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CD/DVD/BD Robot systems

CD/DVD/BD-Robot system DISCUS X-SL 2.0

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.

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CD/DVD/Blu-Ray Robot cluster

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).

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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.

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OpenRC Diagram

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.

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Product versions

CD/DVD/BD-Robot system DISCUS X-RL

 

DISCUS X-RL 1.0

 High end CD/DVD/Blu-Ray robot (desktop version) with two to ten drives and a capacity of up to 600 discs.

The robot system DISCUS X-RL 1.0 will automatically burn and label up to 120 CDs and accordingly up to 60 DVDs per hour, depending on the data volume and the technical options used for the production and printing. Depending on the requirements, the device tower can be extended subsequently without changing the whole robotic - a maximum of 10 devices without printer and a maximum of 6 devices with printing system is possible. A capacity of up to 600 discs is possible, whereupon different types of discs (CD, DVD, Blu-Ray) can be used in each bin (a maximum of four bins is possible).

Due to the use of conventional standard components (burner drives, power supply units, etc.), no specialist knowledge is required to service the robotics itself.

The software framework OpenRC manages all functions of the robot. A web GUI allows control and management of the robot independent of platform and location.

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Technical Data

Dimensions (WxDxH): 460 x 550 x 700 mm
Weight: Basic configuration about. 20 - 40 kg (depending on the number of burning devices and the printing system)
Power consumption: 230 V, max. 450 W (without conrol unit)
Network:
  • Gigabit Ethernet (10/100/1000 Base-T)
  • RJ45
Environmental requirement:
  • dust-free
  • vibrations-free
  • surrounding temperature: 5 - 35°C
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Options

  • Webcam for visual status control over the network
  • Power management
  • UPS - uninterruptible power supply (to bypass short blackouts)
  • parallel control of additional devices possible (e.g. printer for brief paper instructions, guarantee board e.g.)
  • front panel individually designable
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CD/DVD/BD-Robot system DISCUS X-SL 2.0

CD/DVD/BD-Robot system DISCUS X-SL 2.0 - Maintenancedoor at the back

DISCUS X-SL 2.0

The compact rack solution for the robot system DISCUS X-RL guarantees high security for the professional production of CD, DVD and Blu-ray. External doors that are lockable and a cooling system protect the integrated high end robot against external impacts (e.g. heat, dust) or unauthorised access.

This allows to settle the operation directly into production environments or at public places.

Each robot system of the series DISCUS X-RL as well as robot systems of the company ADR AG can optionally be integrated in the rack system - even afterwards. The robot system can be pulled out of the rack easily and fast. When moved out completely, the robot system protrudes the rack system over 80 cm. A service door at the back eases the access to the connectors.

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Technical Data

Dimensions (WxDxH): 800 x 800 x 1.200 mm
Plinth height: 100 mm
Power consumption: 230 V, max. 450 W (without control unit)
Network:
  • Gigabit Ethernet (10/100/1000 Base-T)
  • RJ45
19'' add ons: 6 height units for server and other network components are available
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Options

  • Cooling system ranging from 300 to 4000 watt
  • Power management
  • Web cam for visual control of status over the network
  • Remote inquiry program, inclusive of controlled reaction: access sensor (door), temperature sensor, humidity sensor, voltage control, motion detector
  • UPS (uninterruptible power supply) to avoid voltage fluctuation and make up for short power failures
  • Lockable door with slash opening for the removal of created media
  • Integration of additional components (e.g. label printer, bar code scanner, printer for short manuals, written guarantee etc. on paper)
  • Front panel with individual logo
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CD/DVD/BD-Robot system DISCUS X-SL 1.0

 

DISCUS X-SL 1.0

Advanced rack unit with additional advantages in order to protect the robot system DISCUS X-RL. Each particular component of the DISCUS X-SL 1.0 is specifically adjusted to the professional production of individual CDs, DVDs and Blu-Rays in an industrial production environment.

The rack unit DISCUS X-SL protects high end robot systems and especially the professional production of individual CD, DVD an Blu-ray against unauthorized access. At the same time, the rack protects against external impacts like heat or dust. This allows the operative use of the robot system directly in production environments as well as e.g. in public mail rooms.

Each robot system of the series DISCUS X-RL as well as robot systems of the company ADR AG can optionally be integrated in the rack system - even afterwards. The robot system can be pulled out of the rack easily and fast. When moved out completely, the robot system protrudes the rack system over 80 cm. A service door at the back eases the access to the connectors. A inspection window at the side allows easy and fast maintenance of the printing system.

DISCUS X-SL 1.0 is constructed in a way that allows the integration of additional components like e.g. label printer directly into the rack. Thereby the whole systems allows different functionalities that are assimilated in one hardware. An integrated monitor shows the state of the robot system and of the disc production.

The software framework OpenRC manages all function of the robot. A web GUI allows a controlling and managing by way of an independent platform and location. The controlling is also over e.g. tablet PCs possible.

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Technical Data

Dimensions (WxDxH): 800 x 800 x 2.000 mm (without cooling system)
Plinth height: 100 mm
Weight: Basic configuration about 200 - 350kg (depending on the actual equipment)
Power consumption: 230 V, max. 450 W (without add ons)
Network:
  • Gigabit Ethernet (10/100/1000 Base-T)
  • RJ45
Cooling: Standard air conditioning for 19'' racks or cooling with an existing cooling system; the software OpenRC or a special sensor systems control the air conditioning. The cooling system can also be assembled sidewise.
insertion slide-in for server: variable elements 19''
Screen:

17''

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Options

  • Cooling system ranging from 300 to 4000 watt
  • Power management
  • Webcam for visual control of status over the network
  • Remote inquiry program, inclusive of controlled reaction: access sensor (door), temperature sensor, humidity sensor, voltage control, motion detector
  • UPS (uninterruptible power supply) to avoid voltage fluctuation and make up for short power failures
  • Lockable door with slash opening for the removal of created media
  • Integration of additional components (e.g. label printer, bar code scanner, printer for short manuals, written guarantee etc. on paper)
  • Front panel with individual logo
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