achievements
The Assembler Levitation is an ultra-flexible robotic assembly cell, specifically designed for assembling complex components in luxury cosmetics (caps, inserts, collars, pumps). Its major innovation lies in the use of a magnetic levitation transport system, which intelligently routes products to “Plug & Play” assembly modules (screwing, clipping, gluing, inspection). Capable of feeding parts from thermoformed trays or bulk bins, this line guarantees impeccable quality and meticulous handling of parts at a rate of 60 products per minute.
Full automation of multi-component assembly (up to 4 different parts per finished product).
Intelligent, product-independent routing that allows any sequence of assembly operations to be executed.
Ability to simultaneously handle both bulk parts (from feeders or hoppers) and organized parts (from thermoformed trays, carts, or pallets).
Process complexity and scalability: Thanks to its “Plug & Play” stations, the machine adapts to your needs. The stations (gluing, clipping) can be easily swapped out, added, or removed.
Risk of scratches and contamination: Frictionless transport (levitation) and the integration of anti-static hoods and cleaning nozzles protect premium cosmetic parts.
Format changeover time (SMED): Drastic reduction in downtime thanks to 3D-printed grippers and tool changes without complex tools.
Dimensional variability: Integration of servo presses with force control and vision cameras to dynamically reposition and orient parts with an accuracy of +/- 3°.
Hybrid feeding: Components arrive either in bulk (de-bunkering modules) or stacked in thermoformed trays. A multi-jointed robot handles the unstacking of the trays.
Loading onto Planar: Robots pick up the components and place them on the transport system’s independent magnetic shuttles.
Vision-Based Alignment: Cameras locate visual reference points on the parts to ensure perfect alignment before assembly.
Modular assembly: The shuttles move from one station to another (hot-melt/UV gluing, pre-insertion, servo-press clipping, fluidic testing) depending on the selected process. A manual station is available.
Quality Control: The line performs real-time checks (height tolerance of +/- 0.5 mm, fluid flow control, and press force inspection).
Sorting and Ejection: Finished products are discharged, while non-conforming items and quality samples are automatically diverted to specific lanes.
Production rate: Up to 60 products assembled per minute.
Footprint (dimensions): Approximately 6,600 mm (length) x 5,000 mm (width).
Types of products processed (shapes): Covers, inserts, collars, pumps, metallized caps (Max. dimensions: Ø 80 mm x H 100 mm).
Accepted materials: Plastic, metal, glass.
Format changeover time: Quick, HMI-assisted, using magnetic or clip-on parts.
Compliance / Standards: Modular architecture with Harting quick-connect connectors (Air/Electrical/Communications), integration of state-of-the-art components (B&R Acopos 6D, Fanuc/ABB robots, Cognex/Keyence vision systems).
Luxury Cosmetics Industry (Perfume, Skincare, Makeup) and Pharmaceutical Industry.
Not at all! The Assembler is designed around the concept of “plug-in function modules.” The frame features empty slots equipped with quick-connect ports. This means you can add a new gluing or vision inspection module months after installation without altering the machine’s underlying structure.
Product protection is at the heart of this machine. On the one hand, the conveyor system is magnetic and completely friction-free. On the other hand, the machine incorporates cleaning stations equipped with antistatic bars, ionization nozzles, and exhaust hoods to ensure that no particles contaminate your parts before assembly.
No, the robot grippers are equipped with quick-change tooling systems, and the pucks on the magnetic shuttles can be secured without heavy machinery. In addition, all recipes are stored in the PLC and can be activated with a single click from the touchscreen.
Contact UNISTA for a customized assessment.
