Modular workpiece carriers for pick-and-place automation

Process stability, variant capability and gripper accessibility for highly dynamic handling processes

In modern production lines, pick-and-place processes are central automation modules - whether in machine loading, assembly, testing or packaging. However, the full cycle performance of a robot or gantry system only unfolds if the component handling is standardized and works in the exact position.

ZELL workpiece carrier systems have been specially developed for these applications - modular, gripper-friendly, versatile and field-tested in numerous robot cells worldwide.

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Typical problems in pick-and-place processes - and how ZELL solves them

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Why modular? - An advantage for any automation architecture

Automation engineers and integrators benefit from the separation between the carrier base and the holder module:

⚙️ The carrier platform (e.g. 600 × 400 mm stainless steel) remains identical across many projects - ideal for conveyor systems, palletizers, AGVs or handling gantries.

The brackets (clips, multiclips, contour pockets) are adapted specifically to the component - economically, as standardized interfaces are used.

This saves time in layout planning, reduces engineering effort and creates cost benefits for series changes or assembly variants.

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‍Vision & gripper-friendly down to the last detail

Pick-and-place only works reliably if accessibility and repeat accuracy are right.

That's why ZELL takes this into account when designing clips:

This significantly reduces the need for "teach-in" and interference contour adjustments - particularly valuable for robot changeovers and short set-up times.

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Continuous material flow without relocation

ZELL carriers are compatible with pick-and-place, CNC loading, washing baskets, inspection stations and packaging modules. This means:
A part is separated once and remains in the same carrier until delivery.

Added value for integration:

• No additional transfer point / media break
• Fewer conveyor technology interfaces
• Same carrier geometry for palletizers, AGVs, feeder modules

Optionally available with RFID or DMC marking to support part and position tracking on the software side (MES/ERP link, traceability).

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Practical examples from automation projects

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Modular workpiece carriers reduce engineering costs, increase process stability and create interface clarity in automation projects.

For system integrators, this means:
Plan faster. More secure access. Scale more flexibly.

For end users:
More quality. Less waste. Consistent transparency.

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