Palletizing robots

A Palletizing robot is engineered to move items from a conveyor belt or another type of feed and stack them onto a pallet in a specific arrangement. This may sound simple, but the complexities arise when you consider the types of objects being handled and the need for precision and speed.

Palletizing robots take items that have been packaged or prepared and place them onto pallets in a predetermined pattern. They can handle different types of goods, from boxes to bags, and can even manage items of varying sizes and shapes.

These are some types of robotic arms used in palletizing:

• Articulated robots: These are the most commonly used type and usually have 4, 5, or 6 axes. The additional degrees of freedom allow these robots to pick items from various orientations and place them with high precision.
• Cartesian robots: These have three linear joints that use the Cartesian coordinate system (X, Y, Z). They are generally less flexible but are a great choice if you need items moved over a significant distance outside of the reach of an articulated arm.

These robot arms have different end-effectors or grippers that they use in handling pallets.

• Vacuum grippers: These are suitable for handling boxes and other sealed, delicate items. They are generally quicker but might struggle with irregularly shaped or porous items.
• Mechanical grippers: Best for handling a wide variety of shapes and sizes but generally less gentle than vacuum grippers.
• Magnetic and specialized grippers: Used for specific applications, like handling metal objects or items with unique handling requirements.

Real-world applications

Layer-based palletizing: Here, the robot picks up items and places them layer by layer onto the pallet. This is usually done for uniform, boxed items.

Mixed-case palletizing: The robot picks and places different types of items onto the same pallet. This requires a more sophisticated setup, usually involving a Six-Axis robot and advanced grippers to handle varied items.

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Sortation robots

Sortation robots are specialized to automatically sort items based on specific criteria like size, weight, or destination. They operate in sync with conveyor systems or other robotic elements. These robots drastically streamline the process of segregating inbound or outbound goods. 

There are two main types of sortation/sorting robots:

• Linear sorters: These use linear motion to slide items into designated bins or chutes. They usually have a paddle or pusher as their end-of-arm tool to push items off a conveyor belt into the sorting bin. Though they are a little limited in flexibility, they're excellent for high-throughput environments.

• Swivel sorters: They use a rotating arm to direct packages to their destination. These are particularly effective where multi-directional sorting is needed.
• Robotic arms: These use complex articulated arms, often Six-Axis, to pick up, move, and place items in designated locations. They usually have mechanical and vacuum grippers to handle irregularly shaped objects. This type is ideal for more intricate sorting needs.

Real-world applications

Parcel sorting: Often seen in shipping and receiving areas, these robots can sort parcels based on size, weight, or destination zip code.

Inventory segregation: In larger warehouses, Sortation robots can assist in dividing received inventory into different categories for easier storage or fulfillment.

Order fulfillment: When combined with other systems like Automated Storage and Retrieval Systems (AS/RS) and conveyor belts, sortation robots become part of a seamless order fulfillment process.

Pick and place robots

Pick and place robots are designed for exactly what the name suggests: picking up items from one location and placing them in another. These robots are crucial in tasks like assembly, packaging, and machine tending, where speed and accuracy are paramount.

There are different types of robotic arms for pick-and-place activities:

• SCARA robots: With 3 or 4 axes, these robots are excellent for horizontal movements. They excel in tasks that don’t require a lot of vertical motion, like assembling circuit boards.
• Delta robots: These are Four-Axis parallel robots that are incredibly fast and accurate, ideal for high-speed pick and place tasks.
• Articulated robots: Often Six-Axis, these robots offer the most flexibility, capable of reaching around obstacles and working in tight spaces.

For pick and place robots, their end effectors are usually finger or vacuum grippers. The finger grippers are the most versatile and can be used for a wide range of picking tasks. The ‘fingers’ can be adjusted to pick up objects of various sizes.

Sometimes the grippers are made of soft, compliant materials, to handle delicate objects without damaging them.

Real-world applications

Machine tending: These robots can load and unload CNC machines, injection molding machines, or any other type of machinery that requires frequent material change.

Assembly lines: Whether it’s electronics or automotive parts, pick and place robots can perform repetitive assembly tasks with high precision.

Food packaging: With specialized, food-grade grippers, these robots can be used to package different types of food items quickly and hygienically.

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Inventory management robots

Inventory management robots are geared towards keeping track of stock levels, restocking shelves, and even collecting data for inventory analysis. These tasks are critical for the efficient running of a warehouse. The robots often collaborate with warehouse management systems (WMS) to synchronize data and improve real-time visibility.

The types of robots commonly used for warehouse inventory management include:

• Automated Guided Vehicles (AGVs): These are usually 2-axis robots that move along predefined paths. They are often used for transporting goods to and from inventory locations.
• Autonomous Mobile Robots (AMRs): Unlike AGVs, AMRs can navigate freely around the warehouse, thanks to sensors and onboard intelligence. They're often used for complex tasks like shelf scanning and real-time data collection.
• Robotic arms for shelving: These are usually Six-Axis robots that are designed to reach into shelving units to pick or place items.

Their end-of-arm tooling usually has sensors and scanners:

• Barcode scanners: These are essential for tracking inventory. They're often integrated into the robot to scan items as they are picked or shelved.
• Vision systems: Cameras and machine learning algorithms can identify items, even in low-light conditions. This is particularly useful for error reduction.
• Mechanical grippers: These are often used in robotic arms that need to pick up and place items onto shelves. The gripper's design can vary based on the shape and fragility of the inventory items.

Real-world applications

Restocking: AMRs equipped with shelving systems can transport goods from receiving areas directly to storage or picking zones, reducing human intervention.

Shelf auditing: Robots equipped with scanning technology can autonomously check stock levels and update the WMS, thereby reducing errors and improving stock visibility.

Data collection: Advanced sensors and cameras can collect data on stock levels, product conditions, and even environmental factors like temperature and humidity, which are crucial for sensitive goods.

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Collaborative robots (Cobots)

Cobots are designed to work alongside human operators, assisting in tasks that range from material handling to complex assembly. Unlike traditional industrial robots, Cobots prioritize safety and human interaction. They often come with features like force sensors and machine vision to adapt to changes in their environment. The robotic arms in Cobots are most often articulated (Six-Axis).

Cobots have different safety and sensing mechanisms that they use:

• Force sensors: These enable the Cobot to detect unexpected obstacles, like the human arm, and adjust its force accordingly, which is vital for safe human interaction.
• Machine vision: This includes cameras and sometimes laser sensors, which allow the Cobot to perceive its environment and make real-time adjustments.

Cobots often come with interchangeable grippers, suction cups, or even specialized tools, enabling them to handle a variety of tasks.

Real-world applications

Quality inspections: With advanced vision systems, Cobots can identify defects in products and either remove them or flag them for human review.

Machine tending: Cobots can load and unload materials in CNC machines, presses, and injection molding machines, often using specialized EOAT to handle specific materials.

Assembly assistance: In automotive or electronics assembly lines, Cobots can handle delicate or repetitive tasks, reducing strain on human workers.

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Conclusion

When it comes to selecting the right robot, you're not just shopping for a machine—you're investing in a solution tailored to your warehouse’s specific challenges. It's crucial to dig into the technical aspects like the type of robotic arm, axis configurations, and the various end effectors or grippers available. These technical details, coupled with the robot's primary function, will influence how well it integrates into your existing systems and how efficiently it performs its tasks.

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Next steps

You don’t have to buy a whole collection of robots to automate your warehouse operations. RO1 by Standard Bots is built in the USA and is flexible for multiple use cases.

• From machine tending to inspection, RO1 is your all-in-one automation solution.
• It easily integrates into any manufacturing and machining setup.
• It is affordable while still boasting faster movement and heavier payload capacity than competing robots.

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Speak to our solutions team today to get an engineering analysis.