Pick and Place System Engineering

Understanding Pick and Place Systems in Modern Manufacturing

In the rapidly evolving landscape of industrial automation, pick and place systems have emerged as fundamental components that drive efficiency, precision, and productivity across manufacturing operations. For businesses throughout Atlantic Canada, particularly in Nova Scotia's growing manufacturing sector, understanding and implementing these sophisticated systems can mean the difference between competitive success and operational stagnation.

Pick and place systems are automated mechanisms designed to pick up objects from one location and place them precisely in another. While this description may sound straightforward, the engineering complexity behind these systems involves intricate coordination of mechanical components, sophisticated control algorithms, advanced sensing technologies, and seamless integration with existing production infrastructure.

As Maritime manufacturers face increasing pressure to improve throughput while maintaining quality standards, pick and place automation offers a compelling solution that addresses labour shortages, enhances workplace safety, and delivers consistent operational performance around the clock.

Core Components and Engineering Principles

A well-engineered pick and place system comprises several critical subsystems that must work in perfect harmony. Understanding these components is essential for any technical manager or engineer considering automation investments for their facility.

Robotic Manipulators and Actuators

The heart of any pick and place system is its manipulator assembly. These range from simple two-axis Cartesian systems to complex six-axis articulated robots, depending on application requirements. Common configurations include:

• Cartesian (Gantry) Systems: Operating on X, Y, and Z axes, these systems offer excellent precision (typically ±0.05mm repeatability) and are ideal for rectangular work envelopes common in packaging and palletising applications.

• SCARA Robots: Selective Compliance Articulated Robot Arms excel in high-speed assembly operations, achieving cycle times as low as 0.3 seconds for simple pick and place tasks.

• Delta (Parallel) Robots: With their distinctive spider-like configuration, delta robots can achieve speeds exceeding 150 picks per minute, making them ideal for food processing and pharmaceutical applications.

• Six-Axis Articulated Robots: Offering maximum flexibility with payload capacities ranging from 3kg to over 500kg, these systems handle complex trajectories and orientation changes.

End-of-Arm Tooling (EOAT)

The end effector or gripper represents the interface between the robot and the product being handled. Engineering the correct EOAT solution requires careful analysis of product characteristics, including weight, geometry, surface properties, and fragility. Common gripper technologies include:

• Vacuum Grippers: Utilising venturi or pump-generated vacuum, these systems handle flat, non-porous surfaces with suction forces typically ranging from 20N to 500N per cup.

• Mechanical Grippers: Pneumatic or electric actuated fingers provide positive grip on irregular shapes, with force control ranging from delicate 5N handling to robust 1000N+ applications.

• Magnetic Grippers: Permanent or electromagnetic systems for ferrous material handling, common in Nova Scotia's metal fabrication industry.

• Adaptive Grippers: Soft robotics and compliant mechanisms that conform to product geometry, reducing the need for precise positioning.

Vision Systems and Sensing Technologies

Modern pick and place systems increasingly rely on machine vision to locate products, verify orientation, and ensure quality. Vision-guided robotics (VGR) systems typically incorporate:

• 2D cameras for pattern matching and barcode reading (resolution typically 1-5 megapixels)

• 3D vision systems using structured light or time-of-flight sensors for bin picking applications

• Force/torque sensors for assembly verification and delicate handling

• Proximity sensors and light curtains for safety interlocking

System Design Methodology and Engineering Process

Developing an effective pick and place solution requires a systematic engineering approach that begins with thorough requirements analysis and extends through commissioning and ongoing optimisation.

Requirements Definition and Feasibility Analysis

The engineering process commences with comprehensive data gathering. Critical parameters include:

• Throughput Requirements: Expressed in units per minute (UPM) or cycles per hour, accounting for peak demand periods

• Product Specifications: Weight range, dimensional tolerances, surface characteristics, and packaging variations

• Placement Accuracy: Positional tolerance requirements, typically ranging from ±2mm for rough positioning to ±0.1mm for precision assembly

• Environmental Conditions: Temperature ranges, humidity, dust levels, and washdown requirements particularly relevant for Atlantic Canada's seafood processing industry

• Integration Points: Upstream and downstream equipment interfaces, conveyor speeds, and buffer requirements

Simulation and Virtual Commissioning

Before committing to physical hardware, modern engineering practice employs digital twin technology to validate system performance. Simulation tools enable engineers to:

Analyse cycle times with realistic motion profiles, accounting for acceleration limits (typically 10-25 m/s² for high-speed applications) and settling times. Identify potential collisions and optimise robot placement within the workcell. Validate reach envelopes and confirm that all pick and place positions fall within the robot's dexterous workspace. Test control logic and error recovery routines in a risk-free virtual environment.

This approach significantly reduces commissioning time—studies indicate 20-30% reduction in on-site installation duration—which is particularly valuable for projects in remote Maritime locations where engineering resources must be deployed efficiently.

Control System Architecture

The control system forms the nervous system of any pick and place installation. A robust architecture typically incorporates:

• Programmable Logic Controller (PLC): Providing deterministic control with scan times under 10ms for coordinating discrete I/O and safety functions

• Robot Controller: Dedicated motion control hardware executing trajectory planning and servo control at 1-4ms update rates

• Human-Machine Interface (HMI): Operator panels enabling recipe selection, diagnostics, and performance monitoring

• Industrial Network Infrastructure: EtherNet/IP, PROFINET, or EtherCAT providing high-speed, deterministic communication between system components

Industry Applications Across Atlantic Canada

Pick and place technology finds application across virtually every manufacturing sector represented in Nova Scotia and the broader Maritime region.

Food and Beverage Processing

Atlantic Canada's robust seafood industry presents unique automation opportunities. Pick and place systems in this sector must address:

Hygienic design requirements compliant with CFIA regulations, including stainless steel construction (typically 304 or 316 grade), IP69K-rated components, and CIP (clean-in-place) compatibility. Variable product presentation inherent in natural products, requiring adaptive vision systems capable of handling shape variations of ±15-20%. Cold environment operation, with systems engineered for continuous operation at temperatures down to -25°C in freezer applications.

Typical applications include case packing of processed seafood products, tray loading for fresh fish portions, and palletising of finished goods for distribution throughout North America.

Manufacturing and Assembly

Nova Scotia's growing advanced manufacturing sector, including aerospace components and precision machining, benefits from pick and place systems in:

• Machine tending applications, loading and unloading CNC equipment with cycle time optimisation

• Assembly operations requiring precise component placement with tolerances under 0.1mm

• Quality inspection stations integrating vision-guided picking with automated measurement systems

• Kitting operations for mixed-product assembly lines

Packaging and Logistics

Distribution centres throughout the Maritimes increasingly deploy pick and place automation for:

Order fulfilment operations handling diverse SKU ranges, with modern systems capable of processing 800-1,200 picks per hour per station. Case erecting and packing, reducing labour requirements while improving package consistency. Palletising applications handling loads up to 2,400kg per pallet with optimised stacking patterns that maximise trailer utilisation.

Performance Optimisation and Continuous Improvement

Achieving optimal performance from pick and place systems requires ongoing attention to several key factors.

Cycle Time Analysis

Breaking down the pick and place cycle into constituent elements enables targeted improvement:

• Approach Time: Robot motion from home or previous place position to pick location

• Acquisition Time: Gripper actuation and settling (typically 50-200ms depending on gripper type)

• Transfer Time: Motion from pick to place location, often the largest cycle time component

• Release Time: Gripper release and retraction

• Return Time: Motion to next pick position or home

Optimising each element through motion profile tuning, path planning, and mechanical improvements can yield cumulative cycle time reductions of 15-25%.

Overall Equipment Effectiveness (OEE)

Monitoring OEE provides insight into system performance across three dimensions:

Availability: Targeting 95%+ uptime through preventive maintenance programmes and rapid fault recovery. Performance: Ensuring actual cycle times meet theoretical capabilities, with losses typically stemming from minor stoppages and speed reductions. Quality: Minimising placement errors, product damage, and rework requirements.

World-class pick and place installations achieve OEE values exceeding 85%, though 65-75% is more typical for complex applications with significant product variability.

Safety Engineering and Regulatory Compliance

Pick and place systems must comply with Canadian safety standards, including CSA Z432 (Safeguarding of Machinery) and applicable sections of CSA Z434 (Industrial Robots and Robot Systems).

Risk Assessment and Mitigation

A systematic risk assessment identifies hazards including:

• Crushing and impact hazards from robot motion

• Entanglement risks with moving components

• Ejection of workpieces or gripper failures

• Electrical and pneumatic energy sources

Mitigation strategies range from physical guarding and safety-rated monitored stops to advanced collaborative robot applications where reduced speeds (≤250mm/s) and force limits (≤150N) enable human-robot coexistence without traditional fencing.

Collaborative Robot Considerations

For applications where human workers must interact with the pick and place system, collaborative robots (cobots) offer compelling advantages. These systems incorporate:

• Power and force limiting technology with certified safety functions

• Rounded geometries eliminating pinch points and sharp edges

• Intuitive programming interfaces enabling rapid redeployment

• Payload capacities now reaching 16-25kg for latest generation cobots

Return on Investment and Project Justification

Justifying pick and place automation investments requires comprehensive financial analysis considering both tangible and intangible benefits.

Tangible Benefits

Direct cost savings typically include:

• Labour Cost Reduction: A single pick and place station often replaces 1.5-3 full-time equivalents when accounting for shift coverage

• Throughput Improvement: Consistent cycle times and reduced variability can increase line output by 15-40%

• Quality Improvements: Reduced product damage and placement errors, with defect rates typically falling below 0.1%

• Reduced Workplace Injuries: Eliminating repetitive motion tasks decreases workers' compensation claims

Investment Considerations

Capital costs for pick and place systems vary widely based on complexity:

Simple single-axis pneumatic systems may start at $15,000-25,000 CAD. Standard vision-guided robot cells typically range from $150,000-350,000 CAD. Complex multi-robot installations with advanced vision can exceed $500,000 CAD.

With typical payback periods of 18-36 months for well-specified applications, pick and place automation represents a sound investment for growing Maritime manufacturers.

Partner with Sangster Engineering Ltd. for Your Automation Success

Implementing a successful pick and place system requires deep engineering expertise, thorough understanding of application requirements, and meticulous attention to integration details. As Atlantic Canada's manufacturing sector continues to modernise, partnering with an experienced engineering firm becomes essential to navigating the complexities of automation investment.

Sangster Engineering Ltd., based in Amherst, Nova Scotia, brings comprehensive engineering capabilities to pick and place system projects throughout the Maritime provinces. Our team combines practical automation experience with rigorous engineering methodology to deliver solutions that meet your performance requirements, timeline constraints, and budget parameters.

Whether you're exploring automation opportunities for the first time or seeking to optimise existing systems, we invite you to contact Sangster Engineering Ltd. to discuss how pick and place technology can transform your operations. Our engineers are ready to analyse your application, develop customised solutions, and support your journey toward manufacturing excellence.

Contact Sangster Engineering Ltd. today to schedule a consultation and discover how professional automation engineering can drive your competitive advantage in Atlantic Canada's evolving industrial landscape.

Partner with Sangster Engineering

At Sangster Engineering Ltd. in Amherst, Nova Scotia, we bring decades of engineering experience to every project. Serving clients across Atlantic Canada and beyond.

Contact us today to discuss your engineering needs.