MULTI-PALLET ROBOT LAYER BUILDER & HMI PATTERN CREATOR
Automated Multi-Pallet Robot Palletizing Cell
This project showcases a highly flexible, industrial robotic palletizing cell designed to automate packaging lines with zero-downtime product switchover. The cell features a centralized 4-axis articulated robot, automated pallet conveyors, slip-sheet magazine stations, and an integrated dual-pallet configuration system.
By designing and programming a dynamic HMI "Layer Builder" utility on the PLC backend, we eliminated the need for a robot programmer to modify code when introducing new packaging sizes. Operators can visually configure, edit, and animate custom pallet patterns on-the-fly directly from the HMI.
- Hardware Platform: Fanuc Industrial Articulated Robot, Allen-Bradley ControlLogix PLC.
- HMI Integration: Dynamic pattern generation, real-time coordinate translation, and live collision verification.
- Dual-Pallet Design: Completely independent build sequences for Left and Right pallet lines to handle different products simultaneously.
Instead of relying on hard-coded coordinates, the HMI provides an interactive playground for creatin
- Step 1: Adding the Base Pack
The operator adds Box 1 to the pallet boundary at the (0,0) origin. - Step 2: Placing Box 2
A second box is added. Its alignment remains vertical ("Not Rotated") and snaps alongside Box 1. - Step 3: Building the Pattern
Box 3 is positioned, defining the boundaries for a secure, stable, interlocking stack. - Step 4: Smart Multi-Pick Grouping
The robot's tool-on-gripper is optimized by grouping multiple packs (up to 5) into a single physical pick sequence.
Independent Recipe Management
Layer Sequencing & Tier Stability
Layer Sequencing & Tier Stability
The system manages separate production lines across two distinct physical pallets:
- Left Pallet: Running a GMA-standard pallet configuration, stacking a 6-layer sequence of 257mm x 422mm boxes.
- Right Pallet: Operating a EURO-standard pallet configuration, running a 5-layer sequence of 259mm x 408mm boxes.
- Clearance Offsets: Custom approach paths (X and Y) can be specified per recipe to prevent gripper collisions during tight placements.
Layer Sequencing & Tier Stability
Layer Sequencing & Tier Stability
Layer Sequencing & Tier Stability
To ensure the stack doesn't collapse during high-speed transit, operators can configure structurally sound layer sequences:
- Pattern Alternation: Assign saved patterns (e.g., Pattern 1 vs. Pattern 2) to specific tiers to create alternating, interlocking layers.
- Slip-Sheet (Layer Pad) Controls: Toggle cardboard slip-sheet placements on or off for individual tiers (Layers 1 through 7).
- Vacuum System Setpoints: Adjust low and high vacuum thresholds for the tool gripper to handle varying box cardboard densities.