ZEKEEP AI Vision-Guided Inspection, Sorting & Palletizing Workstation

An integrated automation solution combining vision positioning, AI quality inspection, high-speed picking, automatic palletizing and optional AGV transportation for downstream injection molding production processes.

The ZEKEEP AI Vision-Guided Inspection, Sorting & Palletizing Workstation is an integrated automation solution designed for injection-molded parts, plastic components and other regularly shaped products. It brings together typical downstream production processes, including product discharge, vision positioning, precision picking, appearance inspection, NG rejection, qualified product palletizing and material transportation through a modular system design.

The workstation is built around two 4-axis robots, each assigned to a different task: product picking and palletizing. The ZKG4V60L1 4-axis high-speed robot (1 kg) handles product retrieval and vision-guided picking, while the ZKG4V90L3 4-axis palletizing robot (3 kg) arranges and palletizes qualified products. Combined with an industrial vision system, conveyor mechanisms, vacuum suction grippers and a control system, the workstation can be configured to support automated workflows according to actual product and production line requirements.

During vision positioning, industrial cameras capture images of products on the conveyor. Vision algorithms identify product positions and relevant features, generating target coordinates for robotic picking. During quality inspection, the system can be configured to detect issues such as burrs, surface defects, dimensional abnormalities, missing material and assembly defects. Products are classified as OK or NG, and defective products can be directed into a designated collection bin through air-blow rejection or other configured sorting methods.

For batch palletizing of regularly shaped products, the workstation can use multi-cup vacuum grippers to pick multiple products simultaneously and arrange them according to a predefined array pattern. Together with the conveyor system and optional AGV transportation module, the solution can further automate product conveying, inspection, palletizing and downstream material handling.

The complete solution adopts a modular design approach. Robot configurations, gripper types, conveyor dimensions, camera layouts and material handling solutions can be adjusted according to workpiece dimensions, weight, shape, inspection requirements, gripping methods and site layout.

Compared with traditional manual picking, inspection, sorting and stacking, the core value of this solution lies in integrating multiple repetitive operations into a continuous automated workflow. It helps reduce repetitive manual labor, improve product quality consistency and provide configuration flexibility for future automation upgrades.

Core Highlights and Product Features

1. AI Vision Positioning for Automatic Product Picking

Identify product positions and provide target coordinates for robotic picking.

Industrial cameras capture product images, and vision positioning algorithms identify product locations and relevant orientation information. The positioning results are then used for robotic picking control.

For compatible product specifications and operating conditions, this can reduce dependence on manual positioning and support automated picking of regularly shaped products on conveyor lines.

2. AI Vision Inspection for Automatic Product Quality Classification

Upgrade from manual visual inspection to vision-assisted quality inspection.

The workstation can be configured with inspection tasks according to product characteristics, covering burrs, surface defects, dimensional abnormalities, missing material and assembly defects.

The inspection system outputs OK / NG results according to the configured algorithms and inspection rules, providing a basis for downstream product sorting. The actual inspection scope, false positive rate and false negative rate must be verified through sample testing and agreed acceptance criteria.

3. Automatic NG Rejection to Prevent Defective Products from Entering Downstream Processes

Coordinate inspection and sorting to reduce manual reinspection and handling.

Products identified as NG can be automatically rejected using air-blow mechanisms or other configured methods, then directed into a designated NG collection bin.

By integrating defect classification with the sorting mechanism, the workstation helps reduce the risk of defective products entering palletizing and subsequent processes.

4. Dual-Robot Coordination for Separate Picking and Palletizing Tasks

1 kg high-speed picking + 3 kg palletizing, with different robots assigned to different processes.

The solution uses the ZKG4V60L1 4-axis high-speed robot for product picking and the ZKG4V90L3 4-axis palletizing robot for product arrangement and palletizing.

Each robot is assigned to a specific process, allowing the configuration to be matched to the working radius, payload and cycle time requirements of each operation.

5. Multi-Cup Vacuum Grippers for Batch Picking Efficiency

Configure the number of suction cups and gripper structure according to product arrangement.

The workstation supports vacuum gripper configurations with 1–8 suction cups, as indicated in the product specifications. The gripper design can be customized according to product shape, dimensions, weight and arrangement.

When product compatibility and robot payload requirements are satisfied, simultaneous multi-product picking can reduce the number of repeated picking operations and improve batch handling efficiency.

6. High-Speed Intelligent Palletizing for Organized Product Arrangement

Pick, arrange and place products according to predefined array patterns.

The palletizing robot executes palletizing movements according to the product arrangement and target tray layout.

Combined with a compatible multi-cup gripper and predefined programs, it can arrange regularly shaped products in organized arrays, reducing repetitive manual stacking and arrangement work.

7. Integrated Conveyor and Control Systems

Connect product conveying, positioning, inspection and palletizing into a continuous workflow.

The workstation uses a belt conveyor system. Conveyor width, operating speed and positioning methods can be selected according to actual workpiece dimensions and production line layout.

Combined with the PLC, PC-based control system and control logic of each functional module, the system coordinates conveying, robotic movements, vision inspection decisions and NG sorting.

8. Optional AGV Integration for Automated Downstream Material Handling

Extend fixed-station palletizing to automated material transportation.

An AGV transportation module can be added according to site logistics and tray handling requirements. It can support empty tray pickup, loaded tray transportation and connections with designated workstations.

Whether an AGV is included, and which navigation and scheduling methods are used, must be determined according to the actual site layout and material handling plan.

9. Modular Design for Different Regularly Shaped Products

Adjust the automation solution according to product specifications and site conditions.

The workstation supports modular adjustments to grippers, conveyors, camera layouts, robot configurations and material handling methods.

The documented application directions include plastic bottle caps, small injection-molded parts, small rubber products and other regularly shaped items. Larger workpieces, products with special surfaces or products requiring different gripping methods need dedicated evaluation and solution customization.

10. Complete Project Implementation from Equipment Delivery to On-Site Integration

More than an individual machine – an automation solution designed around production processes.

The documented project implementation process covers requirement communication, site evaluation, solution design, equipment manufacturing, installation and commissioning, training and acceptance.

According to actual project requirements, interfaces between equipment modules, process cycle times, quality inspection standards and after-sales service arrangements can be defined to support successful on-site implementation.

Frequently Asked Questions (FAQ)

1. What is the AI Vision-Guided Inspection, Sorting & Palletizing Workstation mainly used for?

It is mainly used for automatic picking, vision inspection, NG rejection, qualified product palletizing and downstream material transportation of injection-molded parts, plastic components and other regularly shaped products. It helps integrate multiple repetitive operations into a continuous automated workflow.

2. Which robot models are used in the workstation?

The workstation uses a ZKG4V60L1 high-speed picking robot (1 kg) and a ZKG4V90L3 palletizing robot (3 kg). They are assigned to product picking and palletizing tasks respectively.

3. What types of visual inspection does the workstation support?

Inspection items can include burrs, surface defects, dimensional abnormalities, missing material and assembly defects. The actual inspection scope must be determined according to product characteristics, defect samples and the selected vision solution.

4. How are NG products handled?

The workstation can classify products as OK or NG based on vision inspection results. For NG products, the documented solution uses automatic air-blow rejection to direct defective items into a designated collection bin. The actual rejection mechanism and operating logic depend on the selected configuration.

5. What types of plastic products are suitable for this workstation?

Potential applications include plastic bottle caps, small injection-molded parts, small rubber products and other regularly shaped items. Actual compatibility depends on workpiece dimensions, weight, surface condition, suction requirements and inspection specifications.

6. What is the production cycle time of the workstation?

The product information provides a reference production rate of approximately 35–40 pieces per minute. Actual throughput depends on product specifications, vision inspection time, the number of products picked per cycle, palletizing paths, gripper configuration and site layout. Sample testing and cycle time verification are recommended.

7. Does the workstation support simultaneous picking of multiple products?

Yes. Multi-cup vacuum grippers can be designed according to product arrangement requirements. The documented configuration range is 1–8 suction cups. The actual number of suction cups and products picked simultaneously must be determined according to workpiece characteristics, gripper weight and robot payload capacity.

8. Can the workstation be equipped with an AGV for automatic transportation?

Yes. An AGV module can be added according to site logistics and transportation requirements. It can support empty tray pickup, loaded tray transportation and connections with designated workstations. The AGV is optional, and the vehicle model and navigation solution must be selected according to site conditions.

9. Can the conveyor dimensions be customized?

Yes. Conveyor dimensions can be customized according to product specifications, production requirements and site layout.

10. Does the workstation support non-standard customization?

Yes. The solution can be adjusted according to product dimensions, shape, weight, gripper design, conveying method, inspection requirements, palletizing layout and material handling needs. Special products require sample testing and solution evaluation.

Product Selection and Project Consultation

To ensure that the solution matches actual production requirements, we recommend confirming the following information before product selection and project consultation:

• Product Information: Product name, material, external dimensions, weight, surface characteristics and product photographs.

• Production Requirements: Current product discharge method, existing manual operations, target cycle time and shift requirements.

• Vision Inspection Requirements: Types of burrs, surface defects, missing material, dimensional or assembly abnormalities to be inspected, as well as acceptable false positive and false negative rates.

• Picking and Palletizing Requirements: Number of products picked per cycle, suction cup configuration, gripper weight, target arrangement pattern and tray dimensions.

• Conveying and Control Requirements: Conveyor layout, positioning method, PLC interfaces and communication requirements with existing production lines.

• Material Handling Plan: Whether AGV transportation is required, empty tray pickup method, destination for loaded trays and available site passage dimensions.

• Delivery and Acceptance Requirements: Equipment installation location, available site space, actual cycle time, inspection standards and project acceptance requirements.

Based on the above information, the robot selection, vision system configuration, gripper solution, conveyor system and AGV module can be further evaluated to develop an automation solution suited to the actual products and production line.