Delta robot for high-load layer forming

A new generation Delta robot is entering the end-of-line automation segment with the objective of combining high throughput and heavy-load handling in the layer preparation phase preceding palletizing. The system, named Octopus, has been developed by Ercopac together with Zodiac Robotics for the mechatronic architecture and Bosch Rexroth for motion control and drive technology.

Layer preparation before palletizing
In high-speed packaging lines for beverage, food, tissue, ceramics, dairy, paper and pet food, layer forming represents a critical transition between primary packaging and palletizing. At this stage, grouped products must be arranged into stable, geometrically precise layers compatible with pallet dimensions and downstream logistics requirements.

Traditionally, Delta robots have been associated with lightweight pick-and-place tasks characterized by high accelerations but limited payload. Anthropomorphic robots, by contrast, are typically selected for heavier loads, often at lower dynamic performance. The Octopus project addresses this technological gap by targeting elevated payloads combined with dynamic performance typically associated with parallel kinematics.

The system is designed to manage heavy product groups while maintaining high cycle rates, enabling consistent layer formation under continuous production conditions. This configuration supports integration into automated packaging lines where throughput, positional accuracy and repeatability directly influence overall equipment effectiveness.

Mechatronic architecture and motion control
The mechanical platform was developed by Zodiac Robotics with a focus on structural rigidity and dynamic stability under load. The Delta kinematic structure distributes forces across multiple arms, reducing moving mass compared to serial robots and enabling high acceleration profiles.

Motion control and drive components are supplied by Bosch Rexroth. The control architecture coordinates multi-axis synchronization, trajectory planning and torque management, ensuring precise positioning even at elevated speeds. In high-throughput end-of-line environments, deterministic control and real-time communication between drives and controllers are essential to maintain repeatability and minimize vibration during rapid product handling.

By combining mechanical optimization and advanced motion control, the system is engineered to operate in packaging environments where mechanical stress, variable product dimensions and frequent format changes are common.

Application fields and operational model
Founded three years ago through the acquisition of the Ercoservice business unit, Ercopac is headquartered in Scandiano (Reggio Emilia), Italy, with commercial branches in Spain, France and Tunisia. The company focuses on customized end-of-line packaging machinery, adapting mechanical layouts and control logic to specific production requirements.

Beyond new machine development, the company provides maintenance, revamping and 24-hour technical support services. The introduction of a high-load Delta robot platform expands its portfolio in automated layer preparation systems, particularly for sectors requiring both speed and structural robustness.

In automated packaging lines where space constraints, throughput targets and integration with palletizing cells must be balanced, parallel-kinematic robots with extended payload capability offer an alternative to traditional serial architectures. The Octopus platform positions itself within this context, addressing the need for high-speed, heavy-load handling in end-of-line automation.

www.boschrexroth.com