Pick-and-place

Pick-and-place is an automated action in which a Robot, manipulator or automation system picks up objects, moves them and positions them at another location. The technique is widely deployed within Industrial Automation, the electronics industry, logistics, assembly lines and packaging processes.

Within OT environments, pick-and-place is a core function of modern robotic systems and flexible production cells. The process combines Motion Control, Vision systems, Real-time control and industrial communication.

Pick-and-place is used for:

• Assembly
• Sorting
• Packaging
• Palletising
• Component placement
• Machine loading
• Warehouse automation

🤖 What is pick-and-place?

In pick-and-place, a system detects an object, grasps it and places it at a predefined position.

The process usually consists of:

1. Object detection
2. Position determination
3. Picking up
4. Moving
5. Positioning
6. Releasing

Important characteristics:

🏭 Applications within Industrial Automation

Pick-and-place is applied across diverse industrial sectors.

Common integrations:

• Robot
• Cobot
• PLC
• SCADA
• MES
• AGV

⚙️ Technical Architecture

A pick-and-place system consists of multiple components.

Typical components

Systems commonly use:

• Servo motors
• Pneumatics
• Vacuum grippers
• Electric actuators
• Vision AI

🧠 How pick-and-place systems work

Pick-and-place systems combine multiple technologies.

Process steps

Real-time processing requires:

• Low Latency
• Deterministic Behaviour
• High precision
• Continuous feedback

RTOS-based controllers are commonly used here.

👁️ Vision systems

Modern pick-and-place systems use vision technology for object recognition.

Important functions:

Vision systems often combine:

• Industrial cameras
• AI
• Machine Learning
• Edge processing
• Sensor fusion

🦾 Grippers and end-effectors

The gripper determines how objects are picked up.

The choice depends on:

• Weight
• Shape
• Material
• Speed
• Accuracy

📡 Industrial communication

Pick-and-place systems communicate via industrial networks.

Systems integrate with:

• SCADA
• MES
• Historian
• Production platforms
• Robot controllers

⚡ Motion control

Motion control is crucial for accurate pick-and-place processes.

Important aspects:

Motion control commonly uses:

• Servo Drives
• Encoders
• Real-time controllers
• PID control

🛡️ Functional Safety

Pick-and-place systems contain moving parts and require Safety measures.

Important safety functions:

• Emergency Stop
• Collision detection
• Safety zones
• Speed limiting
• Position monitoring

Relevant standards:

Many systems use:

• Safety PLC
• Light Curtain
• Safety relays
• Safety laser scanners

🔐 Cybersecurity risks

Modern pick-and-place systems are connected to OT networks and introduce cybersecurity risks.

Important threats:

Connected robotic systems require OT-specific Security.

🔒 Security measures

Recommended security measures:

Many organisations follow guidelines from IEC 62443.

🚗 Pick-and-place in logistics and AGVs

Within logistics automation, pick-and-place is combined with:

• AGV
• Cobots
• Conveyor systems
• Warehouse automation
• Vision AI

Examples:

🌐 Pick-and-place within Industry 4.0

Modern pick-and-place systems integrate with:

This creates flexible and autonomously optimising production cells.

📈 Benefits of pick-and-place automation

Key benefits:

• Higher productivity
• Fewer human errors
• Constant quality
• Higher speed
• Improved safety
• Lower operational costs
• Flexible production

Pick-and-place also supports:

• LEAN
• High-mix production
• Smart manufacturing
• Continuous production processes

⚠️ Challenges

Important challenges: