Created on 10.19
Industrial Palletizing Automation: Integrating Robots with AGVs and AMRs
The automation of palletizing can be considered one of the steps towards improving the end-of-line processes. Stacking goods on a pallet is, however, only one of the aspects of the entire procedure. After loading the pallet, it needs to be delivered to the next point for storage or processing.
If the transport process depends on manual handling, then the entire workflow may still be slowed down despite the use of automation at the palletizing stage.
The integration of industrial palletizing robots with AGVs or AMRs can be used by manufacturers to optimize the coordination of palletizing and the transportation of materials in the production facility. This approach means that the two systems work together as one workflow with their specific functions.
Such integration cannot be achieved simply by putting different machines in the same factory; manufacturers need to take into account different factors.
1. Understanding the Functions of Palletizing Robots, AGVs, and AMRs
It is necessary to know the functions of each of the mentioned pieces of equipment in order to design an efficient system.
Industrial Palletizing Robots
The industrial palletizing robots stack goods into a specified pattern of arrangement on the pallets. They are capable of handling different products such as cartons, bags, etc., depending on the application and type of equipment used.
Their primary function is to stack consistent pallet loads in accordance with the requirements of the production line.
Automated Guided Vehicles (AGVs)
AGVs move loads along preprogrammed or infrastructure-based routes based on the type of navigation system employed. For a palletizing operation, an AGV can be programmed to move empty pallets into a working zone or transport full pallets to a designated point.
The choice of the proper AGV would depend on the nature of the load, route, layout of the plant, and extent of automation desired.
Autonomous Mobile Robots (AMRs)
AMRs have inbuilt sensing and navigation mechanisms allowing them to navigate through their environment. Depending on how they are configured, they are able to handle internal material transport along flexible routes. The use of autonomous mobile robots (AMRs) is also expanding across manufacturing and logistics applications.
For the case of palletizing processes, a suitable AMR can be employed to move pallets or similar load carriers between specified work zones.
AGVs and AMRs cannot be interchanged in all applications. The nature of their navigation techniques, load-handling interfaces, environment, and traffic control mechanisms needs to be compared with the actual transport operation.
2. The Relationship Between Industrial Palletizing Robots and AGVs/AMRs
The possibility for improvement that can result from using palletizing robots along with mobile transport units arises because of the necessity to coordinate the workflow in the process of stacking products and transporting pallets.
The following procedure can be performed in a typical example.
Step 1: Get Ready an Empty Pallet
An empty pallet needs to be ready before starting to stack products on it. It can be brought to the station by either an operator, pallet dispenser, conveyor, or another automated transport unit.
If there is AGV/AMR transport involved, then it needs to be coordinated with the palletizing station.
Step 2: Perform the Palletizing Process
The industrial palletizing robot will place the product on the pallet based on the stacking pattern that has been programmed. This will depend on factors such as the size of the product, the stability of the load, the size of the pallet, and what the final stack should look.
The system should also be able to determine when the pallet is finished and ready for the next process.
Step 3: Verify Pallet Completion
In order for the completed pallet to be transferred, the system must have a way of verifying this.
This verification process may use robot signals, PLC signals, sensors, and conveyors, among others. This will depend on the equipment and interface chosen for the project.
This status information prevents the vehicle from arriving before the completion of the pallet or moving the pallet before the completion of the robot’s job.
Step 4: Move the Finished Pallet
Once the pallet is ready and there is an appropriate place for its transfer, the appropriate transfer equipment will collect or accept the load and deliver it to the next destination.
This may require an appropriate conveyor transfer, docking, or other engineering solution. The pallet itself, transport device, and transfer interface should be compatible with each other.
Step 5: Getting Ready for Next Cycle
Once the pallet moves away from the workspace, the system gets ready for the next palletizing cycle. The next cycle may begin with providing the empty pallet, verifying the availability of the transfer place, and changing the status of the relevant equipment.
The idea here is to synchronize the timing of the palletizing and transportation processes in order to prevent unnecessary delays for either process.
The above process steps show one of the possible system configurations and do not describe any standard system configuration.
3. Important Challenges in the Integration of Industrial Palletizers
The integration of palletizer robots with AGVs or AMRs involves certain coordination issues that need to be considered while planning the project.
Coordination Between Palletizing and Transport
Sometimes, the palletizing robot finishes the pallet before there is an available vehicle for transport, and sometimes the vehicle arrives while the palletizing robot is stacking up products.
In this case, the manufacturers need to evaluate the cycle of palletization and pallet changeover, transport time, and how much transport will be needed.
This will help them decide whether they need more vehicles or some other strategy. The goal is not only to make the machines work faster but also to provide a complete process to satisfy the production volume.
Handling of Empty and Loaded Pallets
Empty pallet availability is equally important to loaded pallet removal.
If empty pallets are not available in a timely manner, the palletizing cell will need to wait. If loaded pallets cannot be removed, there will be congestion in the downstream area.
The pallet handling strategy needs to clearly define what empty pallet storage location is used, the delivery method, the collection of loaded pallets, and the response of the system when the destination is occupied.
Equipment Status Coordination and Communication
Robot, vehicle, conveyor, and control supervisory systems can have different manufacturers and need to be compatible with the defined flow.
The project team needs to define how the system communicates with regard to such events as pallet ready, transfer allowed, destination occupied, vehicle not available, and detection of the error.
The required hardware and software, communication protocol, and integration approach need to be confirmed during engineering.
Safe Areas for Movement and Handovers
Mobile robots and palletizing machines have distinct operational areas and safety considerations. It is important to analyze them when considering the overall system design.
Think about traffic lanes for vehicles, robot working areas, access for people, pallet handover locations, emergency stops, and other safety features that are needed in the process.
A safe setup will depend on the type of equipment used and risk assessment. Just adding a mobile robot to the existing palletizing cell will not ensure safe operation.
4. Factors that Manufacturers Should Consider Before Integration
For any successful industrial palletizing operation, it always starts with the requirements of production rather than equipment design.
There are a number of factors that manufacturers should consider before picking out the equipment and designing the process.
Product and pallet requirements
- Dimensions, weight, and product package.
- Dimensions and stacking pattern of the pallets.
- Weight, height, and stability of the finished pallet.
- Compatibility of the pallet with the chosen method of transportation.
Requirements of production and transportation
- Requirements of production and transportation
- Required rate of palletizing and production plan.
- Distance from the palletizing to the point of destination.
- Routing, intersections, and chances of congestion.
- Requirement for empty pallets and the removal of filled pallets.
- Space for storing pallets temporarily.
Integration requirements
- Robot-to-conveyor, robot-to-mobile equipment, and supervisory control communication.
- Arrangements for vehicle docking and pallet transferring.
- Procedure for fault handling and recovery.
- Safety measures in case of sharing the working area.
- Opportunities for commissioning, testing, and other maintenance services.
These considerations help determine whether AGV or AMR transport is appropriate and what additional equipment or controls may be required.
5. Combining Palletizing with End-of-Line Automation
Palletizing and internal transportation should be thought of as two interrelated stages of the manufacturing process. The industrial palletizing robot itself might work efficiently in the stacking process; however, the whole line will be limited by the lack of pallets, blockage in the transfer station, or slow pace of further transportation.
Therefore, it is important for the manufacturer to understand how the combination of product feeding, conveyor transportation, palletizing, outfeeding, and pallet transferring works.
Techflowbot offers industrial palletizing robot solutions in robotic case packing, palletizing, conveyor transportation, and end-of-line integration. It is possible to estimate the industrial palletizing robot solution as part of the project depending on the products, pallets, goals of production, and layout of the premises.
If the use of AGV or AMR transport is considered, then the supplier of the vehicle, interface needs, transfer type, and responsibilities in the integration process should be agreed on.
6. Design for Reliable Material Flow
The point of combining palletizing robots and AGVs/AMRs in manufacturing operations is not merely adding some additional automated machinery but linking up product stacking and material transportation so that the first stage helps the second one.
It would be wise for manufacturers to start by mapping out the existing flow of pallets to find possible bottlenecks and to determine where handovers are necessary. They could then analyze available equipment, communication, security, and processes.
A comprehensive test of the entire process under practical conditions is also needed. Commissioning should prove the proper delivery of pallets, stacking, transferring, dispatching of vehicles, fault management, and recovery processes before production starts as usual.
The result should reflect reality and should not assume that one integration layout would fit all factories.
Conclusion
Automation of palletizing processes doesn't necessarily stop at the level of robots. If the operation of palletization is combined with AGVs or AMRs, then it becomes possible to plan a more integrated solution regarding the interaction between the process of stacking products and their transportation inside a plant.
This can be achieved by taking into account such elements as the availability of pallets, the cycle time, interface, transport arrangements, and safety. The evaluation of these aspects from the very start of the project will help manufacturers make a more informed decision concerning the integration of the technologies.
If you are going to implement automation of end-of-line processes, check out Techflowbot solutions for robotic packaging.
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