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Types of pallet stacking robots

Pallet stacking robots are automated systems that can stack and unstack goods on pallets. Often regarded as a key component of a fully automated warehouse, these robots can perform the crucial task of stacking products, cartons, boxes, or even pallets themselves on top of one another. They generally come equipped with a variety of sensors and cameras to help them identify items that need to be stacked or unstacked, as well as their own environment, and are typically controlled through a simple-to-use interface.

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Though pallet stacking robots are generally divided into two main categories based on the technology they employ to carry out their stacking and unstacking duties, it should be noted that industrial robots are not limited to these two categories alone. Custom-built robots may employ a combination of various technologies to meet specific industrial needs.

• Robots with arms: These robots come equipped with a mechanical arm fitted with a gripper or suction cup that allows it to pick up objects of various shapes and sizes. Palletizing robots with arms, also known as palletizing robot arms, can stack items according to a predetermined pattern. The stacking is generally done based on shape and size to maximize space. These robots are further divided into two main categories based on whether they are jointed or not. Unjointed robots have a fixed number of joints, while jointed robots have more joints and are able to move more like a human arm.
• Robots without arms: These robots have a mobile platform that allows them to move around and pick up objects from different locations. Mobile pallet stacking robots are also able to use their computer vision and sensors to identify items that need to be stacked and the best locations to stack them. Autonomous mobile robots (AMRs) are one kind of mobile pallet stacking robot. They are able to move freely in their environment without any human intervention and navigate to different locations to carry out tasks, thanks to advanced sensors and software. Another kind is automated guided vehicles (AGVs), which are programmed to follow fixed paths or routes to navigate. AGVs are often used in conjunction with other automation technologies to carry out specific tasks in an industrial setting.

Specification & Maintenance

• Load Capacity:

  Typically, a pallet stacking robot can bear weights ranging from a few hundred kilograms to several thousand kilograms. The capacity of the robot must be aligned with the weight of the pallets and the products on them.

• Stacking Height:

  This indicates the maximum height to which the robot can stack pallets. Stacking height varies based on the design of the robot. Some robots are designed to stack pallets and shelves only up to a certain height. In contrast, others can reach greater heights, thus eliminating the need for additional manpower.

• Gripper Type and Size:

  The gripper (also known as an end effector) of pallet stacking robots comes in multiple styles and sizes, depending on the job on hand. Common forms include pneumatic clamps, vacuum systems, and custom-designed fixtures, to name a few. The size and design of the gripper must correspond with the size and form of the pallets and products being handled.

• Control System:

  Robots are often controlled by the use of automation or programming languages. For instance, robot control systems may integrate with warehouse management systems (WMS) or enterprise resource planning (ERP) systems, allowing for seamless coordination between inventory management and robotic operations. Moreover, robotics may be programmed to follow predetermined patterns and algorithms for pallet stacking and unstacking.

• Battery and Runtime:

  Usually, pallet robots have batteries that support their operation in a factory or warehouse setting. The work these robots can do in a given time is referred to as their runtime. Robots with high-capacity batteries and energy-efficient designs can operate continuously for longer periods without frequent recharging.

Regular maintenance is crucial for ensuring the optimal performance and longevity of pallet stacking robots. Here are some of the most important maintenance tips for pallet stacking robots:

• Inspection:

  Periodic inspection of the robot stacking machine is essential for maintaining its efficiency. The crucial parts of the stacking robot, such as the grippers, belts, and clamps, should be checked frequently for any signs of wear or damage. Any minor faults should be repaired immediately to prevent further damage.

• Lubrication:

  Robots have moving parts, such as bearings and joints, which should be regularly lubricated. Lubrication minimizes wear and tear on moving parts and helps to enhance efficient and smooth operation.

• Software Updates:

  It is very important to keep the robot software up to date. This is crucial for enhancing performance, security, and functionality. Regularly check the manufacturer's website or support channels for available software updates, and follow the provided instructions to safely apply the updates.

Scenarios of pallet stacking robots

• E-commerce and retail warehousing

  Pallet stacking robots are great for handling pallets and improving the efficiency of warehouse operations. Warehouses often have different-sized pallets and many of them, so stacking and unstacking them can make the most of the available space. Robots can easily sort through products on pallets or help prepare pallets of products for shipping without tiring out or slowing down.

• Food and beverage industry

  Plants that make things like drinks or baked goods need smart ways to store everything. Robots that can stack pallets make it easier to put products away and get them back out when needed. These robots know how to store things in coolers, freezers, or dry areas, and they can do it without causing contamination. Using pallet robots means products get stored correctly and workers can focus on more important tasks.

• Automotive and manufacturing

  Pallet stacking robots help with materials in production lines by making it easy to organize items on pallets. These line robots can handle heavy pallets and know how to put them in the right places for assembly. Using these robots means items are always moved smoothly, and assembly efficiency is increased. The stacking will be done safely and accurately.

• Retail and e-commerce fulfillment

  Robots that can stack pallets are useful in warehouses for online orders and regular retail. They can easily handle the large number of pallets needed for order fulfillment. Not only do these robots help maximize storage capacity, but they also streamline order-picking processes. Furthermore, the automation they provide means orders can be fulfilled more quickly and accurately.

• Third-party logistics and transportation hubs

  Logistics operations that store goods should consider investing in pallet stackers. Using robots to stack pallets makes it easier to get shipments ready and ship them out to different locations. This helps out distribution centers and transit points as well as 3rd party logistics providers who need to efficiently handle incoming and outgoing inventory. With more cargo having to be moved daily, pallet robots will make logistics work more smoothly.

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How to Choose a Pallet Stacking Robot

When choosing a stacking robot for business purposes, it is essential to select one that meets the requirements of the operations. Consider the following factors:

• Payload Capacity

  Payload capacity refers to the weight of the merchandise the robot can handle. Businesses should first assess the weight of the products they stack. It is important to note that stacking robots with high payload capacity tend to be more expensive. Therefore, it is ideal to choose a robot with a payload capacity that suits the stacked goods.

• Stacking Height

  Different robots have varying maximum heights they can reach when stacking items. Businesses should consider the height of the goods they stack, especially if they use shelving or pallets in warehouses.

• Architecture

  Robots are designed in different architectures. Some designs resemble human arms, while others use cylindrical sections that move along tracks. Select a robot whose architecture is suitable for the type of item to be stacked and its storage facilities.

• Flexibility

  Flexibility refers to the ability of the stacking robot to handle different types of goods. For businesses with the potential to handle different types of products, it is necessary to select a robot that can manage various shapes, sizes, and weights.

• Integration Capability

  Integration capabilities refer to how well the stacking robot will work with existing systems, such as warehouse management software, other automated systems, and automation tools. It is crucial to consider the configuration capabilities of the robot chosen to ensure smooth workflow and efficient operations.

FAQ

Q1: How does a pallet stacking robot work?

A1: The pallet stacking robot works by using programmed instructions to move and place goods onto pallets. These robots typically have artificial intelligence, which enables them to adapt and optimise the stacking process automatically.

Q2: What are the benefits of pallet stacking robots?

A2: The benefits of pallet stacking robots are reduced labour costs, increased efficiency, improved safety, greater flexibility and higher accuracy.

Q3: Can pallet stacking robots handle irregularly shaped items?

A3: Yes, pallet stacking robots can handle irregularly shaped items. With advanced features like adaptive grippers and machine vision systems, the robots can identify, adjust to and safely stack items of different shapes and sizes.

Q4: Are pallet stacking robots cost-effective for small businesses?

A4: Yes, pallet stacking robots are cost-effective even for small businesses. While the initial investment may be significant, the robots can improve efficiency, reduce labour costs and minimise error rates, leading to substantial long-term savings for businesses of all sizes.

Q5: Can existing warehouse operations be integrated with pallet stacking robots?

A5: Yes, pallet stacking robots can be integrated into existing warehouse operations. With customisation and proper planning, the robots can work alongside other systems and processes to enhance overall productivity.

Our robots for the palletizing of medium payloads (up to 40 kilograms) are very fast, reaching a top working speed of up to 56 cycles per minute. The palletizing robots for medium payloads also stand out in terms of reach – and are thus perfectly suited to the precise stacking of europallets.

Find out more about the KR 40 PA and its capabilities.

The KR QUANTEC PA are the fastest, most precise and most powerful robots in their class. The streamlined design and low weight enable maximum dynamic performance and unbeatable precision. The KR QUANTEC PA machines are thus perfectly suited to challenging palletizing tasks with  load capasity from 120 to 240 kilograms and maximum reaches – including the Arctic version designed specially for use in cold-storage rooms. They can be used to stack multiple pallet handling to a great height effortlessly. KUKA also offers the palletizing robot in a “Hygienic Oil” (HO) variant, which uses food-compatible NSF H1 lubricants  in all axes and the energy supply system. 

KUKA palletizing machines for heavy loads can get to grips with far more. As well as their high  load capacity, combined with a reach of up to 3,150 millimeters, they stand out for their extremely high working speeds. They stack heavy payloads at high speed – with extremely long maintenance intervals.

The hollow-wrist design with its extra-large opening measuring an unbeatable 60 millimeters enables space-saving cell concepts. Discover our palletizers for heavy loads and their outstanding flexibility: KR 300-2 PA, KR 470-2 PA and KR 700 PA

With the palletizing robots of the KR titan series, you can lift the heaviest loads with ease. The KR titan PA is the world’s first robot for  load capasity of up to 1,300 kilograms – with unrestricted dynamic performance and short cycle times, it is the strongest palletizing robot on the market. With their long reach and minimal disruptive contours, the strong palletizing robots of the titan series open up additional workspace. 

Read how the KR titan lives up to its name.