Consumer products often involve high SKU variety and frequent changeovers. Motionwell has delivered cobot-based unloading stations handling mixed SKUs (consumer beverage products, snacks, detergent) with electromagnet quick-change EOAT that automatically switches between gripper and vacuum modes. We also build SCARA-based panel assembly systems for home appliance manufacturers (P23045 for industrial sensor panels) and end-of-line packaging automation with vision-guided labeling.
We design for flexibility without sacrificing consistency: recipe-driven mode switching on the HMI, modular fixtures that swap in minutes, and vision verification that catches variant mix-ups before they leave the line.
- Cobot unloading stations with auto-adjusting pitch for different package sizes, handling mixed SKUs including beverages, snacks, and household products
- Electromagnet quick-change EOAT with 5-magnet array, pneumatic gripper mode, and vacuum suction mode for automatic tool switching
- End-of-line packaging automation: wrapping, vision-guided labeling, case packing, and palletizing integration
- SCARA robotic assembly for home appliance panels, consumer electronics, and wearable device components with vision-guided alignment
- Changeover time and operator simplicity: recipe-driven mode switching via HMI with no mechanical adjustment needed
- SKU variant management with vision verification of color, label, barcode, and pack content at line speed
- Cost-effective automation that starts semi-auto and scales to full automation as volume grows
- Robust handling for varied packaging materials: carton, plastic, shrink-wrap, bottles, and pouches
- Universal Robots cobot with custom EOAT design combining gripper, vacuum, and electromagnet modes
- OPC-UA and Ethernet/IP communication for line integration and production data exchange
- Vision-based variant verification and label inspection with multi-recipe programming
- Modular fixture design for fast SKU changeover without mechanical rework or special tools
Featured: Cobot Unloading Station with Quick-Change EOAT
Motionwell designed a cobot-based unloading station for a consumer goods distribution center handling mixed SKUs including consumer beverage products, snacks, and detergent. The system features a 5-magnet electromagnet quick-change EOAT that automatically switches between gripper and vacuum modes depending on the package type, with auto-adjusting pitch for different carton sizes.
- Robot: Universal Robots cobot with custom multi-mode EOAT
- EOAT modes: 5-magnet electromagnet array, pneumatic gripper, vacuum suction
- SKUs: Mixed consumer products (beverages, snacks, household goods)
- Switching: Automatic mode selection based on product type, no manual changeover
How the Modular Unloading Station Works
A carton box enters the modular unloading station via a carton box conveyor. A barcode scanner reads the carton ID label. Tote bins enter via tote bin conveyors and their tote IDs are also scanned. The carton is securely clamped at the work zone.
Based on the carton ID information, the robot arm equipped with a customized End-of-Arm Tool (EOAT) automatically reconfigures to the correct tool set from a tool change rack. The tool reconfiguration is predefined in the Host PLC. The robot unloads SKUs from the carton box into tote bins. Once unloading completes, the carton ID updates with process code and the emptied carton conveys out of the station. Every filled tote bin updates with SKU information and conveys out.
The X and Y axis pitch adjustment runs different stepper motors for picking different items as required by the process. This allows the same EOAT to handle different product sizes and packaging formats without mechanical changeover.
Integration Architecture
The unloading station uses its own PLC for local machine control while communicating with other stations through OPC-UA protocol. This architecture allows each station to operate independently while remaining coordinated within the larger production line. Barcode-based tracking ensures every carton and tote bin is accounted for throughout the process.