Siléane and HBK embed tactile sensors in robot grippers for cosmetics packaging

Siléane, a France-based advanced robotics specialist, partnered with Hottinger Brüel & Kjær (HBK) to solve a persistent problem in high-speed cosmetics manufacturing: how to safely grip and handle lightweight, flexible components—such as thermoformed trays—at production pace without causing product loss or deformation.

The core challenge stems from a limitation inherent in traditional industrial robotic systems. While robots are renowned for execution speed and repeatability, they lack tactile feedback. In cosmetics packaging lines moving at high volume, an imbalanced or poorly calibrated grip on a flexible component can result in silent failures: imperceptible tray deformation or product damage that compromises both the product and brand integrity. Existing validation methods—relying on simple position tracking or binary detection signals—offer minimal insight into the actual quality of physical contact, leaving manufacturers unable to guarantee confidence in every cycle without slowing production or adding costly external inspection steps.

Siléane's solution embeds force measurement directly at the gripper's contact points, eliminating the need for separate validation infrastructure. Working with HBK, Siléane integrated four factory-calibrated PW22i smart load cells into the robotic gripper, positioning one sensor at each contact point. The PW22i—an evolution of HBK's proven PW22 load cell, originally developed for high-speed dynamic weighing applications like checkweighing and filling—was enhanced with IO-Link connectivity to meet modern automation integration demands. This Industry 4.0 configuration allows the robot to capture real-time force data, validate grip quality instantly at the source, and respond immediately to any physical deviations during the gripping cycle, all while integrating seamlessly into existing automation architectures via simplified cabling.

HBK product manager Simon Kleefeldt underscored the significance of the development: "This project reflects a fundamental shift in automation: embedding intelligence at the sensor level, to build systems that are more reliable, more autonomous and easier to deploy." For the cosmetics manufacturer, the integration delivered measurable operational benefits: zero-defect grip validation across all contact points in real time, significant reductions in product scrap and tray deformation, simplified system architecture with reduced cabling, faster commissioning times, and improved repeatability across installations—ultimately resulting in a faster return on investment.

The challenge addressed by this partnership reflects a fundamental limitation in conventional industrial automation: while robots excel at speed and repeatability, they operate without physical sensation—a critical gap in industries handling delicate, lightweight components under tight tolerances. In cosmetics manufacturing, where product quality and packaging integrity directly affect brand reputation and regulatory compliance, this gap creates real operational risk. Traditional solutions relying on simple position tracking or binary detection provide minimal visibility into actual grip quality, leaving manufacturers vulnerable to hidden failures that downstream inspection may catch too late.

Siléane's approach—embedding measurement intelligence directly at the point of interaction rather than bolting on external validation stages—represents a shift toward what HBK's Simon Kleefeldt calls a "fundamental shift in automation: embedding intelligence at the sensor level." By integrating four IO-Link-enabled load cells into the gripper itself, the system achieves what earlier solutions could not: real-time, per-cycle visibility into grip force at every contact point, with immediate feedback to correct deviations before they become defects. This design choice has practical merit: it avoids the complexity, cost, and latency of external inspection systems while simplifying the cabling and integration challenges that have historically slowed deployment of advanced sensing in production environments.

No comments yet. Be the first to share your thoughts!