What robots does Motionwell use for palletizing?

Motionwell integrates ABB and FANUC industrial robots for palletizing applications. Robot selection depends on payload requirements, reach, speed, and the specific application needs.

Can the system handle multiple product sizes?

Yes. Programmable layer patterns accommodate different carton sizes and pallet configurations. Changeover between products requires only recipe selection, not mechanical adjustment.

What throughput can palletizing robots achieve?

Throughput depends on carton weight, size, and pallet pattern. Typical systems handle 8-15 cartons per minute, significantly exceeding manual palletizing rates.

Palletizing Robot System — Automated End-of-Line Palletizing

Motionwell integrated ABB IRB 460 and FANUC M-410iC palletizing robots for automated end-of-line pallet stacking in Singapore warehouses.

Palletizing Industrial Robot ABB FANUC Logistics

Palletizing robot system for automated end-of-line operations

Project Overview

Motionwell Automation integrated automated palletizing robot systems for manufacturers in Singapore, replacing manual end-of-line pallet stacking with robotic automation. The systems use ABB and FANUC industrial robots selected for their payload capacity, reach, and reliability in high-duty-cycle palletizing applications.

System Design

Robot Selection

Motionwell selects palletizing robots based on application payload, reach, and cycle time requirements:

ABB IRB 460: 4-axis palletizing robot with 110kg payload capacity and 2.4m reach. Capable of over 2,190 cycles per hour, making it one of the fastest palletizers in its class. Used for standard carton palletizing up to 25kg per case.
FANUC M-410iC/315: 5-axis palletizing robot with 315kg payload capacity and 3.1m reach. Selected for heavy-duty applications involving multi-case grabs, full-layer picks, or individual cases exceeding 30kg.
Both platforms integrated with Motionwell’s standard Mitsubishi iQ-R PLC control architecture via EtherNet/IP, with ABB IRC5 and FANUC R-30iB Plus controllers managing robot motion independently.

Custom vacuum and mechanical gripper designs are engineered for each application. Typical grippers use Schmalz FXCB vacuum area grippers for carton picking, with Festo DSNU pneumatic cylinders for side-clamping when handling unstable or open-top cases.

Conveyor Integration

The infeed conveyor system uses Interroll drum motors driving 24V MDR (motor-driven roller) zones, providing zero-pressure accumulation upstream of the robot pick station:

Powered roller conveyor infeed rated at 30 meters per minute from production line
3-zone accumulation buffer with SICK WTB4S photoelectric sensors for zone occupancy detection
Carton squaring station with pneumatic side guides to ensure consistent pick position
Reject lane with pneumatic diverter for out-of-spec cartons detected by upstream checkweigher

Layer Pattern Programming

Motionwell programs layer patterns using ABB RobotStudio and FANUC PalletTool offline simulation software, verifying pallet stability and cycle time before deployment:

Up to 50 stored patterns for different carton sizes and pallet layouts (1200x1000mm EUR and 1200x800mm standard pallets)
Recipe-based changeover triggered by barcode scan or MES command, requiring zero mechanical adjustment
Column, interlocking, and pinwheel pattern options optimized for pallet stability during transport
Automatic pallet full detection via layer count and height sensor, triggering pallet conveyor indexing for stretch wrapper transfer

Safety System

The palletizing cell is enclosed with Troax machine guarding panels and SICK M4000 safety light curtains at the pallet removal openings. Access doors use Schmersal AZM201 safety interlocks. The safety circuit is designed to ISO 13849 Performance Level d, monitored by an ABB Pluto safety PLC.

This project demonstrates Motionwell’s robotics integration and machine vision inspection expertise for the warehouse & intralogistics industry.

Challenge

A manufacturer needed to automate end-of-line palletizing to reduce manual labor, improve stacking consistency, and increase throughput for shipping preparation.

Solution

Motionwell integrated industrial palletizing robots (ABB/FANUC) with conveyor infeed, vision-guided carton detection, and programmable layer patterns for different product configurations.

Outcome

Consistent pallet stacking at higher throughput than manual operations. Programmable patterns accommodate different carton sizes and pallet configurations. Reduced physical strain on operators.

More Case Studies

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