Robotic Palletizer - Robot Manager, for Mixed Cases

The Robot Manager is a Mixed Case Palletizer software package that utilizes an industrial robot to stack any size package onto any size pallet or package holding device, such as a cart. This palletizer was developed for a major beverage producer in order to rapidly distribute a varied product mix to their customer.

Robotic Palletizers have several pluses over traditional palletizers. They have unlimited product mix capabilities for each pallet stacked and the changeover time from one product size to another is very fast, usually from one case to the next.

When palletizing mixed package sizes, the standard robot control system is not good enough. The Robot Manager is required due to the advanced decision making that needs to take place. The robot control system would normally be too slow to make the required calculations in time, if at all. Robot controllers are designed to handle spacial coordinates and motor control, not order processing.

The Robot Manager software developed by ATSI is a Windows based control system for mixed package palletization. Currently, the system is capable of simultaneously controlling up to 10 robots, all running asynchronously. The system stacks in "layers" as well as in columns. Even with 10 robots, the RM typical impact on cycle time will be approx. 20-30ms.

The system is capable of "buffering" product for later use, stacking "overflow" product, (i.e., product that wasn't required) and also slip-sheet insertion.

The system utilizes an onboard PLC for communication (either Remote or discrete I/O) with the robot(s) and the area/conveyor control PLC. The RM can work with any make or model of robot supporting Remote or discrete I/O. Communications with the host case management system is by way of Ethernet.

The only limit to the size of the packages is the capability of the robot end effector to pick up. The RM also serves as an operator interface. There are several displays to inform operations personnel of the status of the pallet and/or load.