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Case Study
Enabling High-Density, Safe, and Efficient Robot Cell Induction
Customer:
Robotic Integrators
Application:
High-throughput e-commerce and fulfillment operations that demand robust, modular, and scalable conveyor & sorting systems
Challenge
Safety & Energy Efficiency
Traditional conveyor systems often use high-voltage (e.g., 480 VAC) drives, leading to larger maintenance burden, safety hazards, and high power consumption.
Integrators need conveyor partners that minimize these risks and operating costs.
Safety & Energy Efficiency
Traditional conveyor systems often use high-voltage (e.g., 480 VAC) drives, leading to larger maintenance burden, safety hazards, and high power consumption.
Integrators need conveyor partners that minimize these risks and operating costs.
Modular, Scalable Automation
As throughput demands change, integrators must scale robot work cells, induction zones, and sortation without a full re-design.
Flexibility is key: conveyors must adapt to different layouts (merges, diverts, transfers, accumulation), and be easily reconfigured or extended.
Reliability & Uptime
Downtime in a robot-fed system is costly as jams or faults at induction or sort zones result in cascading effects throughout the cell.
Maintenance must be fast, modular, and localized.
Solution
24VDC MDR Technology
Much safer than high-voltage systems: reduces pinch-point risk, torque hazards, and eliminates many major hazard sources.
Energy-efficient: Facility Functions claims up to 60% energy savings compared with conventional 480 VAC conveyor systems.
Quiet operations: much lower noise (< 50–55 dB(A) typical) compared to legacy systems (~75–85 dB).
Zone Logic & Accumulation
Customizable accumulation controls: zero-pressure accumulation (ZPA), minimum-pressure, and other zone control logics.
Modular zones: rollers are logically segmented, allowing independent control, diagnostics, and reconfiguration without rewiring entire lines.
This helps maintain smooth, jam-free flow even during surges, avoiding robot starvation or overloading induction buffers.
High-Precision Flow Control
Each zone and roller can maintain exact spacing and velocity for each package or part, ensuring robots receive items at consistent, predictable intervals and locations.
Minimizes robot downtime, mis-picks, or jams caused by variable spacing, critical for high-speed e-commerce operations.
Integration-Friendly Design
Conveyor layouts can include curves, merges/diverts, spirals, sort/divert modules, and more.
Seamless interface with automation: Easily integrate with PLC/WCS/WMS, enabling coordination with robot controllers, sortation logic, and higher-level software.
Service & Lifecycle Support
Full turnkey service: design, manufacturing, installation, commissioning, and ongoing maintenance.
Diagnostics built in: real-time roller status, fault detection, load detection.
Modular maintenance: zones can be swapped or serviced quickly, minimizing downtime
Results & Benefits
Improved Throughput + Uptime
Smoother merges, precise gap control, and reliable accumulation reduce jams and flow disruptions.
Fewer interruptions to robot cells results in better utilization and more predictable performance.
Enhanced Precision & Robot Efficiency
Accurate control of package velocity and spacing ensures robots operate at maximum efficiency
Reduces errors, improves pick accuracy, and allows tighter cell spacing without sacrificing speed
Lower Cost of Ownership
Energy savings from 24V lowers operating costs significantly.
Reduced maintenance cost thanks to fewer mechanical parts, modular repairs, and diagnostics.
Safety Gains
Safer operation for technicians and integrators, reducing risk and improving compliance.
Quiet operation improves the facility environment.
Scalability + Flexibility
Modular conveyor zones make it easy for integrators to expand or reconfigure as clients scale or change layouts.
New sort/destination lines can be added without a major rework.
System Integration Efficiency
Tight controls and diagnostics feed into integrator's supervisory systems (PLC, WCS), enabling better orchestration.
Lower risk during robot handoff because conveyor behavior is precise and predictable.
Conveyor with AI-powered robotic arm for high-volume parcel sorting
In the video below, you will see our conveyor belt integrated with an AI-driven robotic arm designed for small-parcel sortation in busy delivery hubs. The system sits next to each conveyor belt and handles more than 1,000 lightweight packages per hour. It identifies, picks, and places parcels into the right containers with a level of speed and consistency that manual sorting can’t match.
In a real-world pilot, the setup boosted hourly sorting capacity by roughly a third and helped the facility keep up with a sharp jump in pickup and delivery stops tied to online shopping. It supports larger digitalization efforts aimed at handling growing shipment volumes while keeping service levels high.