Presentation Date: Feb 14, 2026
AGSA Abstract
Recent advancements in consumer-oriented industrial robotics have created new opportunities for automation in the beauty and skincare sector, where precision formulation, hygienic processing, and consistent product quality are critically important. This paper presents a comprehensive systems integration architecture for an intelligent robotic beauty and skincare automation workcell. The workcell consists of multiple processing stations, including ingredient dispensing, controlled heating, flash-freezing, whisking/mixing, capping, and labeling, all coordinated by a Beckhoff PLC-based control cabinet and a KUKA KR C4 industrial robot controller. The proposed architecture employs deterministic PLC–robot communication using fieldbus, EtherCAT, and Ethernet protocols, digital and analog handshake signals, and standardized I/O mapping to synchronize multi-station operations. The PLC is responsible for executing safety logic, driving station-level actuators, and enforcing thermal and timing constraints, while the robot performs high-precision part manipulation, inter-station routing, and tool engagement. A digital twin of the entire workcell was developed using TwinCAT XAE Shell to validate sequence logic, process timing, and fault-handling strategies before commissioning. Experimental validation of the integrated system demonstrates improved cycle repeatability, enhanced thermal processing accuracy, and higher uniformity in skincare product preparation. The coordinated control structure ensures smooth transitions between formulation steps, rapid response to process deviations, and robust automatic recovery from common faults. This study provides an adaptable blueprint for deploying advanced robotics in beauty and skincare manufacturing, emphasizing modularity, safety, and scalable system integration techniques suited for next-generation autonomous consumer product workcells.
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