Non-stop Pick-and-Place

In packaging technology, every moment of downtime costs valuable throughput. In this context, cycle interruptions during pick-and-place operations are not a technological necessity—but rather a design choice. What matters is not merely a robot's speed, but its ability to remain continuously synchronized with the running machine. Lenze offers numerous solutions to address this challenge.

At the core of this approach is the interplay between Rotary Tracking, open interfaces, and the Lenze Fast Robotics Template. Pick-and-place processes on rotating tables are executed without requiring the mechanical system to come to a standstill—efficiently, precisely, and with significantly reduced engineering effort. Machine builders benefit from higher line performance, shorter cycle times, and a faster time-to-market for their applications. Inline Robotics with Rotary Tracking: Continuous Motion Instead of Stop-and-Go.

A Delta robot picks up products from two rotating tables and places them down in perfect synchronization, without ever halting the tables' movement. This is made possible by Rotary Tracking—a motion and robotics concept in which the robot computationally "rides along" with the continuous motion of the mechanical system. The position, velocity, and acceleration of the rotating axes are continuously captured via high-precision servo drives and encoders, and processed in real time within the Lenze Controller. Based on this data, the controller calculates a dynamic target trajectory for the robot, allowing it to virtually "lock into" the rotation and execute the pick-and-place operation while the mechanical system remains in motion. The rotary table never stops—eliminating unnecessary cycle delays, reducing mechanical wear, and maximizing throughput.

Configuration instead of programming: rapid commissioning with Fast robotics

Another key focus lies on ease of implementation: Instead of relying on traditional, cost-intensive robot programming, Lenze utilizes Fast Robotics as part of its Lenze Fast Application Software suite. This modular software toolkit is based on PLCopen standards and enables the seamless integration of robotic kinematics into the overall machine automation system. Predefined robot types, pre-engineered technology modules for pick-and-place applications, and an integrated robotics core significantly reduce engineering effort. Motion sequences are configured via parameters rather than programmed; system extensions can be implemented with minimal risk, and existing applications can be scaled flexibly.

Furthermore, a digital twin facilitates virtual commissioning: motion sequences and processes can be tested and optimized before the actual plant is even assembled. This lowers project risk, shortens on-site commissioning times, and ensures a faster time-to-market. For machine builders, this translates into reduced development effort, lower costs, and a robust, future-proof foundation for high-performance robotics applications.

Open, integrated and future-proof: robotics without system breaks

A key characteristic of Lenze Inline Robotics is its consistent openness. With Lenze Fast Robotics, robot kinematics can be integrated directly into the machine automation system—without the need for an additional robot controller, a separate programming environment, or an extra control cabinet. Motion control, logic control, and robotics all run on a single shared platform, managed by a single Lenze controller. This reduces system complexity, simplifies engineering, and delivers sustainable cost savings throughout the entire lifecycle of the machine.

Machine builders retain complete design freedom: in addition to integrated robots, both commercially purchased and custom-developed kinematics can be incorporated into the system. A wide variety of robot types—ranging from Delta and SCARA robots to gantry axes, articulated-arm robots, and palletizing solutions—can be implemented regardless of the specific application or motion control requirements. Changes to geometry, product formats, or line layouts can be executed via software, eliminating the need to redesign the entire system architecture from scratch.

This capability is built upon open standards: for its integrated robotics solutions, Lenze relies consistently on PLCopen motion control standards. This ensures vendor-independent compatibility, facilitates the expansion of existing machinery, and offers investment security—even in the face of future requirements or partner solutions. The result is a future-proof automation platform that enables the efficient implementation of complex robotics applications—open to partnerships, flexible in design, and robust in operation.