Whether bin-picking or pushing crates - the Match system has the right gripper for every task. The RECB generates the necessary vacuum purely pneumatically. © J. Schmalz

The concept was quickly finalized, although two details were particularly challenging for Schmalz's technological expertise: firstly, picking from the pallet and placing the packages tightly into the boxes despite the high variance, and secondly, recognizing an intermediate layer with an unknown imprint. Another complicating factor here is that the design of the layer pads can be similar to that of the boxes. "The only approach that worked reliably here was the use of artificial intelligence," explains Frey. Schmalz implemented the defined setting pattern with workpiece-specific programming: Würth initially started with a limited range of parts that utilized the first cell to 100 percent capacity. The picking performance of the subsequent cells was then optimized and the range of parts for automated storage was expanded. In contrast, the challenges posed by the tight space conditions at the site and the additional task of picking the empty containers from a crate conveyor were relatively easy to meet. This is because a laser scanner makes a safety fence superfluous and ensures a lean cell. As soon as a person approaches, the collaborative robot reduces its speed and continues to work safely with reduced forces.

One system, three grippers - flexibility for all carton sizes

To complete the different gripping tasks, the cobot can independently swap the suction cups of the SBPG bin-picking gripper and - thanks to the match quick-change module - the entire gripper. "One load receptor is always on the robot arm while the other is waiting in the gripper station. If, for example, a crate needs to be moved, the cobot picks up the PXT gripper designed for this purpose. Thanks to the standardized connection and communication, it is immediately ready for use," explains Frey. The SBPG has three suction cups at its disposal, the SAOF oval, the SPB1 60 and the SPB1 80, so that the robot can safely handle any size of carton. The required vacuum is provided by the RECB pneumatic vacuum generator; its integrated SEP nozzle ensures efficient and energy-saving operation. Schmalz has implemented software that allows employees to enter the current order via the user interface. The software communicates with the camera, the cobot and the safety laser scanner and adapts the robot control and the camera to the task after the input. Currently, around 30 percent of the extensive range of goods is covered - and the trend is rising. Würth controls the entire order management of the robot cell via the software. Other features include the target container check, in which the camera checks whether the KLT provided is really empty, the recognition and removal of intermediate layers from the source box and the collision check. The software calculates the waypoints that the robot approaches and uses the digital twin to check whether there are any collisions. If this is the case, it avoids the obstacles and defines new waypoints.

The Cobot has been in operation at VZ West for just over a year. The staff in the incoming goods department are delighted and have integrated the robot into their daily processes. The employees use the pallet truck to move a Euro pallet with boxes to the designated area. The boxes are between 100 and 250 millimetres long, 90 to 100 millimetres high and 90 millimetres wide. The robot picks up the KLT target container itself from a conveyor belt. The robot cell fills as many KLT containers until the Euro pallet is empty. As they are pushed onto the conveyor system, the containers are scanned and recorded in the SAP system. This solution shows how a collaborative robot in combination with a camera system and the right programming can help to reduce the workload of employees.