Projects
Machines running, with the build details left visible.
Three machines designed mechanically, programmed, and commissioned by the same team, built on the modular hardware and CODESYS foundation that carry into every Levra project. They run on our own floor as demonstrators, which is exactly why we can show you every part of them.
Project 01 · Shop demonstrator
Rotary disk stamper with vacuum pick and magazine reload.
What was built
A compact rotary cell that picks disks from a stack, indexes them to a stamping station, and ejects finished parts. Mechanical design, controls, pneumatics, and the operator HMI were delivered together rather than handed between disciplines.
Because the build inherited the modular hardware and the CODESYS foundation, the machine-specific engineering went into the rotary kinematics, the vacuum picker, and the stamp head rather than controls plumbing.
The magazine reload pattern was designed around the operator: refilling is a routine task that keeps the cell running without engineering involvement.
- Function
- Pick single disks from a stacked magazine, index to stamp, eject
- Motion
- Rotary indexing stage with distinct pick, stamp, and eject positions
- Pick
- Vacuum picker, single-disk pickup from the magazine
- Stamp
- Pneumatic stamp head with sensed home and stamp positions
- Reload
- Quick-refill magazine pattern, handled by the operator
- Controls
- Controls, motion, pneumatic and power bricks + CODESYS template
- HMI
- Auto/Manual modes, job tracking, fault recovery inherited from the template
- Status
- Runs on the Levra shop floor as a demonstrator
Project 02 · Shop demonstrator
Pneumatic can crusher with sensor-based classification.
What was built
A demonstrator that classifies a loaded can by geometry — standard 12oz, tall, or invalid — then crushes it with a pneumatic cylinder if it is valid. The classification logic and crush sequencing are the project-specific code; mode management, guard interlock, fault recovery, and cycle counting come from the controls template.
This machine is a useful demonstration of interlock discipline. The discharge waits for the guard and the crush waits for classification, so the wrong command never executes. The HMI shows the can class before the crush is permitted, so an operator can see why the machine is or is not proceeding.
- Function
- Classify a loaded can by geometry, crush if valid
- Classes
- Standard 12oz / tall / invalid
- Actuation
- Pneumatic crush cylinder, 5/3 paired valve control — deterministic extend, hold, retract
- Interlocks
- Every motion gated by sensors; discharge waits for guard, crush waits for classification
- Telemetry
- Cycle counts, runtime, and classification results exported per job
- Controls
- CODESYS template + project-specific classification and sequencing
- Status
- Runs on the Levra shop floor as a demonstrator
Project 03 · Bench demonstrator
A compact pick-and-place cell with resume-from-step recovery.
What was built
A bench-scale cell that picks a ball from the bottom of a ramp and places it at the top, where it runs down into a recessed nest. When the operator presses release, an air cylinder extends and the ball rolls back to the pickup point, ready for the next cycle.
The cell exists to show recovery behavior on real hardware. Pick retries play out on screen. When retries exhaust, the machine escalates to a fault; after the operator presses Reset, the cycle resumes from the exact step it stopped on rather than starting over. The operator can also Hold mid-cycle: motion pauses cleanly while the vacuum keeps gripping, and Resume continues from the same step.
That behavior is the difference between a machine an operator trusts and one they work around.
- Function
- Pick from ramp bottom, place at top; gated nest release via air cylinder
- Pick
- Vacuum pick with automatic retry; self-recovers when the ball returns
- Fault recovery
- Retries exhaust → fault → Reset → cycle resumes from the interrupted step
- Operator hold
- Hold pauses motion mid-cycle while vacuum keeps gripping; Resume continues from the same step
- Controls
- Modular bricks + CODESYS template
- Status
- Bench demonstrator
The same foundation, built around your parts.
Every machine on this page runs on the hardware patterns, controls shell, and recovery behavior that carry into every Levra build. Yours inherits the same proven foundation and gets engineered around your process. Send us what goes in, what comes out, and how fast it needs to run. If that is defined enough to quote responsibly you get a budgetary proposal at no cost; if it needs layouts or cycle-time validation first, we’ll say so and scope a short paid feasibility phase that credits toward the build. Either way, we’ll tell you if automation is the wrong answer.