benlong 
Carga robótica de bandejas
Custom robotic tray loading system for circuit breakers and PBT components. High‑speed pick‑and‑place (10‑15 picks/min), soft gripper (no scratches), high‑density matrix pattern, conveyor integration. Replaces manual packing, reduces labor cost, ensures 100% orientation. Ideal for end‑of‑line automation.
High‑Precision Robotic Tray Loading System for Circuit Breakers
The robotic tray loading system has been designed to provide an end-of-line automated (also called unit-load or bulk-load) solution for finished circuit breakers by arranging them into predefined matrix grids in both shipping trays and injection mold trays. The robot picks and places each breaker into the correct location using pick and place technology, which allows for high throughput and 100% proper orientation. In addition, the robot offers protection from any type of surface damage to components during handling, and it also eliminates inconsistencies in manual labor, as well as greatly reducing cycle times.
This method utilizes a high-speed industrial robot outfitted with a custom-designed vacuum or mechanical gripper for handling PBT moulded parts. The gripper design ensures that the parts are handled without leaving any marks or scratches on them. There are sensors installed to identify finished parts at the outfeed conveyor; once an identified part is detected, the robot will pick and place the individual parts into a high-density matrix configuration at the required location. The system is crucial for applications such as high-volume circuit breaker assembly, because it guarantees that every part is structurally sound while maintaining the same output. Typical throughput rates range from 10 – 15 parts picked per minute; however, these will vary based on tray size and part shape.
Standard delivery: 45-60 days | Custom gripper design | Seamless line integration
What is a Robotic Tray Loading System?
The Robotic Tray Loading System is an efficient and automated way to load finished products (circuit breakers or other electronic components) into trays to be shipped off (end-of-line). The robotic arm will pick up products from a conveyor belt in matrix pattern at a programmed speed and then gently place them into the proper position based on the varying geometries of the products. The use of a robotic arm versus manually packing the product into a tray allows for precision with the product placement based on orientation, gap distance between all products, and proper handling. A typical Robotic Tray Loading System consists of the following: high-speed robot arm with a custom designed end effector (i.e., vacuum cup or soft gripper), tray magazine or conveyor to supply the trays while the robot is packing the product into the tray, safety guarding and a programmable interface to allow for easy operator use. The Robotic Tray Loading Systems is perfect for high production applications where product integrity (scratching of molded plastic housings) and traceability (i.e., barcode scanning prior to loading the tray) is required. We provide non-standard/custom solutions tailored to meet your products specific characteristics (geometrical shape, material type, and tray size) by providing you with custom designed end effectors, robot speed and tray layout.
Vacuum or soft mechanical gripper – no marks, no scratches on PBT/plastic parts.
Programmable row/column pattern maximizes tray utilization.
Photocell sensors trigger robot pick; seamless line integration.
Ensures 100% correct part placement (up/down, left/right).
System Features & Integration
Especificaciones técnicas
| Robot type | 6‑axis industrial robot (Fanuc, Yaskawa, or equivalent) |
|---|---|
| Payload capacity | Up to 5‑10 kg (depending on model) |
| Pick‑and‑place cycle time | Approx. 3‑6 seconds per pick (10‑15 picks/minute)– |
| Gripper type | Custom vacuum cup (soft) or mechanical gripper with soft pads– |
| Part compatibility | MCB, MCCB, contactors, PBT housings, any clean‑surface component– |
| Tray matrix | Programmable rows (2‑20) and columns (2‑20), auto‑increment after each layer– |
| Conveyor interface | Photocell + PLC handshake (I/O or Ethernet/IP)– |
| Safety features | Safety fence, light curtain, emergency stop, area scanner– |
| Sistema de control | Robot controller + integration PLC (optional), HMI for tray setup– |
| Fuente de alimentación | 380V ±10% 50Hz | Compressed air 0.6MPa (for gripper)– |
Ventajas técnicas principales
No part marking or scratching
The customized gripper uses soft vacuum cups or foam‑lined mechanical fingers, specifically designed for PBT and other molded plastics. This eliminates surface damage that would cause cosmetic rejects.
100% orientation accuracy
The robot is taught exact pick points and placement orientation. Parts are always placed with correct polarity (if applicable) and consistent spacing – eliminating manual errors that lead to tray misalignment.
Seamless line integration
The system connects directly to your outfeed conveyor. Sensors detect incoming parts, and the robot places them into trays. Full I/O handshake ensures no jams or missed picks.
Quick changeover for different tray sizes
HMI‑based recipe selection allows the robot to switch between different tray dimensions and matrix patterns in under 5 minutes. Mechanical tooling (gripper pads) can be swapped in 10 minutes.
Customer Success Story – Circuit Breaker Assembly Line
Linda Fab facility, which is a major manufacturer of miniture circuit breakers (MCB), employed six operators to manually load finished MCBs into trays. This was a slow process, with parts being damaged from mishandling on a number of occasions. Benlong implemented a robotic tray loading system using a custom vacuum gripper. After three months of being in operation, the results were as follows:
The system paid for itself in 8 months and increased overall line OEE by 12%.
Aplicaciones e integración
Ingeniería y entrega a medida
Request a Custom Robotic Tray Loading Quote
Please provide us your sample piece, dimensions of the tray, and target productivity. Our engineering staff will create an individual solution for picking and placing your product using a scratch-free gripper and providing a complete ROI calculation.
WhatsApp: +86 150 5837 0007 | Correo electrónico: xsb@benlongkj.cn | Soporte en inglés y chino
Why Choose Benlong for Robotic Tray Loading?
- 15+ years integrating robotic tray loading systems for electrical component lines
- Custom gripper design – vacuum or soft mechanical, no marking
- High‑density matrix pattern programming – maximizes tray utilization
- Seamless conveyor integration with I/O or Ethernet/IP
- Soporte técnico y de repuestos a nivel mundial
Typical Custom System Includes
6-axis industrial robotic (fanuc/yaskawa) custom end-effector (vacuum /soft gripper) tray magazine or conveyor safety fencing with interlocked robot controller/hmi PLC integration (optional) conveyor photoeye sensors installation and Training 1 yr warranty
Preguntas frecuentes
MCB (1P/2P/3P/4P), MCCB, RCBO and other similar molded-case devices; gripper and/or pick positions can be configured specifically for the part’s geometry.
We don’t use hard vacuum cups (except when installing parts on heavy steel). Instead we use silicone vacuum cups or mechanical grippers with soft, foam lined fingers that have been tested for each of the PBTs and other molded plastics. Marking Tests are performed during the acceptance testing.
A tray magazine can hold a whole bunch of empty trays (10 to 20) high stacked up. Once the current tray is full, the robot will automatically move to the next tray. The changeover time to a different tray type is 5 to 10 minutes depending on recipe selection and mechanical adjustments.
A barcode scanner can definitely be integrated prior to the pick station, after which the robot places the component into trays oriented correctly to maintain traceability after being processed.
The return on investment (ROI) when replacing 4-6 manual packers on a line producing 10,000 units/shift is generally between 6-10 months based on savings in labor and reduced rework costs due to parts being damaged during manual processing.
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