CD/DVD/BD Robot systems

DISCUS X-SL 2.0

Our copying systems of the series DISCUS can do more than record and label CDs, DVDs, DVD-DL, Blu-Ray or Blu-Ray-DL. Network-controlled and integrated in existing infrastructure, there are no limits to the application areas and possibilities.

The CD/DVD/BD copying systems with integrated priting systems are manufactured in Germany. They are designed for resist stresses and strains. The industrial robot systems for professional use of optical media have the following characteristics:

• 4 to 6 CD/DVD/BD devices
• capacity of up to 600 optical media
• integrated PC
• network-compatible
• warranty up to 5 years
• industrial components of high-quality
• choice of different printing system
• mixed production of CD, DVD and Blu-Ray possible

Robot systems of the series DISCUS can be arranged with different printing methods: thermo re-transfer, thermo transfer or ink jet. With TurnTable X-TT 3.0, individual imprint can be labeled CDs and DVDs whereas the ground image is always the same. It is also possible to change the printing system subsequently without having to change the whole robotic.

Robot Cluster

The software framework OpenRC allows the clustering of CD/DVD/BD robot systems that are different of their size and even are produced from different manufacturer. A robot cluster can link numerous robot systems that are situated at one location or at different locations all over the world. The controlling and monitoring takes place over one web GUI, e.g. through the main office.

The media production can be completely integrated in existing working processes and procedures and is fully adapted to the needs and requirements of our customers. The following scenarios are possible:

• The production is started automatically, e.g. when the ERP system receives all information that belong to a product, a file folder has reached a defined size etc., and the corresponding robot system is allocated automatically (e.g. through location settings, load balancing or working load etc.).
• An employee starts the production over a web GUI, the media is burned and printed at the robot system that is assigned.

The data itself can be stored on centralized server or be spread on a number of server (even in different locations).

Powerful Blu-Ray-Production

Modularer Aufbau

The DiscMaker contains up to 15 embedded boards, which are located at two devices each. This guarantees a modular construction. Further on, the DiscMaker can be equipped with 2 to 30 devices depending on the needs.

To produce individual Blu-ray Discs with 25 GB or even 50 GB of data, there has to be considered a special solution for transferring the data. We have developed our own embedded system that links-up the devices directly to enable the automated production of Blu-ray Discs where each disc has another content.

Blu-ray discs and their childs are developed especially for huge mounds of data and high definition video formats. The huge mounds of data are a challenge when Blu-ray Discs should be produced with standard robot systems. Especially, when each Blu-ray Disc has individual and unique content, the transferring of the data (up to 50 GB) for each Blu-ray Disc) is not trivial any more. The data has to be transferred from the data source to the robot system - at the same time for each device. Additionally, the editing of data can be necessary before burning it on a Blu-ray disc (e.g. the creation of an ISO image). If the ISO image is already generated before the data is transferred to the robot system, the whole ISO image has to be transferred. But if the data is divided in static and variable content that is transferred differently, the ISO image is generated at least directly at the robot system.

Powerful connection for our robot systems

To be able to manage huge mounds of data and a high computing capacity at the same time, we have developed an embedded system that connects the devices directly over SATA. One embedded board controls two devices at a time. The processor is positioned close to the devices to maximize the data rate.

The embedded boards read in the data automatically from one or from a number of network devices and burn them on the media. This procedure gives more space to the OpenRC server - who is only in charge of the coordination of the devices and the generation of the burning data (ISO file).

In the case that one board has an error, a maximum of two devices are not available any more. All other devices that are controlled over another board can still go on with the production.

on demand Production

Content is recorded on a data carrier with in corresponding versions and language. Apart from greater flexibility, cost reductions of up to 70 % compared to classic paper documentation can be realised. Additionally, there is the further bonus of being able to address end customers on a personal level.

Software OpenRC

Our software framework OpenRC (Open Robot Control) automates the production of data carrier (SSD, CF, Cfast, USB, CD, DVD, BD etc.) which are personalised and/or product-specific. We developed OpenRC as individual software that is paying close attention to the needs and requirements of our customers.

Among flexible solutions, OpenRC is the first choice, as robot systems can be tied in to existing structures and individual process sequences. Because of this integration, the recording of data carriers takes place automatically, out of existing systems. OpenRC supports the production of single copies as well as copy jobs that are covering a marginal quantity or the mass production of product specific media.

Advantages

• cost-effectiveness when in full operation
• just-in-time productions
• recording process is asynchronous
• integration of copy stations into the production environment of the customer
• enables the recording of several thousands of data carrier (SSD, CF, Cfast, USB, CD, BD etc.) a day
• enables the parallel recording of different media types (e.g. SSD and CF)
• verification after the copy process
• central logging of each copy job
• optional: encryption of the data in customized container files
  optional: test processes before and/or after the recording
• deployment of users and robots worldwide, clustering of robots
• parallel controlling of additional equipment possible (e.g. printer for brief instructions, a written guarantee etc. on paper)
• scalable and expandable
• can be used directly in production lines, with possible connection to different systems (e.g. ERP, PPS, DMS)
• high system stability
• remote problem solving or through a company worker directly on-site (at robot location)
• clear data recognition and assignment to the relevant product (e.g. through barcode)

High Flexibility Supports the Production of Storage Media in Industry 4.0

It does not make any difference whether a copy job covers 2.000 SSD, a single copy on USB that has to be sent directly to a customer or the mass production of fast with product-specific content. OpenRC processes each copy job just-in-time.

Especially production plants that position themselves in industry 4.0 need flexible solutions for transmission and integration of data in a safe way. Forward-looking technology and intelligent software allow high variability of the content and avoid mixing-up of personalized data. Data carrier can be recorded with individual data that corresponds to the particular customer or business partner. Additional processes before or after the recording of the data improve the data security.

Using Linux and open source components allows us to offer flexible, open and manageable solutions that have been tried and tested many times, especially in industrial environments. OpenRC software is distributed and used worldwide by robot clusters to reliably burn and print more than 100,000 individual media per year.

Product versions