Another advantage: During plant planning, the solution could be realized without external safety devices. The deployed cobot, with its integrated safety functions, takes over process monitoring and integrates seamlessly into the existing infrastructure.
Deployed Hardware
- UR7e from Universal Robots
- Flexibowl 800 from ARS Automation
- Custom Machine Frame from PAMO Automation
Real results that convince
- Optimized throughput with a cycle time of approximately 5 seconds
- Significant relief for employees in monotonous tasks
- Flexible system, which can easily be adapted to new requirements
- Cost-efficient automation without unnecessary technical complexity
Technology that Pays Off
The well-thought-out system concept provides the customer with a clear competitive advantage. The existing infrastructure was selectively and economically expanded—without extensive renovations or high additional costs.
The return on investment for this solution is achieved in less than two years.
Automation with Added Value
The implemented system integrates perfectly into the existing production environment and operates reliably in daily operations. Additional efforts for the customer could be avoided. Thanks to the simple, practical system design, the solution remained not only technically convincing but also economically attractive.
This creates automation that relieves employees, increases throughput, and pays off from day one—in line with sustainable and future-proof production.