Modular workpiece carriers for pick-and-place automation

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

In modern production lines, pick-and-place processes are central automation components – whether in machine loading, assembly, testing, or packaging. However, the full cycle performance of a robot or gantry system can only be realized if the component handling is standardized and positionally accurate.

ZELL Part carrier systems were specially developed for these applications – modular, gripper-friendly, variable, 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 every automation architecture

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

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

🔩 The holders (clips, multi-clips, contour pockets) are specifically adapted to the component – economical due to the use of standardized interfaces.

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

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‍Vision- & gripper-friendly down to the last detail

Reliable pick-and-place is only possible if the accessibility and repeatability are right.

Therefore, ZELL considers the following in clip design:

This significantly reduces the need for teach-in processes and interference contour adjustments – particularly valuable for robot retrofitting 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, test 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 disruption
• Fewer conveyor technology interfaces
• Identical carrier geometry for palletizers, AGVs, and feeding modules

Optionally available with RFID or DMC marking to support software-based part and position tracking (MES/ERP coupling, traceability).

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Practical examples from automation projects

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

For system integrators, this means:
Plan faster. Grip more securely. Scale more flexibly.

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

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