Pick-and-Place Assembly Systems
assemblean engineers specialized robot cells that resolve chaotic feeding situations, handle sensitive components without damage, and replace rigid mechanical feeders with intelligent software and kinematics concepts.
The choice of robot system defines the physical limits of speed, payload, and range of motion. A targeted selection prevents mechanical wear and ensures the system reliably achieves the required cycle times.
| Analyse-Parameter | Delta Kinematics (Parallel Arm) | SCARA Robot (Horizontal Articulated) | 6-Axis Articulated Robot | Cartesian Gantry Systems |
|---|---|---|---|---|
| Workspace Geometry | Cylindrical (ceiling-mounted) | Kidney-shaped (compact footprint) | Spherical (fully 3D workspace) | Cubic (rectangular x-y-z workspace) |
| Max. Acceleration | Extremely high (up to 10G+) | High (short, linear x-y moves) | Moderate (optimized for complex paths) | Low to medium (payload-dependent) |
| Repeatability | ±0.05 mm to ±0.1 mm | ±0.01 mm to ±0.02 mm | ±0.02 mm to ±0.05 mm | ±0.01 mm (spindle-dependent) |
| Cycle Time Limits (Pick & Place) | Unmatched in high-speed range (< 0.35 s) | Extremely low for planar joining (< 0.45 s) | Process-dependent (typically > 0.8 s) | Linearly scalable by travel distance |
| Primary Process Focus | Sorting, packaging, high-speed singulation | Precision joining, electronics placement | Multi-angle handling, 3D bin-picking | Large-area palletizing, heavy components |
We view the robot arm merely as the actuator of an intelligent overall solution. The technological edge of our handling systems is based on seamless integration of sensors, software, and custom-engineered gripper mechanics.
We engineer product-specific gripper systems — from material-friendly vacuum multi-suction cups and magnetic grippers to servo-electric parallel grippers. Integrated sensors monitor grip pressure and vacuum level in real time to immediately detect component slip.
Our control systems synchronize robot arm movement in real time with the speed of moving conveyor belts. Components are precisely picked or placed while in continuous motion — time-consuming stop phases of conveyor belts are eliminated entirely.
When joining the smallest components, we use highly sensitive force-torque sensors directly at the robot flange. The system "feels" mechanical resistance during insertion, autonomously compensates for tolerances, and prevents component damage during the joining process.
Every component places individual demands on handling physics — from sterile syringe packaging to oily stamped parts.
Ultra-fast loading of trays, blisters, or cartons using cleanroom-compatible robots in hygienic design. The kinematics are resistant to aggressive cleaning agents and use food-grade NSF-H1 lubricants.
High-precision placement of connectors, PCB components, or housing parts. Full ESD protection of the entire system safeguards sensitive semiconductor structures against electrostatic discharge.
Automated gripping and sorting of components delivered in bulk without order. The system autonomously calculates the optimal pick sequence and prevents collisions with container walls.
Component characteristics determine the cell architecture. To identify the optimal integration for you, we divide our turnkey systems into three specialized product categories.
Designed for maximum pick rates with lightweight components (up to 3 kg). The cell is mounted directly above existing conveyors and operates in continuous flow mode. Application: Fast re-potting, orientation, and sorting of small parts, confectionery, or medical primary packaging.
Key Feature: Extremely low moving mass through lightweight carbon fiber composite arms.
Optimized for fast pick-and-place cycles combined with high joining force in the vertical Z-axis. Ideal for the assembly of components with tight tolerances. Application: Screwing, joining, press-fitting, and populating in electronics and automotive supply manufacturing.
Key Feature: Design-inherent extreme stiffness in the vertical axis combined with flexibility in the horizontal x-y plane.
The system for the notorious "pick from bin" challenge. Eliminates the need for complex mechanical sorting bowls by singulating disordered bulk parts directly from deep transport containers.
Application: Feeding of blanks, forged components, castings, or complex plastic geometries for further processing. Key Feature: Integrated AI software analyzes the 3D image of the bin and identifies which component can be picked without collision risk.
Without visual feedback, a robot arm depends on perfectly positioned components. Our integrated vision systems break this rigidity and give the system cognitive capabilities.
Using high-resolution 2D or 3D camera systems, the integrated machine vision determines the exact position, rotational orientation, and top or bottom side of a component on the conveyor.
The software translates these visual pixel data into a mathematical coordinate system within milliseconds and sends the exact transformation matrices to the robot.
While the robot is still moving the component, the vision software compares its contours against the original CAD model. Dimensional deviations, geometry defects, or material breakouts are detected immediately, and faulty components are rejected directly.
For complex geometries or long conveyors, we coordinate multiple camera systems via a central software architecture to guarantee continuous data flow without latency.
Process
A clear flow, one point of contact, and a well-coordinated manufacturing process.
Real-world trials in our TechCenters using your actual components to determine optimal gripping forces and vacuum parameters.
Virtual cell build for precise calculation of the cycle time budget, reach envelopes, and final robot type selection.
Definition of camera types, lenses, and lighting concepts (e.g., coaxial or infrared light) to proactively eliminate optical interference factors in your production facility.
Physical installation of the robot cell, calibration of machine vision, and software-side configuration of all travel paths.
Fine-tuning of acceleration ramps under real operating conditions in full compliance with all safety standards for shift operation.
Let us maximize the dynamics and precision of your handling processes. Contact our automation experts for a detailed initial consultation on your component requirements — well-founded, practical, and exactly focused on your cycle times.
FAQ
To prevent components from slipping or being lost due to inertia at accelerations up to 10G, we use a combination of flow-optimized suction cups with high volumetric flow and electronic vacuum monitoring.
For mechanical grippers, a precisely calculated form-fit geometry of the gripper jaws — combined with servo-electric force control — ensures the component remains rigidly fixed even during extreme directional changes.
In static gripping, the transport system must stop precisely so the robot can pick the component at a predefined, fixed coordinate — costing valuable cycle time. In dynamic gripping (conveyor tracking), an encoder on the belt reads the transport speed.
The robot calculates its trajectory dynamically in advance, synchronizes its own speed with the belt, and picks the object smoothly during motion.
Reflective surfaces create fatal light reflections that blind conventional edge-detection algorithms. We solve this physical problem by using polarized light, diffuse dome illumination (light tents), or switching to alternative wavelengths such as infrared or UV light.
Additionally, our vision systems use robust contour-search algorithms that reliably identify geometric features regardless of brightness variations or surface gloss.
They are the key to economic flexibility during frequent product changeovers. Automatic tool-change systems allow the robot to exchange its gripper tool fully autonomously within seconds.
The integrated air, vacuum, and signal connections are coupled loss-free via quick-connect fittings. The controller simultaneously loads the software profile for the new gripper, allowing production to continue without any manual operator intervention.
When multiple delta or SCARA robots share the same workspace at a conveyor, a master line controller (Line Master) is deployed. This software manages a dynamic object list of all incoming components and assigns dedicated components exclusively to each robot arm.
Simultaneously, an electronic collision protection system monitors the virtual protection zones (geofencing) of the robot arms relative to each other and prevents mechanical damage.
Knowledge hub
Trusted by
Book a personal meeting
Contact us now
Assembly process planning can make a significant difference in making production more efficient.
How do individual components become complex, functional assemblies? An overview of joining processes, quality assurance, and automation.
Produce yourself or purchase externally? We help you make the right decision for your manufacturing.
© assemblean 2026 | All rights reserved.
