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Depalletizing application

Managing box variability for reliable depalletizing

Context

Depalletization introduces different challenges compared to palletization. In particular, box positions on incoming pallets are more likely to vary due to manual handling, transportation shifts, or damaged packaging. This article outlines the most common types of variability and provides solutions to help ensure reliable box picking and placement using Robotiq hardware and features.

Information

Common Depalletization Challenges

  1. X/Y axis variability

    • Boxes may shift due to:

      • Manual (hand) palletizing

      • Transportation vibrations

      • Partial box deformation or sag

    • Consequences:

      • Inaccurate picking

      • Risk of collisions or missed picks

  1. Z axis variability

    • Uneven box height due to:

      • Deformation

      • Load compression

    • Consequences:

      • Unreliable grip

      • Increased risk of dropping or damaging boxes

How to Manage Box Variability

  • Managing X/Y Variability

    • Use a smaller gripper footprint than the box
      This allows for centering tolerance and reduces the risk of misalignment.

    • Use an external vision system to locate the box center
      Helps detect shifted or misaligned boxes, especially on mixed or manually stacked pallets.

    • In this  case :

      • vision detects and calculate real box center point ( black ).
      • The palletizer will perform trajectory to theoretical box center ( we recommend a bit above)
      • Then you need to perform a custom move to go to real box center

      Depalletisation order is always the same each layers



  • Managing Z Variability

    •  Enable force sensing on the robot
      Use the robot’s force feedback to detect contact with the box surface before initiating grip. This ensures proper box engagement and helps avoid crushing or missing the box due to height inconsistencies.

       

  • Considerations for Conveyor Placement

    • Allow space margin on the conveyor
      The same variability affecting pickup will also impact drop accuracy. Ensure that the conveyor’s drop zone has enough space to accommodate position variation.

       

Conclusion

Depalletization requires careful handling of position variability. By using smaller grippers, vision systems, and force sensing, you can significantly improve reliability. Don’t forget to apply the same thinking to the drop zone to avoid jams or misplacement.