Cell and gene therapies (CGTs) treat life-altering diseases, such as cancers and genetic diseases, at the root level by modifying DNA, living cells or tissue. Among the most complex and advanced medical treatments under development, these therapies have the potential to deliver long-lasting or even curative treatment. However, access to these treatments worldwide is limited due to the costly, labour-intensive manufacturing processes involved.

“The challenge today is that the biology is phenomenal, but the manufacturing capacity and the ability to scale that to the world is not there.” Says Leo Steenson, Head of Robotics at Cellular Origins.

Cellular Origins set out to change this by developing a scalable, robotic system that could fit into existing or new manufacturing facilities. To automate cell therapy manufacturing, Cellular Origins needed a way to transport materials between different stations for each stage of the production process. Unlike systems that rely on higher-grade cleanroom environments, Cellular Origins’ method uses sterile tube welding to form closed connections, supporting operation in Grade C/D environments while mitigating contamination risk and reducing gowning requirements for operators. The whole system would be controlled by a unified software orchestration layer to track every step, coordinate equipment and process activities, and collect data.

It became clear to the Cellular Origins team that Integrated Mobile Robots (IMRs) would be the ideal solution to facilitate the transport of materials. It was important that the system could navigate autonomously around dynamic environments, enabling human interaction as required. Another key consideration was that the mobile robot base had an open interface that would allow it to be integrated with the central software system, as well as an industrial robot arm, which would sit on top of the mobile unit.

Collaborative, autonomous navigation

After considering multiple options, including AGVs which would require tracks to run on, Cellular Origins engaged with RARUK Automation for a demonstration of the MiR250 autonomous mobile robot (AMR), developed by Mobile Industrial Robots, a Teradyne Robotics company. The demonstration highlighted the model’s compact footprint and collaborative, autonomous navigation capabilities. Additionally, MiR’s Agility Boost feature enables faster, smoother navigation in narrow and dynamic environments, which makes the AMR ideal for operating within the space-constrained layouts CGT manufacturing requires.

“The MiR250 is the ideal size, weight, payload, but crucially it is the easiest to integrate.” Remarks Steenson.

A key differentiating feature for the MiR250 was its open architecture, which enables communication with a wide range of industrial systems and devices. This provides manufacturers with the freedom to build tailored automation solutions without being constrained by proprietary interfaces or rigid system designs.

“The MiR platform is what we call an open platform. It’s able to communicate with multiple different industrial devices,” explains Ross Lacy, Sales Director at RARUK Automation. “It allows the users to build a platform that fits into their application around that, so it’s quite unique in that sense.”

In addition to its flexibility to integrate with a range of technologies, the MiR250 (along with the rest of the MiR range) has smart charging capabilities. The mobile robot monitors its own battery levels and automatically docks for charging at a logical break point. When multiple MiR robots are managed by MiR Fleet software, the software coordinates jobs and charging schedules across the fleet. Robots can take turns charging while others continue working, helping maintain continuous, 24/7 operation.

“[MiR AMRs] can autonomously charge, they are scalable, they have a piece of fleet software that allows up to 100 to be used in the same environment,” says Lacy. “They are very straightforward to get to grips with and get going.”

After Cellular Origins selected the MiR250 as the foundation of its integrated mobile robot (IMR), the implementation process progressed rapidly. The platform’s ease of use enabled the team to begin operating the robot almost immediately following initial training. Working closely with RARUK Automation, Cellular Origins then focused on refining the system and addressing the technical requirements needed to integrate the MiR250 with its other technologies.

As Steenson recalls: “After some training with Ross and the team, we got [the MiR] running within hours and, after that, we worked very closely together to figure out all of the integration details. Within a few months we had a working IMR.”

Technical advice and support

As well as the strong technical foundation provided by the MiR250, the collaborative working relationship between Cellular Origins and RARUK Automation proved instrumental both during development and now, as the solution is deployed at scale. From technical advice and support to facilitating discussions with the manufacturer, Mobile Industrial Robots, as operations scale, RARUK Automation prides itself on being a local partner that streamlines and simplifies the automation process.

Reflecting on the partnership between the two companies, Steenson comments: “[RARUK Automation] brings that wealth of expertise: they’ve worked across multiple different industries, they’ve worked with mobile robotics for years. They’ve listened, they’ve understood and they’ve delivered time after time.”

A vision of scalable cell therapy manufacturing

Since its launch in May 2023, Constellation is the materialisation of Cellular Origins’ vision of scalable cell therapy manufacturing, with IMRs playing a central role in its flexible, automated ecosystem. The platform can achieve up to 30 times greater space efficiency, a 16-fold reduction in labour requirements and a 51% reduction in cost of goods compared with conventional manufacturing approaches, helping make advanced therapies more accessible and economically viable.

Crucially, by unlocking the cost-savings achieved through smart automation, Cellular Origins’ Constellation is improving access to life changing therapies – helping more patients receive the treatment they need.

Steenson concludes: “Success for Cellular Origins ultimately is in the treatment of the patients. Starting from the first dose through to tens-of-thousands and RARUK Automation enables us to do that as quickly as we possibly can.”

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The manufacture of wiring harnesses is one of the last major challenges in industrial automation. While robots have long been performing a wide range of tasks in many industries, the assembly of complex wiring harnesses has remained the domain of manual labour until now. The reasons for this lie in the nature of the task itself: cables are flexible, dimensionally unstable components that are difficult to handle.

That is why cable harnesses are still manufactured exclusively by hand. Cable harness manufacturing is a classic “migratory industry” that moves to countries with low labour costs because of this. However, with rising demands, the desire for greater resilience within supply chains, and the goal of bringing production back to high-wage countries, there is also a growing effort to automate this process.

Cellios, which emerged from the Fraunhofer Institute for Manufacturing Engineering and Automation (IPA) in Stuttgart and was founded in 2024, has developed a solution specifically for this purpose. The company specialises in the manufacture of robot-based automation systems for cable assembly. At the heart of its portfolio are modular robot cells that digitise and automate the manual cable assembly process. The project partner for the world’s first fully automated cable harness is TE Connectivity.

“Previous solutions often covered only partial steps of cable processing, meaning that pre-assembled cables had to be further processed manually. The goal of the project with TE Connectivity was therefore to fully automate the entire process, right up to electrical testing,” explains Dr. Frank Nägele, CTO at Cellios.

First fully integrated, fully automated wire harness

Achieving this requires overcoming numerous challenges. For example, the terminated cable ends, known as crimps, which are only a few millimeters wide, must be inserted into the corresponding connectors. The greatest challenge, however, is the cable itself. Because cables do not have a rigid shape, the position of the crimp in the gripper changes with every handling operation. To reliably guide the crimp into the tiny cavity of a connector, an accuracy of at least one-tenth of a millimetre is required.

“In addition to the technical issues, there are also complex process-related questions. After all, the objective is to automate a process that has been entirely manual. Components such as connectors, cable-processing machines, and so on are designed for use by humans, not robots. On top of that, there is an enormous variety of wire harness variants that we want to accommodate through the flexible design of our assembly cells,” explains Dr. Nägele.

Cellios’ answer to these challenges is a modular system. The company maps the various stages of wire harness assembly to different modules. The individual process steps include connector singulation, cable preparation, crimping, cable routing, producing splice connections with an ultrasonic welding device, taping, and finally end-of-line testing. The most difficult task to automate so far is routing followed by contact insertion. As described above, the robot has to insert crimps measuring only a few millimetres into the connectors.

Until now, this task has been performed exclusively by hand directly on the routing board and has required the operator to exercise the utmost concentration, visual acuity, and dexterity. In the newly developed robot cell, the robot moves the gripped component to a 2D camera. There, the position and orientation of the crimp are determined and sent to the robot as a correction for assembly. A second camera is used to measure the target position.

The robot can therefore reach its target position through precise corrective movements and reliably insert the crimp into the connector. The necessary sensitivity is achieved through force control and force monitoring: A force-torque sensor on the robot measures the forces during insertion and regulates them so that the crimp is inserted optimally. Machine vision ensures the required accuracy.

Giving robots sight

“Without precise ‘vision’, the robot would literally be blind and unable to make the necessary corrections reliably and independently,” explains Dr. Nägele. To overcome these challenges, Cellios turned to machine vision.

Sensors alone were not sufficient to determine the exact position (X-Y) and orientation (Z angle) of the crimp. Machine vision is therefore the system that helps the robot recognize the components to be inserted and identify deviations resulting from upstream process steps, such as crimping the cable, as well as from the unpredictable nature of the cables themselves.

“Without precise measurement, we would not be able to insert components with an accuracy of 0.1 mm, which is what we need to align the connector with the crimp,” adds Dr. Nägele. The robot cell is equipped with a range of different hardware components to meet these challenges. In addition to a robot, these include robotic taping applicators, force-torque sensors, devices for accurately gripping the connectors, and a conveyor system. Cellios uses two 2D cameras for image processing.

On the software side, the system uses Cellios software and MVTec MERLIC. Munich-based MVTec Software GmbH develops technologically leading software for industrial machine vision worldwide. MERLIC makes it possible to automate complex applications quickly, even without specialized programming expertise.

Efficient application development

Cellios selected MERLIC because of its practical low-code approach: The clearly structured configuration interface makes it easy to select all required tools using drag and drop. Thanks to its intuitive user guidance, MERLIC enables users to get started quickly with developing a machine vision application without requiring in-depth knowledge of programming or image processing.

“For innovative companies such as Cellios, time to market is crucial. MERLIC provides the perfect leverage here: Its graphical user interface makes it possible to configure complex machine vision applications, such as the precise matching of very small components, quickly and efficiently without sacrificing the performance of proven algorithms,” explains Ulf Schulmeyer, MERLIC Product Manager at MVTec.

MERLIC supports the application developed by Cellios in several ways. Within the image-processing workflow, powerful matching technologies enable the exact position and orientation of the crimps to be determined. In addition, MQTT and REST interfaces ensure seamless integration into the overall system, providing support that extends even beyond MERLIC’s core role as machine vision software.

MERLIC’s low setup effort and ease of use proved particularly advantageous: Two Cellios employees implemented the application using only videos and sample applications without any additional training. “Our collaboration with Cellios is an impressive demonstration of how machine vision is pushing the boundaries of what is possible in robotics. When robots learn to see with the same precision and flexibility as humans, even highly complex processes can be automated. MERLIC acts as the intelligence that translates image data into precise instructions for the robot,” Schulmeyer adds.

Pioneering advancement in wire harness assembly

The developments by Cellios and its project partner TE Connectivity are pioneering. The prototype was presented in November 2025, and the official market launch is planned for early 2027. The benefits of the solution extend far beyond simply increasing productivity: Automation makes wire harness production economically attractive again in high-wage countries such as Germany.

Shorter transport routes also significantly reduce the carbon footprint of production, setting new standards for sustainability. In addition, digital monitoring of every insertion operation improves quality and enables complete traceability of the wire harnesses.

Based on initial feedback and customer discussions, Cellios is already planning to extend the automation solution to additional wire harness variants and new areas such as control cabinet wiring. Future machine vision systems are also expected to be used for self-healing processes and advanced quality inspections.

As aerospace manufacturers prepare for significantly increased production rates on future aircraft programmes, the industry faces growing pressure to deliver larger volumes of complex composite structures while maintaining the highest standards of precision and quality. Loop Technology’s FibreLINE system – with the FANUC M-2000 robot at its heart – has been developed specifically to meet these challenges, offering a scalable and highly automated solution for the production of large composite aerostructures.

Founded in 1998, Dorset-based Loop Technology has established a strong reputation for delivering advanced manufacturing solutions across demanding industrial sectors. The development of FibreLINE originated from early involvement in composite wing development programmes and collaborative aerospace research initiatives, where the need for more efficient and scalable composite manufacturing processes became increasingly evident.

Addressing the challenges of composite production

Manufacturing primary aerospace composite structures requires exceptional positional accuracy, often to within ±1 mm, while handling large and complex components. Production environments must also accommodate the combination of delicate composite materials and heavy tooling, creating significant demands on automation systems.

Traditional gantry-based solutions can struggle to provide the flexibility, scalability and cost efficiency required for future aerospace production rates. To overcome these limitations, Loop Technology sought a robotic platform capable of combining high payload capacity with exceptional accuracy and repeatability.

One of the world’s highest-payload articulated industrial robots, the FANUC M-2000 offers exceptional rigidity and high payload capability, enabling FibreLINE to perform demanding manufacturing processes on large aerospace structures without compromising on accuracy. When combined with Loop Technology’s advanced vision systems, photogrammetry technologies and integrated motion control, the platform consistently achieves accuracy levels of around 1 mm across large-scale components.

The result is a manufacturing solution that combines strength, precision and flexibility, enabling aerospace manufacturers to automate complex processes that were previously difficult to scale economically.

Enabling high-rate aerospace manufacturing

The aerospace sector is increasingly focused on future single-aisle aircraft programmes that are expected to require production rates of up to 80 to 100 aircraft per month.

Meeting these ambitious targets using conventional composite manufacturing methods would typically require extensive factory floor space and multiple production machines. FibreLINE offers a significantly more efficient alternative.

A single FibreLINE system can achieve the equivalent output of between five and ten conventional manufacturing machines, helping manufacturers reduce factory footprint, capital investment and operational complexity while increasing throughput and productivity.

A new era for composite aerospace production

The collaboration between Loop Technology and FANUC demonstrates how advanced robotics is enabling a step change in aerospace manufacturing, helping manufacturers unlock new levels of efficiency and competitiveness.

By combining Loop Technology’s expertise in automation and composite production with the strength and performance of the FANUC M-2000 robot, manufacturers can achieve the scalability required for next-generation aircraft programmes while maintaining the precision and quality standards demanded by the aerospace industry.

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The system leverages Comau’s MyCo collaborative robot with a ROS2-based software architecture and integrates intelligent sensors and an advanced modular gripper to autonomously manage picking, handling, and palletising tasks across variable product flows.

Comau’s role within the MASTERLY project reflects its use of advanced AI-backed automation to address evolving production challenges, including increasing variability, supply chain disruptions, and the need for rapid reconfiguration. Indeed, the intelligent warehousing and logistics solution, developed in collaboration with the project’s ecosystem of technology partners, underscores the importance of scalable and versatile automation designed to improve workplace ergonomics, reduce physical strain and enhance operational flexibility within human-centric production environments.

The project parameters were driven by Decathlon’s operational requirements within the targeted fulfilment process, which has provided the foundation for implementing and validating several advanced functionalities. Key partners included Decathlon itself and STAM, a Genoa-based systems integrator, alongside the broader MASTERLY consortium.

In addition to the MyCo collaborative robot and intelligent gripper, engineered to manipulate objects varying in shape, weight, and material, the solution incorporates advanced sensors, vision-based object recognition, digital twin capabilities, and workflow orchestration tools. As a result, it can easily manage the rigid, soft, and porous materials commonly found in e-commerce fulfilment environments.

The system also grants real-time optimization and seamless interaction between operators and the automated processes, ensuring high flexibility while maintaining consistent throughput and operational reliability.

Furthermore, the knowledge gained and functionalities validated during the project will contribute to the continued evolution of Comau’s MyCo collaborative robotics platform and are expected to become part of its broader portfolio of advanced intralogistics capabilities.

“Comau’s role in the MASTERLY project is fully aligned with our commitment to advancing next-generation manufacturing by promoting reconfigurability, efficiency, and human-centric automation,” explains Alessandro Piscioneri, Head of Product and Solution Management – Advanced Automation Solutions at Comau.

“The project also highlights the strategic value of combining intelligent robotics, digital technologies and systems integration to create highly flexible logistics and fulfillment operations capable of adapting to rapidly changing production and market demands while maintaining operational continuity, scalability and ease of use. Comau’s growing strategic focus on intralogistics includes strengthening our capabilities through acquisitions, including Automha and Invent, which enable us to deliver increasingly integrated and intelligent solutions across the entire warehouse and production value chain.”

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By embedding smart sensing directly into the end-of-arm tooling (EOAT), the project provides real-time grip quality validation, ensuring precision and reliability in highly regulated, fast-moving packaging lines.

In high-speed cosmetics manufacturing, traditional robotic handling systems often struggle with lightweight, flexible components that have tight tolerances, such as deformable thermoformed trays. Whilst industrial robots excel at execution, speed and repeatability, their physical interactions present significant risks. Without tactile feedback, an imbalanced grip can lead to product loss or tray deformation. Traditional validation methods relying on simple position tracking or binary detection offer very little visibility into the actual quality of physical contact, prompting Siléane to seek a measurement-driven alternative to guarantee confidence in every cycle without slowing down the process.

Tactile intelligence at the point of interaction

Rather than increasing system complexity with external inspection steps, Siléane embedded force measurement directly at the point of interaction between the robot and the product. Partnering with HBK, Siléane integrated four factory-calibrated PW22i smart load cells – equipped with IO-Link – directly into the robotic gripper, placing one sensor at each contact point.

This Industry 4.0 setup enables the robot to validate grip quality instantly at the source, capture real-time force data, and respond immediately to any physical deviations during the gripping cycle – whilst simultaneously integrating seamlessly into modern automation architectures.

Simon Kleefeldt, HBK Product Manager Weighing Technology, explains the significance of this development: “This project reflects a fundamental shift in automation: embedding intelligence at the sensor level, to build systems that are more reliable, more autonomous and easier to deploy.”

HBK accelerated the evolution of its proven PW22 load cell – originally designed for demanding, high-speed dynamic weighing applications like checkweighing and filling – into the PW22i by integrating IO-Link connectivity to meet real-world integration demands.

Immediate operational benefits

The integration of the PW22i load cells delivered immediate operational benefits, demonstrating how physical measurement intelligence can improve manufacturing performance. For the end customer, this translates to: zero-defect grip validation in real time across all contact points; significant reductions in product scrap and tray deformation; simplified system architecture with reduced cabling via IO-Link; and faster commissioning times and improved repeatability across installations, ultimately leading to a faster return on investment (ROI).

Every year, Cranswick produces millions of “pigs-in-blankets” (sausages wrapped in bacon) for the Christmas market. The final stage of the process – picking the sausages off the conveyor belt and placing them in their packaging – was still performed manually, which introduced delays and other constraints. Cranswick commissioned CWM Automation to design and deliver a fully automated pick-and-place system, allowing those employees to take on more skilled tasks.

“Automating this stage of the process presented some complex challenges,” said Asa Arvidsson, regional vice president EMEA north region, Rockwell Automation. “The new system had to operate with remarkable precision and speed. With our strategic collaboration with autonox Robotics, we were able to support CWM Automation in making this possible.”

Powered by Rockwell Automation Allen-Bradley Kinetix VP low inertia servo motors controlled by an Allen-Bradley GuardLogix 5380 safety controller, the new end-of-line pick-and-place system accurately detects the presence and orientation of each sausage. It then uses an autonox Delta robot to pick up the sausage, properly align it and place it in the appropriate package – 240 times a minute.

“We’re very happy with the new pick-and-place system,” said Mark Lundgren, chief engineering manager at Cranswick Gourmet Sausage. “Thanks to Rockwell Automation and CWM Automation, we’re able to meet our production goals and deadlines in a way that is far more efficient and cost effective. Our labour productivity on the line is greatly increased and that means our staff not only have more skilled and comfortable jobs, they’re also often free to work on other production lines.”

“Cranswick had to have the new system up and running to meet their annual production target,” explained Mick Williams, managing director, CWM Automation, a Rockwell Automation Gold-Level OEM. “To achieve this, we worked closely with the Cranswick engineering team and the systems consultants at Rockwell Automation. It was a great cooperation, and together we met what was a very challenging deadline.”

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STOBER supplied a system consisting of synchronous servo geared motors, cables and suitable drive controllers optimally tailored to the requirements.

“Our robot system can pick up a raw egg so carefully that it is not even damaged,” says Peter Butz, Product Developer at Eisenmann. This underscores the sensitivity with which the system can be controlled. Instead of handling eggs, the robot actually grips rims of different sizes and weights and supplies them to a paint line. In addition to industrial painting and handling systems, this mechanical engineering company also develops driverless transport systems and technologies for pre-treatment and filtration.

“All our solutions are unique, because we tailor them to our customers’ specific requirements,” says Butz. “They vary in the complex interplay of process steps and the corresponding conveyor systems.” In its development work, the company focuses on solutions that are cost-efficient and save resources – always with the aim of creating clear, comprehensible added value for its customers.

From pneumatics to electronics

With this goal in mind, Eisenmann has also optimised the handling system. “It consists of industrial robots with one or more grippers. We had previously installed pneumatic drives,” explains Peter Butz. Initially, there was a lot to be said for them: they are simple, dynamic and comparatively inexpensive to buy. Yet they are considered inefficient and only allow limited control. In addition, compressed air generation is energy-intensive, and leaks cause additional losses and costs. For this reason, Eisenmann opted for electric drives. These are significantly more energy-efficient and economical to operate and allow direct integration of sensors.

After deciding on a servo-electric drive solution, the aim was to integrate this technology into the existing gripper concept in a practical way. As they examined the new project requirements, the Eisenmann developers began to focus on drive solutions from STOBER.

With Klaus Buschko as their contact person in Sales and Robert Boger in Application Development, STOBER worked with Eisenmann to develop a suitable solution. The starting point was a pilot system that showed that the competitor’s drive technology, initially used as a prototype, did not fully meet the requirements for controllability. In particular, the two-cable solution originally planned proved to be a disadvantage when during gripper movement.

High-precision drive technology

With the STOBER solution, the gripper attached to the robot first moves towards the component at high speed, then stops a millimetre before touching it and approaches the rim at creep speed in a controlled manner to pick it up. This allows a sensitive approach – even a raw egg can be safely gripped without damaging it.

“A high holding torque is particularly important to us,” explains product developer Peter Butz. This is because the robot arm can stop moving abruptly and start up again quickly, while the rim must be held securely at all times. Therefore, the drive solution had to be lightweight and compact, since it is installed directly in the gripper.

STOBER supplied KL series helical bevel gearboxes with a directly mounted EZ synchronous servo motor. This compact unit offers good installation dimensions and high power density. “Thanks to their robust bearings and high-quality gearing, STOBER helical bevel gearboxes are extremely resilient and tilt-resistant,” explains Buschko.

Another important feature of this series is its very smooth operation. Since the gripper moves along two axes, the compact SC6 stand-alone drive controller is used for control. If additional grippers need to be added, the SC6 can be combined with the SI6 drive controller, which is designed for multi-axis drive systems. This enables solutions with two to five grippers, allowing Eisenmann to respond to a wide range of customer requirements.

The geared motors and drive controllers are connected via STOBER’s One Cable Solution (OCS). The hybrid cable with the future-proof EnDat 3 protocol transmits both encoder data and power data via a single cable. The result is an integrated system consisting of a synchronous servo geared motor, cable and drive controller. This avoids the problem that would arise with the planned two-cable solution and significantly reduces the installation effort.

Independent of the robot type

STOBER has added additional PROFINET functions to the SC6 and SI6 drive controllers. In conjunction with the SU6 safety module, they support safety functions such as STO (Safe Torque Off) and SS1 (Safe Stop 1) via PROFIsafe. “The possibility of free programming allows Eisenmann’s developers to contribute their own know-how at specific points.” The result is a flexible, multifunctional system that can be integrated into different types of robots, regardless of the manufacturer.

During the project, potential for optimising operation was also uncovered. During longer downtimes, the motors remain energised and thus generate heat. To avoid this thermal load, the drives were retrofitted with a brake.

STOBER also fitted torque arm brackets to the gearboxes. These absorb reaction torques or differential torques and transfer them to the surrounding support structure. This prevents the motor or housing from twisting. To achieve an even more compact design, the geometry of the supports was adapted accordingly.

Eisenmann now benefits from a drive system that is specially tailored to its requirements, as well as from responsive technical support. “With STOBER, we have chosen a future-proof, energy-efficient drive solution – one that is sensitive down to the last detail,” says Butz with satisfaction.

Boxes containing small metal parts are stacked to the ceiling in a narrow bay resulting in barely enough space to manoeuvre a single pallet between the wall and liquid tanks. Behind this assembly, there are rows of tightly packed electroplating tanks.

On the electroplating floor of Collini’s Swiss site near Zurich, Switzerland, space is certainly at a premium. That is why the company, which specialises in surface coatings, was looking for a space-saving solution that would give it a fast and reliable way of hanging small parts on racks for the electroplating bath. The conventional method of loading the racks by hand requires a lot of space and human resources because several racks need to be loaded at the same time.

“For that reason, we wanted to switch to a new coating system with automated loading,” explains Marco Fuchs, Head of Product Engineering at Collini. Since a system of this type has yet to be created, he embarked on a search for companies that would have the pioneering spirit to accept the challenge.

Fuchs found the right partner in Swiss automation company Roth Technik, which in turn relies on smart sensor solutions from Baumer for its projects. A specialist in smart, bespoke automation solutions, Roth Technik collaborated closely with its customer Collini to develop a fully automatic and compact loading line.

At the heart of the line are four robots that automatically load parts onto the empty hooks on the racks. The biggest challenge for the system to overcome was the fact that no two racks are the same. The hook positions are not located exactly in the same place on the welded racks every time, and some hooks may be bent, or missing entirely. This is not a problem for human personnel to deal with, but it is very much for robots that require precise positioning data. The enormous variety and high throughput of parts presented two more challenges.

Robots guided efficiently by a smart Baumer sensor

So how did the Roth Technik team solve the problem of rack position inaccuracy, enabling the robots to learn the exact positions of the hooks for each rack?

The development team found a simple yet effective solution in the compact OXM200 profile sensor from Baumer. Mounted on the robot arm, it detects the exact position of each individual hook as it moves down the rack and reports this back to the robot control. With the help of a camera, the robot then picks up one part after the other from the separating carousel and hangs it on a hook. The robot uses the position coordinates previously collected by the profile sensor to finely adjust the position of the part. This method is what enables the smart profile sensor to guide the robot precisely and quickly on the electroplating rack.

To begin with, Markus Roth’s team tested various solutions with camera-based systems and other laser-based scanners. “In the end, we went with the profile sensor from Baumer because it was the best solution for our strict requirements regarding accuracy, compact design, and ability to detect objects,” states Markus Roth, CEO of Roth Technik. The compact OXM200 reliably detects the thin hooks and is still able to scan several hook positions at the same time. Using the control, it then decides whether or not to load the hook.

Thanks to powerful, integrated measuring tools, the sensor outputs measured the values for the X and Z coordinates directly in mm, significantly reducing the number of calculations in the control. The conclusion is that these smart ultra-compact profile sensors are ideal in applications where space is at a premium, whilst eliminating the need for additional human resources.

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Some trades are passed down from father to son – along with a passion for excellence. When Bruno Mériaudeau speaks about the sophistication of the components produced in his workshop, the sparkle in his eyes and the enthusiasm in his voice, tinged with pride, say it all. This affable and good-humored leader has clearly inherited a deep appreciation for precision engineering.

Méca-Précis was founded in 1975 by his father, driven by a strong entrepreneurial spirit and a desire to put his expertise in highly technical component manufacturing to work. This expertise was honed during his time working for the military, where he designed and produced one-off parts tailored to highly specialised applications. His son joined the company in 1982, at a time when Bruno Mériaudeau was the eighth employee of the family business.

Today, he is preparing to pass the torch to his own son, Nicolas, who took over the management of Méca-Précis in 2023. The company now employs 45 people and operates a fleet of 25 machine tools, 18 of which are CNC-controlled. Over the course of nearly half a century, the company – based in Chatillon-sur-Indre (36) – has continuously strengthened both its technical expertise and its production capabilities.

Méca-Précis has more than one string to its bow. It now specialises in prototype parts, one-off components, small and medium production runs, and welded mechanical assemblies. As a manufacturer of complex parts for the aerospace and satellite industries, the company has also maintained, for 48 years, the trust of a global leader in carton packaging machinery, for whom it produces parts and complete sub-assemblies.

While having the expertise and equipment to manufacture sophisticated components is essential, ensuring these parts meet stringent dimensional requirements is equally critical. To this end, Méca-Précis operates a standard measuring machine on the shop floor, as well as a coordinate measuring machine (CMM) housed in a thermally controlled environment. However, certain aerospace and space-sector clients require 100% inspection of all dimensions on every single part produced, both before and after surface treatment.

When inspection becomes a bottleneck in production

“Dimensional inspection of a single pin takes just one minute – but there can be as many as 300 to check. At the other end of the spectrum, inspecting a single complex component for a satellite can require up to 80 hours,” explains Nicolas Mériaudeau.

In this context, as production volumes increased and multiple palletised machining centres operated through the night, the coordinate measuring machine was no longer able to keep pace. “Our two inspectors were overwhelmed. To maintain a high level of service and manufacturing quality, and to ensure reasonable lead times for our customers, we needed to find a solution to eliminate the bottleneck in the inspection process. We therefore began searching for a way to automate and roboticise the inspection process,” explains Bruno Mériaudeau.

As the manufacturer of the coordinate measuring machine (CMM) used by Méca-Précis was unable to provide a suitable solution, Nicolas Mériaudeau turned to Mitutoyo. Mitutoyo proposed the design of a robotic measurement cell integrating the MiSTAR coordinate measuring machine, in collaboration with Engineering Data, a company specialising in fixturing solutions and the automation of machining centres.

Deployment of the robotic measurement cell

Less than a year after the initial meeting between the teams from Mitutoyo, Engineering Data, and Méca-Précis – with both quality inspectors closely involved throughout the project—the robotic measurement cell was installed in the workshop. Following phases dedicated to developing part inspection programs, system commissioning, configuration, and technical fine-tuning, an additional six months were required before the system became fully operational.

“We have effectively removed the bottleneck that was located in the quality control process. This solution brings us greater flexibility and allows us to significantly increase inspection capacity,” says Bruno Mériaudeau with satisfaction.

“If we did not have this robotic measurement cell, we would not be able to cope with the growing production volumes of series-manufactured parts, which are highly demanding in terms of quality control. We now have a solution that fully meets our needs. Throughout this project, we benefited from the quality of exchanges, responsiveness, attentiveness, and geographical proximity of the Engineering Data and Mitutoyo teams,” adds Nicolas Mériaudeau. As a result, the pressure that had been weighing on Méca-Précis’s two inspectors has been significantly reduced.

They can now rely on two measurement solutions to perform all the necessary checks in-house. The robotic cell has significantly reduced their workload by performing automated inspections during the day as well as overnight. Before leaving the workshop, they can load parts into the robotic system, which then carries out the inspections automatically in their absence.

Architecture and operation of the robotic measurement cell

This solution is the result of Engineering Data’s expertise in machine tool loading automation, combined with Mitutoyo’s know-how in dimensional control. The robotic measurement cell is installed within an enclosed structure, defined by glass panels that ensure operator safety while providing full visibility of the system’s internal operation. The cell integrates a multi-axis articulated robot responsible for handling operations, a Mitutoyo MiSTAR coordinate measuring machine designed for shop-floor use, and an automated storage unit capable of accommodating up to 20 pallets on which the parts to be inspected are secured. A loading station, accessible from outside the cell, allows interaction with the operator without interrupting overall operation.

The process begins with the loading phase. The operator places a pallet carrying a part onto the dedicated loading station. Each pallet is designed to hold the component in a position compatible with robotic handling and measurement operations. Using the cell’s human–machine interface, the operator selects the relevant part type. This information is transmitted to the cell’s control system, which automatically associates the component with the corresponding control program. The robot then picks up the pallet and transfers it to the storage unit. This operation can be repeated until the storage system is fully loaded.

Once the pallets have been loaded, the operator initiates the inspection cycle via the interface. The cell then operates autonomously. The robot successively retrieves the stored pallets and places them on the surface plate of the CMM, which is equipped with a clamping device ensuring proper positioning and stability during measurement. The coordinate measuring machine executes the inspection program associated with the part, performing the required dimensional measurements. The duration of this phase depends on the number of features to be checked and the complexity of the component, ranging from a few minutes to several hours.

At the end of the inspection, the robot retrieves the pallet and returns it to the storage cabinet. The cycle then continues automatically until all loaded parts have been inspected. The measurement results are recorded by the system and can be reviewed later by metrology engineers.

The overall operation relies on coordination between the control system, the robot, and the measuring machine. The automation of pallet handling allows the loading operations to be decoupled from the measurement phases, ensuring continuous use of the control equipment while reducing manual handling.

A robotic mandrel gripper, integrated by KOCH Robot Systems, ensures the precise and controlled transfer of rolls to the RoRo StretchPack packaging machine for the wrapping process. This combination of robotics and horizontal stretch hood wrapping technology provides stable and precise control, for wrapping rolls with significant variations in diameter (up to ø850 mm) and length (up to 700 mm).

Designed for controlled and accurate roll wrapping

The robotic mandrel gripper transfers each roll from a conveyor and positions it inside a five-sided stretch hood film prepared in the RoRo StretchPack packaging machine, and carries the roll through the packaging machine, placing it on the output conveyor. The mandrel is released and returned before the final welding of the film end for complete sealing of the roll packaging.

This solution is especially beneficial in cases where conventional belt conveyors are unsuitable or when products type require precise positioning.

Flexible packaging solution for sealed packaging

A key feature of RoRo StretchPack is the delivery of fully sealed packaging, with welded film ends providing reliable protection against external contamination. This capability is crucial for sensitive products such as paper, hygiene materials, and nonwoven rolls, ensuring product integrity during storage and transport.

The flexible design of the RoRo StretchPack packaging machine integrates seamlessly with a wide range of input and output systems, including robotic mandrel grippers. This adaptability allows for tailored packaging lines that meet specific customer requirements.