Robotic Palletising

We design all in one palletising system for Outstanding Palletising Robots Manufacturing Performance

Advantages in Using Palletising Robots

fanuc palletising system

There are a number of advantages in using an industrial robot for  palletising system:

First, as mentioned above this is a highly repetitive task which is very tiring for a human worker. The human worker building up products onto a pallet will require numerous breaks.  On the other hand, the robot will be able to work 24 hours a day, 7 days a week if necessary.

Second, the industrial robot can lift much higher weights than a human worker. The recommended maximum weight for a human worker is 25Kg.  Bear in mind that this reduces when the movements require the arms to be outstretched in the case of building up large pallet formations. However, the industrial robot can work with payloads up to 1000Kg if necessary. 

Although the most common robot types used for palletising tend to be robots with a payload capacity around 180Kg. In this case, it’s usually the required reach that dictates the robot size rather than the payload.

Third, the industrial robot will have a much greater palletising speed than a human can achieve. So, the cycle time between a product being picked up and placed. As well, the robot returning to the pick position will be shorter than that which a human can achieve.

Main Elements of the Palletising Robot Cell

Robotic cell

Types of Robots for Palletising

There are two different types of robots most often employed for palletising cells: the standard robot and the dedicated four-axis robot for palletising operations. Having talked about the advantages and different robot types let's have a look at the main elements that make up the majority of robotic palletising cells.

First, we have the robot itself. Considerations here are for payload, envelope and cycle time. In terms of the payload, this will be the maximum weight that the robot can handle.

The total payload will be the weight of the product plus the weight of the gripper. The robot payload will need to be greater than the combined weight of the product and gripper. Also, it will need to be borne in mind that if the centre of gravity is offset from the centre of the mounting flange this will reduce the payload capacity of the robot.

Dedicated four axis arm
Dedicated four axis palletising robot

Dedicated four axis palletising robot

In the case of the dedicated palletising robot there are only four axes as opposed to six. This means that the tooling is limited in orientation to rotation solely around the vertical axis of the gripper.

However, the majority of palletising operations do not require any tilting of the product.  It means that the advantage in using a dedicated palletising robot will be that the robot speed will generally be quicker and hence a reduced cycle time.

Robot control panel

Robot Control Panel

To control the complete cell a safety panel with cell control pushbuttons will be installed which is electrically connected to the robot controller. This panel will include the safety relays for the two safety circuits for the robot and any ancillary equipment.

One circuit will be for the Estops, these will stop the robot in all modes. The second circuit will be for the cell access and this will stop the robot and spindle whenever the robot is running in Auto mode.

Robot arm cell design

Palletising Cell Design

The robot cell will also need some form of guarding which will form an enclosure to make sure that nobody is present whilst the robot is working in automatic.

The usual layout for a palletising cell is to have two pallet locations with the robot in the middle of the two. The robot will palletise to one side and once completed will move over to palletise the second side. Whilst the robot is working on the second pallet the first pallet is removed and replaced with a new empty pallet.

Each of the pallet stations will have two sets of light curtains to protect the operator. The front light curtain will be active and the robot sidelight curtain muted whilst the robot is working on that station.

If the operator were to try and enter the cell the active light curtain will stop the robot.  In the case of a completed pallet, the operator will select to enter the station and this will activate the light curtain on the robot side.

It mutes the light curtain at the entrance to the station allowing the operator to enter without interrupting the sequence.  Even so, if for any reason the robot tries to enter the station during this time the active light curtain will detect the intrusion and stop the robot.

palletiser gripper

Palletising Robot Gripper

Fitted to the robot will be some form of gripper for picking up the product. There are different types of grippers depending on the product and the required stacking pattern.

In the case of a pneumatic finger type gripper, this will open around the product and have fingers that close to clamp the product to stop it from moving during the movement of the robot.  However, when using this type of gripper you must consider the stack pattern.  Why? Because at the moment of placing the product the gripper will open and push any product that is already palletised.

Usually, when using this type of gripper the product is released above its position in order that the gripper has room to open.

Suction palletiser gripper
Robot Conveyor

Vacuum System for Palletising

An alternative solution is to use a vacuum system rather than fingers for picking up the product. In this case, the product is held in place by an array of suckers which usually grip the product from its upper surface.

This system has the advantage that tight stacking patterns can be produced allowing the products to be placed up against products already on the pallet.

Conveyor System for Palletising

The product will normally be delivered to one or more pickup points usually in the form of a conveyor.

Therefore, the robot requires a separate PLC to manage the conveyor.  This PLC will be part of the machine that is manufacturing or bagging the product.

The interface between the robot and the conveyor is simply the detection of the absence of the pick point being vacant with a combination of the robot clear signal and product present detection.

Robotic palletising cell design

Phoenix provides a complete turnkey solution for palletising robot cells. We work together with all robot manufacturers such as KUKA, ABB, AND FANUC just to mention a few.

MAIN ROBOT APPLICATIONS

Painting Robots

We tend to think of the automotive industry when we consider the use of painting robots. Today, we are seeing a new interest in paint robots for smaller applications.

Milling Robots

Milling cell brings a high level of flexibility and accuracy because industrial robots can produce high-quality, complex and exceptional geometric parts.

Welding Robots

Robotic welding systems help companies gain a competitive advantage over those companies that have not made the transition to welding automation.

Assembly Line robots

Industrial robots are very useful in an automated assembly line operations, improving process efficiency at low operational cost and savings costs.

Palletising Robots

Palletising robots build up layers of products for shipment usually onto pallets. When the pallet is full the operator will remove the completed pallet.

Trimming & Cutting Robots

Robotic cutting and trimming robot application is the process to remove any material to follow a predetermined path.

Turnkey Industrial Robot Solutions

Phoenix integrates and installs complete robotic milling solutions from initial design and consultation to manufacture. Also, we offer robot trainingrobot programmingrobot simulation, commissioning, and technical support. Whether you decide to configure your complete milling robot cell, around a new robot or reconditioned robot.