The project, funded by the European initiative EUREKA under the code 01DS20005, brought together Werner Kuhlmann GmbH, a specialist in box and packaging manufacturing, and Benthor automation s.r.o., a robotics and automation supplier with a strong background in automotive applications. The aim was to develop a digitally connected, fully automated robotic cell capable of assembling transport boxes in small batch sizes, a market segment that traditionally relies on manual, craft‑based production. The collaboration combined Werner Kuhlmann’s expertise in product design, database management, and packaging logistics with Benthor’s knowledge of robotic control, PLC integration, and human‑machine interface (HMI) design. The project commenced after extensive preparatory work and was carried out during the COVID‑19 pandemic, which imposed constraints on travel, component availability, and the procurement of the nailer head used in the cell.

Technically, the core of the system is a 7‑axis industrial robot equipped with a custom‑designed nailer head that can only be oriented vertically relative to the floor. The robot’s workspace was expanded by rotating the housing of the nailer head 90°, allowing the robot to reach all nail positions without changing its configuration during the operation. The nailer head is controlled by a programmable logic controller (PLC) that receives coordinate data from a PC‑based application. The application reads model data from a design database, calculates the necessary coefficients and nail field positions, and writes the resulting coordinates back to the PLC. The PLC then commands the robot to move smoothly between nail positions, pre‑loading the next coordinate while the robot is still in motion, thereby eliminating idle time. The system can hold at least 20 nails in its magazine; when the magazine empties, the robot stops, the operator is notified via the HMI, and the magazine is replaced before the process resumes.

The interface design emphasizes intuitiveness and error minimisation. The HMI displays the selected model type, process status, and a 3‑D visualisation of the product. It also offers diagnostic functions such as simulated robot movement without actual nailing, and the ability to drive the robot to a service position for maintenance. The data flow between the design database, the PC application, the PLC, and the robot is fully automated, with the PLC signalling completion of each part to the PC, which then logs production success back into the database.

Performance testing compared two nailer variants, Toolmatic and Beck. Toolmatic demonstrated superior results, largely due to a more robust application design that provided a larger robot workspace and allowed nailing from multiple angles regardless of the nailer’s inclination relative to the worktable. Although the Beck variant was chosen for the final build because of limited supply of the Toolmatic nailer, the tests confirmed that the system could handle small lot sizes efficiently, reducing dependence on skilled labor and improving product quality.

In addition to the robotic cell, the project delivered a stripper holder with a change system, a user‑friendly interface, and a complete data management solution that integrates customer‑uploaded model data into the production workflow. The final prototype was tested in a proof‑of‑concept phase, after which the operating concept was refined based on the results. The outcome is a scalable, digitalised production cell that can be deployed in German and European markets, offering packaging manufacturers a cost‑effective solution for small‑batch production that was previously unavailable.