Carton palletizing robot

Short Description:

A carton palletizing robot is an automated industrial system designed to pick up finished boxes or cartons from a conveyor line and stack them onto a pallet in a precise, pre-defined pattern. These systems are the “end-of-line” workhorses of modern manufacturing and logistics, replacing the strenuous and repetitive manual labor of stacking heavy boxes.

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How It Works: The Workflow

The process typically follows a four-step cycle:

Infeed: Cartons arrive via a conveyor. Sensors or vision systems detect the box’s position and orientation.
Pick: The robot arm moves its End-of-Arm Tooling (EOAT) to the box. Depending on the design, it may pick one box at a time or a whole row/layer.
Place: The robot rotates and positions the box onto the pallet according to a “recipe” (a software pattern designed for stability).
Pallet Management: Once a pallet is full, it is moved (manually or via conveyor) to a stretch wrapper, and a new empty pallet is placed in the cell.

Key Component: End-of-Arm Tooling (EOAT)

The “hand” of the robot is the most critical part of a carton system. Common types include:

Vacuum Grippers: Use suction to lift boxes from the top. Ideal for sealed cartons and different sizes.
Clamp Grippers: Squeeze the sides of the box. Best for heavy or open-top trays where suction might fail.
Fork/Under-Slung Grippers: Slide tines under the box. Used for very heavy loads or unstable packaging.

Why Automate? (Top Benefits)

Reduced Injury Risk: Eliminates Musculoskeletal Disorders (MSDs) caused by repetitive lifting and twisting.
Higher Density Stacks: Robots place boxes with millimeter precision, creating more stable pallets that are less likely to tip during shipping.
24/7 Consistency: Unlike human operators, robots maintain the same cycle time at 3:00 AM as they do at 10:00 AM.
Scalability: Modern “no-code” software allows floor staff to change stacking patterns in minutes without needing a robotics engineer.