Project overview
Transicon was commissioned to design a pick and place system for a leading manufacturer in the metals industry, which would be suitable for aluminium trapezoidal blanks as well as steel.
The bespoke solution would utilise the team’s expertise in mechatronics, motion and intelligent controls to create a fit-for-purpose stacking system that could be quickly and easily integrated into the customer’s existing press line, while improving accuracy, productivity and quality.
The challenge
The brief for the bespoke pick and place system was complex. The customer’s existing production set up used a magnetic stacker, which was perfect for steel production but unsuitable for aluminium. In addition to the material issue, the customer found that the trapezoidal blanks often landed unevenly on the conveyor belt, which was causing alignment problems and threatening product quality.
As well as resolving these challenges, the new pick and place solution needed to be geared up for high-speed, high-accuracy work, capable of stacking parts within submillimetre tolerance, plus it had to integrate seamlessly within the customer’s existing press line without sacrificing speed or uptime.
The solution
Transicon designed and built a bespoke four-axis high-speed pick and place stacker system using vacuum pads, making it suitable to handle both aluminium and steel blanks.
Key features of the solution included:
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A bespoke mechatronic arrangement with linear and rotary axes, designed inhouse by Transicon engineers
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Integrated dual-camera and motion controllers to monitor and adjust stack alignment in real time
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A fully rotating gripper head for perfect pallet stacking, while maintaining speed and precision
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Dual pallet cart system for automatic loading and unloading, for continuous production
To ensure the pick and place system integrated seamlessly into the existing press line, intelligent controls were introduced to create a common interface for the old and new systems to communicate production and safety data, simplify operations and improve visibility.
The press timing was also reconfigured to cycle when the conveyor space was ready to fully synchronise its timing with the pick and place system, thereby maintaining a continuous flow in production.
Technical outcome
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Adaptable system suitable for aluminium and steel production
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Stack accuracy improved to within 0.5mm
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Installation and commissioning completed during a planned shutdown – no added downtime on a busy production line
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Intuitive operator interfaces and simplified maintenance for ease of use
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Enhanced safety and efficiency features including integrated light curtains and coordinated safety controls
This project is one example of how Transicon works with customers to solve complex, bespoke automation challenges — using a practical, engineering-led approach to deliver measurable results.
If you’re facing a production or process bottleneck and need a solution that fits your existing infrastructure, we’d be happy to help.
Contact us to talk through your requirements.
