Palletizing Robot System | End-of-Line

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.

Technical Details

4-Axis Column Palletizer Architecture

In addition to the 5-axis and 6-axis articulated robot options described above, Motionwell also deploys 4-axis column-type palletizing robots for applications where the cost-performance ratio is the primary selection criterion. The 4-axis column palletizer uses a fundamentally different kinematic architecture from articulated robots:

The column design provides purely vertical lifting motion on J2, which is mechanically more efficient than the shoulder-elbow kinematics of articulated robots when the primary task is lifting cartons vertically onto pallets. The vertical column uses a ball-screw or rack-and-pinion drive with a counterbalance mechanism, reducing the servo motor sizing required compared to an articulated arm that must support the full payload at horizontal extension.

Performance Specifications

The repeat accuracy of +/-1mm is sufficient for carton palletizing where typical dimensional tolerances on the cartons themselves are +/-2-3mm. The 6-10 carton per minute speed range handles most single-line end-of-line palletizing requirements. For higher-throughput applications requiring 12+ cartons per minute, Motionwell recommends the ABB IRB 460 or FANUC M-410iC articulated platforms.

Heavy-Duty Linear Track for Extended Reach

For installations where a single palletizing robot must serve multiple pallet positions (for example, palletizing two or three SKUs simultaneously onto separate pallets), Motionwell mounts the column palletizer on a heavy-duty linear track. The track uses a rack-and-pinion drive system with hardened steel rails, providing:

• Extended working envelope spanning multiple palletizing stations along the track axis
• Positioning accuracy of +/-0.5mm along the track using an absolute linear encoder
• Travel speed up to 1.5 m/s between pallet positions
• Payload capacity rated for the combined weight of the robot, gripper, and maximum carton load

The linear track effectively multiplies the robot’s working area without adding a second robot. A single robot on a 6-meter track can serve three pallet positions with only a 2-3 second transit time between positions, which is absorbed into the natural pallet pattern cycle without reducing throughput.

Cost Advantage Over 6-Axis Solutions

The 4-axis column palletizer with linear track typically costs 30-50% less than an equivalent 6-axis articulated robot solution for standard carton palletizing applications. The cost savings come from three factors:

1. Simpler mechanical design: Four axes with direct-drive column lift require fewer gearboxes, bearings, and structural castings than six-axis articulated arms.
2. Smaller servo drives: The counterbalanced column design and purely vertical lifting motion reduce the motor torque requirements compared to articulated robots that must support payload at varying arm extensions.
3. Simpler programming: 4-axis palletizing requires only position-rotation paths without the complex singularity avoidance and joint-limit management needed for 6-axis robots in confined palletizing cells.

Motionwell recommends the 4-axis column architecture for straightforward carton palletizing up to 200kg, where the application does not require the dexterity of 6-axis motion (such as bag palletizing, multi-face label application, or palletizing into constrained spaces).

Related

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