{"id":71,"date":"2026-06-01T10:38:02","date_gmt":"2026-06-01T10:38:02","guid":{"rendered":"https:\/\/khkrh7q1ur.wpdns.site\/product\/robotic-tray-loading\/"},"modified":"2026-06-09T22:30:14","modified_gmt":"2026-06-09T22:30:14","slug":"robotic-tray-loading-product","status":"publish","type":"product","link":"https:\/\/benlongkj.com\/ru\/product\/robotic-tray-loading-product\/","title":{"rendered":"\u0420\u043e\u0431\u043e\u0442\u0438\u0437\u0438\u0440\u043e\u0432\u0430\u043d\u043d\u0430\u044f \u0437\u0430\u0433\u0440\u0443\u0437\u043a\u0430 \u043b\u043e\u0442\u043a\u043e\u0432"},"content":{"rendered":"
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End\u2011of\u2011line \u00b7 High\u2011speed pick\u2011and\u2011place<\/div>\n

High\u2011Precision Robotic Tray Loading System for Circuit Breakers<\/h1>\n

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.<\/p>\n

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 \u2013 15 parts picked per minute; however, these will vary based on tray size and part shape.<\/p>\n

Standard delivery: 45-60 days | Custom gripper design | Seamless line integration<\/span><\/p>\n<\/p><\/div>\n

\n \"Robotic<\/p>\n
Robot tray loading station (actual product)<\/div>\n<\/p><\/div>\n<\/p><\/div>\n
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What is a Robotic Tray Loading System?<\/h2>\n

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.<\/p>\n

\n
\n Customized gripper<\/strong>
\n Vacuum or soft mechanical gripper \u2013 no marks, no scratches on PBT\/plastic parts.\n <\/div>\n
\n High\u2011density matrix loading<\/strong>
\n Programmable row\/column pattern maximizes tray utilization.\n <\/div>\n
\n Conveyor synchronization<\/strong>
\n Photocell sensors trigger robot pick; seamless line integration.\n <\/div>\n
\n Orientation accuracy<\/strong>
\n Ensures 100% correct part placement (up\/down, left\/right).\n <\/div>\n<\/p><\/div>\n<\/p><\/div>\n
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System Features & Integration<\/h2>\n
\n
\n \"Intelligence<\/p>\n
\u0418\u043d\u0442\u0435\u043b\u043b\u0435\u043a\u0442 \u0438 \u043f\u0440\u043e\u0437\u0440\u0430\u0447\u043d\u043e\u0441\u0442\u044c<\/div>\n<\/p><\/div>\n
\n \"Efficiency<\/p>\n
\u042d\u0444\u0444\u0435\u043a\u0442\u0438\u0432\u043d\u043e\u0441\u0442\u044c \u0438 \u0443\u0441\u0442\u043e\u0439\u0447\u0438\u0432\u043e\u0441\u0442\u044c<\/div>\n<\/p><\/div>\n
\n \"Design<\/p>\n
\u041f\u0440\u043e\u0435\u043a\u0442\u0438\u0440\u043e\u0432\u0430\u043d\u0438\u0435 \u0438 \u0438\u043d\u0442\u0435\u0433\u0440\u0430\u0446\u0438\u044f<\/div>\n<\/p><\/div>\n
\n \"Safety<\/p>\n
\u0411\u0435\u0437\u043e\u043f\u0430\u0441\u043d\u043e\u0441\u0442\u044c \u0438 \u043d\u0430\u0434\u0435\u0436\u043d\u043e\u0441\u0442\u044c<\/div>\n<\/p><\/div>\n<\/p><\/div>\n<\/p><\/div>\n

\u0422\u0435\u0445\u043d\u0438\u0447\u0435\u0441\u043a\u0438\u0435 \u0445\u0430\u0440\u0430\u043a\u0442\u0435\u0440\u0438\u0441\u0442\u0438\u043a\u0438<\/h2>\n
High\u2011speed robotic tray loading system for circuit breakers and PBT components. Custom gripper, conveyor integration, matrix pattern, 10\u201115 picks\/min.<\/div>\n
\n\n\n\n\n\n\n\n\n\n\n\n\n
Robot type<\/th>\n6\u2011axis industrial robot (Fanuc, Yaskawa, or equivalent)<\/td>\n<\/tr>\n
Payload capacity<\/th>\nUp to 5\u201110 kg (depending on model)<\/td>\n<\/tr>\n
Pick\u2011and\u2011place cycle time<\/th>\nApprox. 3\u20116 seconds per pick (10\u201115 picks\/minute)–\n <\/td>\n<\/tr>\n
Gripper type<\/th>\nCustom vacuum cup (soft) or mechanical gripper with soft pads–\n <\/td>\n<\/tr>\n
Part compatibility<\/th>\nMCB, MCCB, contactors, PBT housings, any clean\u2011surface component–\n <\/td>\n<\/tr>\n
Tray matrix<\/th>\nProgrammable rows (2\u201120) and columns (2\u201120), auto\u2011increment after each layer–\n <\/td>\n<\/tr>\n
Conveyor interface<\/th>\nPhotocell + PLC handshake (I\/O or Ethernet\/IP)–\n <\/td>\n<\/tr>\n
Safety features<\/th>\nSafety fence, light curtain, emergency stop, area scanner–\n <\/td>\n<\/tr>\n
\u0441\u0438\u0441\u0442\u0435\u043c\u0430 \u0443\u043f\u0440\u0430\u0432\u043b\u0435\u043d\u0438\u044f<\/th>\nRobot controller + integration PLC (optional), HMI for tray setup–\n <\/td>\n<\/tr>\n
\u0418\u0441\u0442\u043e\u0447\u043d\u0438\u043a \u043f\u0438\u0442\u0430\u043d\u0438\u044f<\/th>\n380V \u00b110% 50Hz | Compressed air 0.6MPa (for gripper)–\n <\/td>\n<\/tr>\n<\/tbody>\n<\/table><\/div>\n

\u041e\u0441\u043d\u043e\u0432\u043d\u044b\u0435 \u0442\u0435\u0445\u043d\u0438\u0447\u0435\u0441\u043a\u0438\u0435 \u043f\u0440\u0435\u0438\u043c\u0443\u0449\u0435\u0441\u0442\u0432\u0430<\/h2>\n
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No part marking or scratching<\/h4>\n

The customized gripper uses soft vacuum cups or foam\u2011lined mechanical fingers, specifically designed for PBT and other molded plastics. This eliminates surface damage that would cause cosmetic rejects.\n <\/p><\/div>\n

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100% orientation accuracy<\/h4>\n

The robot is taught exact pick points and placement orientation. Parts are always placed with correct polarity (if applicable) and consistent spacing \u2013 eliminating manual errors that lead to tray misalignment.\n <\/p><\/div>\n

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Seamless line integration<\/h4>\n

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.\n <\/p><\/div>\n

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Quick changeover for different tray sizes<\/h4>\n

HMI\u2011based 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.\n <\/p><\/div>\n<\/p><\/div>\n

\n \u041d\u0430\u043c \u0434\u043e\u0432\u0435\u0440\u044f\u044e\u0442 \u043b\u0438\u0434\u0435\u0440\u044b \u043e\u0442\u0440\u0430\u0441\u043b\u0438.<\/span><\/p>\n
\n
\n \"ABB\"\n <\/div>\n
\n \"DELIXI\"\n <\/div>\n
\n \"EKF\"\n <\/div>\n
\n \"KRIPAL\"\n <\/div>\n
\n \"HPL\"\n <\/div>\n
\n \"CHAC\"\n <\/div>\n
\n \"Schneider\"\n <\/div>\n
\n \"IEK\n <\/div>\n
\n \"SUNIR\"\n <\/div>\n
\n \"Bevone\"\n <\/div>\n
\n \"Weg\"\n <\/div>\n
\n \"HUYU\"\n <\/div>\n
\n \"RAAD\"\n <\/div>\n
\n \"WALTONE\"\n <\/div>\n
\n \"HAVELLS\"\n <\/div>\n
\n \"C&S\n <\/div>\n<\/p><\/div>\n<\/p><\/div>\n
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Customer Success Story \u2013 Circuit Breaker Assembly Line<\/h3>\n

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:<\/p>\n

\n
15 picks\/min<\/strong> Sustained speed (vs 8 manual)<\/div>\n
0%<\/strong> Part damage (cosmetic scratches eliminated)<\/div>\n
-80%<\/strong> Direct labor cost for tray loading<\/div>\n<\/p><\/div>\n

The system paid for itself in 8 months and increased overall line OEE by 12%.<\/p>\n<\/p><\/div>\n

\u041f\u0440\u0438\u043b\u043e\u0436\u0435\u043d\u0438\u044f \u0438 \u0438\u043d\u0442\u0435\u0433\u0440\u0430\u0446\u0438\u044f<\/h2>\n
\n
\n
Circuit breaker assembly lines<\/strong> \u2013 End\u2011of\u2011line tray loading for MCB, MCCB, RCBO<\/div>\n
Electrical component manufacturing<\/strong> \u2013 Contactors, switches, relays, terminal blocks<\/div>\n
Injection molding cells<\/strong> \u2013 Removing finished parts from mold and placing into trays<\/div>\n
Packaging lines<\/strong> \u2013 Feeding trays to downstream sealing or cartoning machines<\/div>\n<\/p><\/div>\n<\/p><\/div>\n

\u0420\u0430\u0437\u0440\u0430\u0431\u043e\u0442\u043a\u0430 \u0438 \u043f\u043e\u0441\u0442\u0430\u0432\u043a\u0430 \u043f\u043e \u0438\u043d\u0434\u0438\u0432\u0438\u0434\u0443\u0430\u043b\u044c\u043d\u043e\u043c\u0443 \u0437\u0430\u043a\u0430\u0437\u0443<\/h2>\n
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1. Part & tray analysis<\/strong> 7-10 days \u00b7 part samples, tray dimensions, grid pattern<\/div>\n
2. Gripper & cell design<\/strong> 15-25 days \u00b7 vacuum\/mechanical gripper, safety layout<\/div>\n
3. Manufacturing & programming<\/strong> 45-60 \u0434\u043d\u0435\u0439<\/div>\n
4. Pre\u2011FAT<\/strong> \u041d\u0430 \u0437\u0430\u0432\u043e\u0434\u0435 \u0411\u0435\u043d\u043b\u043e\u043d\u0433<\/div>\n
5. Installation & line integration<\/strong> On-site 5\u20117 days<\/div>\n
6. \u0418\u0442\u043e\u0433\u043e\u0432\u044b\u0439 \u044d\u043a\u0437\u0430\u043c\u0435\u043d SAT \u0438 \u043e\u0431\u0443\u0447\u0435\u043d\u0438\u0435.<\/strong> 3\u20115 days \u00b7 acceptance report<\/div>\n<\/p><\/div>\n
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Request a Custom Robotic Tray Loading Quote<\/h2>\n

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.<\/p>\n

\u0417\u0430\u043f\u0440\u043e\u0441\u0438\u0442\u044c \u0438\u043d\u0444\u043e\u0440\u043c\u0430\u0446\u0438\u044e \u0441\u0435\u0439\u0447\u0430\u0441<\/a><\/p>\n

WhatsApp: +86 150 5837 0007 | \u042d\u043b\u0435\u043a\u0442\u0440\u043e\u043d\u043d\u0430\u044f \u043f\u043e\u0447\u0442\u0430: xsb@benlongkj.cn | \u041f\u043e\u0434\u0434\u0435\u0440\u0436\u043a\u0430 \u043d\u0430 \u0430\u043d\u0433\u043b\u0438\u0439\u0441\u043a\u043e\u043c \u0438 \u043a\u0438\u0442\u0430\u0439\u0441\u043a\u043e\u043c \u044f\u0437\u044b\u043a\u0430\u0445<\/p>\n<\/p><\/div>\n

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Why Choose Benlong for Robotic Tray Loading?<\/h3>\n