This is a set of tools that simplify the implementation of Pick & Place multi-robot packaging applications using the Sysmac automation platform. It enables standard Sysmac Machine Controllers to control both OMRON robots and custom or third-party mechanics powered by OMRON EtherCAT -based 1S servos. Designed for packaging applications, it integrates robot kinematics directly into the machine automation architecture, with all logic executed inside the PLC through standard IEC programming. Using a single software environment — Sysmac Studio — engineers benefit from one program and a single point of control for machine and robotics integration. The solution is real-time, scalable, and mechanics vendor agnostic, offering maximum flexibility for machine builders.
Challenges in multi-robot pick & place applications
- Complex system integration: Customers struggle with juggling multiple technologies — robotics, PLCs, motion control, vision, and safety — each requiring separate tools and teams.
- Meeting speed and precision requirements: Packaging lines often demand high throughput and precise handling (multiple robots, synchronized motion, custom kinematics).
- Frequent interruptions due to motion transitions: Rough handovers, robot stops, or inefficient motion cause delays, vibration, and imprecise execution.
- Synchronization between robots and conveyors: Misalignment between robot actions and conveyor movement (straight or curved) causes inefficiencies, rejects, and mis-positioned products.
- Architectural complexity and long engineering times: Multiple software environments, distinct communication networks, and varied hardware increase cost, slow commissioning, and make maintenance harder.
OMRON's Robotic Packaging Library (ORPL)
- One PLC to control full line: robotic part, transport system, IOs logic, sensing and safety.
- Reduces the hardware part and allows to control different robotic kinematic the same time, up to 16 robots in fixed cycle time.
- ONE controller, ONE network, ONE program and a single point of control for the entire machine.
- Symac based, fully IEC compatible, with series of tested Function Blocks we simplify the principles of control and synchronization robotic tasks with product movements in a packaging cycle.
- Since it is fully integrated with Sysmac Studio, customer can create and visualize all the machine execution logic without real hardware and be ready to roll-out the solution in short time range.
- Optimized machine performances, faster and smoother robot motion, improved synchronization between devices including Vision and Safety.
- No dedicated robot controller reduce machine installation layout, provides lesser spare parts, allows easier and fast maintenance and achieves to control costs in scope of PLM.
Customer case: Flowpack tending with pick and place from a vibrating bowl feeder
Samas’ customers face labor shortages and rising costs from low‑value manual loading into flowpack or cartoning systems. The project aimed to automate this operator‑run process to increase speed and profitability, since existing automatic loaders delivered insufficient throughput
OMRON's Robotic Packaging Library at work