Facing Labor Shortages and Logistics Efficiency Challenges in the Manufacturing Industry, Many Companies are Considering Investments in Automation.
However, conventional large palletizers face obstacles such as space requirements and high initial costs, which often cause hesitation, especially in small to medium-sized manufacturing sites.
The solution to this challenge lies in the new generation of compact palletizers. Thanks to the latest robot technology and advancements in safety systems, these palletizers can be installed with approximately one-third of the space of conventional systems. They are being rapidly adopted across various industries, including food, cosmetics, pharmaceuticals, and daily necessities.
In this article, we will explain the features of compact palletizers that enable space-saving automation and how to select the right one.
Types and Evolution of Palletizers: Collaborative Robot Palletizers for Compact Installation
In automating palletizing tasks in manufacturing sites, palletizers that use robotic arms (multi-joint robots) are broadly classified into two categories: “industrial robot palletizers” and “collaborative robot palletizers.” These two systems differ significantly in terms of space requirements and safety.
"Industrial robot palletizers" have long been a proven solution in manufacturing. With capabilities such as a maximum load capacity of over 100kg and speeds of more than 2 meters per second, they have significantly contributed to productivity improvements in large-scale logistics centers and major beverage manufacturers. However, due to the powerful force and high-speed operation of these robots, laws mandate the installation of large-scale safety fences to prevent accidents, necessitating a minimum of 30 square meters for installation. Furthermore, these systems face operational challenges, including the need for complex programming by specialized engineers and long setup times during product changes.
In contrast, "collaborative robot palletizers" leverage collaborative robots for a new generation of palletizing solutions. The most innovative aspect of collaborative robots is their advanced sensing technology, which enables safe collaboration with human workers. Equipped with standard safety features that detect unexpected contact with operators and stop instantly, they eliminate the need for the safety fences essential for industrial robots. As a result, workers can perform tasks in close proximity to the robot, reducing the required installation space.
For small and medium-sized businesses that had previously given up on palletizing automation due to space constraints and operational costs, collaborative robot palletizers offer a revolutionary solution for safe human-robot collaboration.
Comparing Collaborative and Cartesian Robot Palletizers
In addition to "industrial robots" and "collaborative robots," there are also palletizers that utilize "cartesian robots." Unlike multi-joint robots, cartesian robots operate along three axes: X (left-right), Y (front-back), and Z (up-down). While some cartesian robot palletizers are also available in smaller sizes, they are often designed with "high power" and "high speed" capabilities, similar to industrial robot palletizers.
We will compare collaborative and cartesian robot palletizers from three perspectives: “ease of installation,” “mobility,” and “customizability.”
Ease of Installation
When considering ease of installation, the space occupied by the robot is critical. In conclusion, there is no significant difference in installation space requirements between collaborative and cartesian robot palletizers.
Typical small cartesian palletizers occupy approximately 2.5m in width and 2m in depth. Our small collaborative robot palletizer from Closer Robotics requires even less space, fitting within 2m in width and 2m in depth. In terms of height, typical cartesian palletizers require about 2m, while collaborative palletizers offer flexibility and can operate even in rooms with standard 2.5m ceilings.
Mobility
Regarding ease of transport, collaborative robot palletizers are generally smaller and more portable. While a standard cartesian palletizer measures approximately 2.5m wide and 2m deep, our compact collaborative palletizer from Closer Robotics is more compact, measuring around 0.9m wide and 1.5m deep, making it easier to move through tight spaces.
Customizability
Collaborative palletizers also excel in customizability, allowing for smooth post-installation adjustments. For example, while height adjustments in cartesian palletizers require hardware modifications, compact collaborative palletizers can be adjusted through software alone.
Compact Collaborative Palletizers with Lifting Mechanisms
Among collaborative palletizers, some models come with lifting mechanisms. The advantage of these types is the ability to stack items over 2m high. Although Closer Robotics considered developing collaborative palletizers with lifting mechanisms, we chose not to pursue it due to several disadvantages.
First, in terms of safety, while collaborative robot arms are equipped with safety features that stop the robot if it comes into contact with a person, lifting mechanisms lack this safeguard. Consequently, there is a risk of injury if hands or other parts get caught. Second, lifting mechanisms increase the likelihood of malfunctions and maintenance requirements. Finally, contrary to expectations, lifting mechanisms do not significantly reduce installation space, as the robot’s operating range does not change much regardless of its size.
Ease of Adding Layouts
In general, programming palletizing actions in collaborative robots requires "robot teaching" to set coordinates and paths using a “teaching pendant.” Some companies develop palletizing-specific software to simplify this process. However, as the quality of such software varies widely, we recommend testing them before purchase.
At Closer Robotics, we prioritize ease of use and continually refine our software. Our in-house palletizing software, AutoLayout™, offers a user-friendly experience and allows layout creation and execution within about a minute, without the common limitations of other software.
Features of Closer Robotics’ Compact Collaborative Palletizer
Closer Robotics is a manufacturer that develops compact collaborative palletizers. Our palletizers emphasize customer demands for compact size, mobility, and ease of use. If you are considering automation, please consult with us. You can check more details on our website.
