Karakuri for mechanical low cost automation

What is (a) Karakuri?

The term karakuri is an idea from Japan and describes a type of lean automation that uses the laws of mechanics and gravity alone to handle load carriers (e.g. box or small load carriers).

A Karakuri corresponds to the lean philosophy as well as the basic idea of lean production of bundling existing resources (here: gravity and the dead weight of a box) and using them intelligently. In this way, Karakuri solutions not only counter the general trend of increasing digitalisation, but also actively support the reduction of costs (= low cost automation).

Karakuri goes hand in hand with the term Kaizen, which stands for continuous optimisation of existing processes in industry, mostly in the warehouse sector and in production.

Examples of Karakuri solutions

Karakuri applications are primarily designed and used for the automatic lifting, lowering or redirecting of load carriers. The weight of the load carrier plays a decisive role here. We support you in the implementation of your low-cost automation applications. Check out some of our possibilities and examples:

Karakuri: Rocker for returning empty load carrier | BeeWaTec (605104)

This mechanism is suitable for an efficient and ergonomic supply and return of boxes (or cartons), including a separation of the boxes in order to hold back the following boxes accordingly. This solution is used at workstations or assembly stations with a high throughput of load carriers. The worker can return the empty boxes with a simple hand movement without having to lift them out of the track. At the same time, ergonomic gripping of the parts is ensured by the inclined roller tracks.

Karakuri: Shooter / transfer unit for load carrier | BeeWaTec (605110 & 605111)

A shooter-mechanism is a simple yet powerful solution, that unlocks a trigger through pushing. This requirement is crucial for some use cases like automatic box transfer with mobile robots, AMRs, AGVs, etc. Also flow racks / FIFO racks can be automatically or manually pushed to trigger the shooter to optimize the material flow of load carrier in production and logistics. Using a shooter function, all load carrier can run down the track or only one box, when combined with our separation mechanism.

Karakuri: Lift for load carrier (bracket mechanism) | BeeWaTec (605106)

A Lift for load carrier is mainly used to bridge different heights in workplace, production, or logistic processes to ensure ergonomic working. Lifts are often combined with a rocker solution, to ensure the box is passed on to an declined track and moves on. In some cases, (manual) lifts like that can also be used for gradual raising or lowering (locking required) of a working space or load carrier. This further improves the ergonomics of the working processes.

Karakuri: Lift for load carrier (crank handle mechanism) | BeeWaTec (605107)

Karakuri: Separation mechanism for load carrier | BeeWaTec (605108)

A separation mechanism for load carriers ensures, that only one load carrier passes. This requirement is crucial for some use cases like automatic box transfer with mobile robots, AMRs, AGVs, etc. (that have just space for one box). A separation mechanism also alows to create rocker solutions e.g. for empty boxes.

Karakuri: Rotation mechanism | BeeWaTec (605105)

This mechanism helps to execute turning movements for corner solutions or returns and is also used for a redirection of load carrier. It can also ensure rotating table tops or rack solutions. Example of a use case: A worker takes something about of a machine, to hang, stand or lay down for drying. A rotation Karakuri solution helps significantly with space reduction and offers great ergonomics within the working process.

Roller tracks made of single rollers for curves

BeeWaTec Karakuri with mechanical bolt for stopping and forwarding containers

Mobile flow rack with integrated Karakuri function

Mechanical automation with pipe racking system

Rope and deflection pulley for Karakuri applications

Blue rope with weight for Karakuri applications

Pulleys for Karakur solutions made of pipe racking system

BeeWaTec Karakuri with rocker function and rope pulleys

Pulley with steel cable attached to a 28 mm steel pipe by a connector

Good reasons for a Karakuri

Karakuri solutions have the advantage of moving load carriers automatically without having to use cost-intensive drive systems and additional sensors. The mechanical systems offer an intelligent solution for low-cost automation and are very low-maintenance, especially in direct comparison to technical systems. In addition, Karakuri applications lower the often existing entry barrier to the topic of automation.

Simple Karakuri principles can also be used for less complex solutions such as flow racks or conveyor sections. Here, rocker elements are often used that automatically ensure the return of empty containers to roller conveyors that are directed backwards.

Gravity instead of high-tech

The handling of the charge carriers is based on simple physical principles.

Low Cost Automation

Low investment costs, without electricity, sensors, control or maintenance.

Quick implementation

New and existing solutions can be implemented and adapted easily and quickly.

Components of a Karakuri

Our modular steel and aluminium pipe racking system and our aluminium square pipes provide the optimal basis for a Karakuri. Roller tracks also play a central role in low-cost automation, as they transport load carriers from A to B independently even at a slight incline.

Rockers, levers, ropes or springs form additional extension possibilities depending on the application.

Design your Karakuri.

With our 3D software BEEVisio, you can design your individual solution quickly and easily. You have direct access to all the individual components you need for planning.

If required, we can handle the construction work for you. Talk to us and find out more about your options.

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We not only offer you a modular system with all the parts you need for your project. We also support you in finding solutions, planning, construction and assembly. Let's get started!

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Karakuri

For mechanical low-cost automation - lean and cost-efficient.