The 5 key robotic palletizing principles

The 5 Principles

We all know that automation is going to impact the future of manufacturing massively. It already is helping businesses all over the world redesign their processes, maximize their output and grow in the face of a global shortage of labor. But knowing how beneficial automation can be is not the same as knowing how to implement a robotic palletizing solution effectively.

For production and technical managers, there is a lot to juggle. Commodity prices, supply chains, shortening delivery times, changing customer expectations, and a lack of skilled workers are ongoing challenges that automation can potentially help with. Creating the time and space needed to prepare and implement robot-based automation can seem like a tall order. Cobots are designed to be deployed into existing production lines quickly. They are versatile, affordable and easier to use than traditional industrial robots.

Getting the most value out of your cobot as quickly as possible requires preparation and sticking to some basic principles. Here are our top five rules for robotic palletizing:

1. Understand your payload

It may sound simplistic, but you need to make sure your chosen cobot model can carry out the palletizing tasks you want it to. When it comes to payload, this means thinking carefully about the weight of the packages and products being moved as well as the throughput of the conveyor. You might need your cobot to handle multiple boxes at the same time, which can, in turn, require a higher payload.

Also, don’t forget to include in your calculations the weight of the grippers you will be using. It will help ensure you get the best performance possible.

It is also important to understand the limitations of cobot-based solutions. If you need your robot to handle payloads of over 16kg at a time, you will likely need to start looking at traditional industrial robots. These will require more user training and additional safety infrastructure, but will be able to meet your needs. But for most palletizing functions, a cobot’s reach and payload capabilities should be more than enough.

2. Choose the right gripper

Your cobot is only as good as its end effector, otherwise known as its end-of-arm tooling or gripper. Making sure you have the right one is crucial to the success of your project. There are a couple of things to consider here. First, the kind of cardboard your products are packed in will mean that only some types of grippers are suitable, particularly for wrinkled or more lightweight packaging.

Second, you need to factor in the work rate of your cobot and its working environment. If you are going to push your robotic palletizing system to its payload limits consistently for long stretches every day, opting for lighter grippers can help reduce wear and tear. Some grippers will also need an external power source.

Our UR+ ecosystem has many different end effectors, from pneumatic grippers to vacuum ones. It should be your first stop when looking at your options.

3. Measure your footprint

Floorspace is one of the most important assets in a production line and one that is always limited and in demand. This is another area where cobots can have a clear advantage over other kinds of industrial robots, especially when it comes to palletizing. The small footprint of the cobot arm makes it much easier to design a really space efficient palletizing operation where most of the space is dedicated to the pallet rather than the robotics.

Most palletizing operations will be dual pallet. Again, having a robotic palletizing system that is as slim as possible has several benefits. Firstly, cobots don’t usually (subject to a thorough risk assessment of course) require the large protective enclosure that other robots do. Secondly, the small footprint means that it is always easy for human workers to access the pallets or the machine itself.

4. Get to grips with stack patterns

No two palletizing operations are ever the same. This means you will need to make sure the stack patterns you use are the right ones. You will need to do your pallet stacking to the maximum height that can fit into freight trucks and containers. Your stack patterns are important as they dictate how much product fits each pallet and how stable each completed pallet is.

Designing your own stack patterns can be complex. It involves translating the pallet stacking pattern into coordinates for the robot. Luckily, there are lots of software and application kits available that allow users to design and edit their own stack patterns without the need to write a single line of code. These software solutions are invaluable when it comes to democratizing the benefits of automation because they allow users with minimal automation experience and training to jump in and have a go. Explore UR+ where you can find some.

5. Optimize your safety

You should always complete a thorough risk assessment before implementing your cobot. In particular, you want to be sure that it is safe for workers and machines to work closely with regards to sharp edges and moving heavy payloads at speed.

For example, our PolyScope graphical interface for our e-series cobots comes with 17 market-leading safety features to help make sure this is always the case. Without the need for any coding, users can create safety planes and limit a joint’s range of motion. The versatility of your cobot means that you can also enhance the arm with additional sensors and application kits to enable additional functionalitiess – such as detecting when a human worker moves within its range.

The arm will then slow down automatically to its lowest speed until the person has stepped away again. While this feature is useful, it doesn’t completely remove any risk. No cobot arm is inherently safe – it is, after all, a piece of machinery. Training your staff on how to work safely around your new cobots should always be a priority.

Everyone can benefit from cobots

Every manufacturing business needs tools that help them adapt to a changing environment, that are affordable and make workers’ lives simpler. We believe that cobots tick all these boxes. They are an effective way to introduce robotic palletizing and automation without the need to radically redesign existing processes. Plus, their relative simplicity makes them a great tool for upskilling your existing workforce.

We are always on hand to help make sure you get the most value from your cobots. Get in touch to talk about anything to do with collaborative robotics, palletizing, or industrial automation.