An advanced automation solution developed by Transicon Ltd is enhancing safety and productivity at a leading UK steel and aluminium structural materials manufacturer — showcasing the full capabilities of its in-house mechatronics team.
The fully automated robotic stacker system – designed, built and commissioned entirely by Transicon – eliminated the need for manual handling of heavy materials and delivered a step change in operational efficiency and safety.
A key element of the solution was Transicon’s custom-designed dual Delta robot system, developed specifically to handle a wide range of material profiles and finishes.
Jennifer Hughes, general manager of Transicon, said the project exemplified the company’s strengths in end-to-end mechatronic engineering.
“Our client was looking to remove the risks and inefficiencies of manual stacking and needed a partner who could design and deliver a complete solution – not just in control, but in mechanical systems too,” she said.
“This was an ideal project for our team, who developed a highly flexible robotic system tailored to the customer’s exact handling requirements.
“The result was a robust, intelligent design that adapts to material size and sheet characteristics, with built-in safety and full integration into the production line.”
The system features two Delta robots, each fitted with specialist vacuum end-effectors designed to handle steel and aluminium profile in a variety of finishes and material gauges.
The robots operate in either dual-station mode (for sheets under 6,500mm) or tandem mode (for longer material), with seamless switching depending on the job.
To support the system’s high-speed, synchronised movement, Transicon partnered with Bosch Rexroth to incorporate advanced servo drive technology. The servo platform was chosen for its compatibility with the robots’ kinematics and ability to meet precise motion demands. Virtual simulations of the motion system were run during development to refine performance and reduce risk ahead of build.
“We were pleased to work with Bosch Rexroth on the motion control side,” added Jennifer.
“Their technology complemented our robot design perfectly, and their support helped us deliver the precision the project required.”
The solution was delivered entirely by Transicon – including concept design, mechanical and control engineering, build, installation, commissioning, and training.
It continues to operate as a fully integrated part of the manufacturer’s production line, delivering improved throughput and a safer working environment.
Transicon, based at Queensway Business Park in Telford, has been delivering industrial automation and control solutions for decades. The company supports manufacturers across the UK, with clients including Müller, BMW, Tata Steel and major utilities.
