Robotic Cell for Automated Transfer of Parts from Production into Trays

The parts leave the cleanroom environment for the shipping area. A robot automatically loads the parts into trays, which are then transferred beneath a two-axis servo manipulator using a telescopic transfer unit. The servo manipulator automatically distributes the filled trays among six palletizing positions.

The project was designed with maximum operator safety in mind. The palletizing positions feature a unique design based on retractable access openings. When closed, access to the hazardous area is completely prevented. When an opening is accessed, the system automatically prevents the KUKA robot from entering the respective palletizing zone using safety sensors and the KUKA SafeOperation package. Special attention was also paid to the transition state while the access doors are opening, as this creates sufficient space for a person to crawl underneath. This potential risk is eliminated by optical safety light barriers, which are active only while the sliding doors are moving between the fully open and fully closed positions.

The result is a compact robotic cell that combines automation, intelligent mechanical design, and carefully engineered safety features into a reliable and efficient solution.