Mixed bulk parcel streams must be converted into a controlled, continuous flow before automated sortation can operate effectively. Beumer robotpick combines computer vision, adaptive vacuum gripping and intelligent robot control to perform this labor-intensive process while accommodating variations in parcel type, size and packaging.
Controlling unpredictable bulk flows
Parcel hubs face the combined challenges of processing higher volumes, managing fluctuating parcel mixes and reducing reliance on manual labor. At the bulk handling stage, parcels arrive in an unpredictable stream and must be separated and correctly placed for downstream induction. When this task is performed manually, singulation can restrict throughput and increase operational complexity.
Beumer robotpick addresses this challenge by combining autonomous picking, parcel singulation and placement for automated induction. With the correct parcel mix and operating conditions, it offers CEP operators uninterrupted, high-capacity bulk flow by automating 99.9% of the bulk handling process, including polybags, carton bags, cardboard boxes, letters and other difficult parcel types.
By turning bulk parcels into a continuous, singulated flow, the technology helps maintain the supply of parcels to high-capacity automated sortation systems. Items that fall outside the system’s operating specification are identified for alternative handling.
Adapting the pick to each parcel
Every parcel is assessed individually using Beumer Group’s proprietary computer vision technology. The software identifies optimal pick points and adjusts the robot’s movement to the parcel’s size and characteristics. It also controls the vacuum gripper dynamically and synchronizes the picking sequence with conveyor movement.
The movement profile changes according to the parcel being handled. Larger or more challenging items are moved more conservatively, while smaller and less complex parcels can be processed more rapidly. This allows the Beumer robotpick to balance throughput with parcel integrity across a mixed bulk stream.
The vacuum gripper adjusts the position and orientation of its suction cups, as well as the activation pattern used for each pick. This supports reliable handling while reducing double picks and unnecessary energy consumption.
After picking, Beumer robotpick can orient and position parcels for different conveyor arrangements. Supported configurations include triangular, curved and perpendicular destination belts. Integrated underside barcode scanning and placement verification are used to support accurate downstream sortation.
Scaling capacity by adding independent cells
A single robot cell can process up to 1,600 parcels per hour, subject to the parcel mix, flow consistency and operational configuration. Installations can contain between one and four robot cells as standard configuration on one bulk feeding line, enabling capacity to be increased as parcel volumes change.
This modular arrangement allows capacity to be expanded by adding further robot cells without redesigning the entire Beumer robotpick system. It also enables operators to install capacity according to current requirements while retaining a route for later expansion.
Each cell functions independently. A robot cell can therefore be stopped for servicing, repairs or software updates while the other cells on the line continue operating. This limits the effect of individual maintenance activities on overall productivity and supports system availability.
Unpicked or dropped parcels are automatically returned to the bulk flow for another attempt. This recirculation process reduces interruptions and limits the manual intervention required when an initial pick is unsuccessful.
Integrating control, monitoring and maintenance
Beumer Group develops, owns and supports the main components behind Beumer robotpick. This includes the computer vision system, robot control software, vacuum gripping technology, parcel feeding equipment, mechanical layout and system interfaces. The approach allows the robotic cells to be incorporated into both new and existing parcel handling facilities and connected with Beumer Group’s wider automation portfolio.
Operational monitoring is provided through Beumer SCADA, while BG Insight software supplies performance data for data-driven and predictive maintenance. To date, the Beumer robotpick technology has processed more than 1.75 million parcels in a live customer environment.
Peter Elmvang is global marketing director at Beumer Group, where he leads company’s global marketing activities. He brings extensive expertise in international B2B marketing, with a particular focus on strategy, data-driven marketing, customer engagement and business intelligence.