How to Handle Box Overhang Using a Fictive Pallet

Context Robotiq's Copilot and Online Simulator require that all boxes remain within the visible pallet boundaries. When your palletizing pattern causes boxes to extend past the edges of the real pallet, you must simulate this layout by creating a larger fictive pallet and repositioning the real pallet using physical spacers. This ensures compatibility with both software and hardware behavior.

Information

Our software URcaps and configurator do not model overhang. Therefore, it is required to : 

• Add a physical overhang kit : 
  • 
• Modelise a larger pallet to take this in account

Step 1: Determine Minimum Spacer Dimensions

To model a pattern with an overhang:

• Fictive Pallet Width = total width of all boxes on the pallet
• Fictive Pallet Depth = total depth of all boxes on the pallet

If using multiple SKUs, base your fictive pallet size on the maximum overhang in each direction.

For example:

• Real pallet width: 800 mm
• Box width: 405 mm
• Overhang per side: 5 mm
• Total required width = 2 x 405 = 810 mm

Therefore:

• Fictive pallet width = 810 mm
• Fictive pallet depth = 1200 mm (no overhang)
   
   

To match this fictive size:

• Use an overhang spacer kit, e.g. 35 mm: Robotiq Overhang Kit 35mm
• Or create your own spacers matching the overhang (e.g. 10 mm)

Final Pallet Positioning Calculation with 35mm spacer:

• Width = Spacer x 2 + Real Pallet Width = 35 x 2 + 800 = 870 mm
• Depth = Spacer x 2 + Real Pallet Depth = 0 + 1200 = 1200 mm

Step 2: Create Pattern in Simulator and URCap

In both the Online Simulator and the URCap:

1. Use the fictive pallet size you calculated
2. Build your box pattern at a corner of the fictive pallet
   1. 
3. Use the center function to reposition the pattern
   1. 

This ensures the box pattern will be centered on the actual physical pallet.

Step 3: Adjusting Pallet Sensor Signals

When adding spacers, some pallet sensors may become misaligned:

• AX10 and PE10 (mechanical): May no longer detect pallets correctly
• PE20, AX20, AX30 (optical): Still detect even if pallet is offset

Solutions:

• Duplicate the signal from a working sensor
• Or simulate the signal by wiring a digital output to the input formerly used by the disabled sensor

Note on Multiple Patterns

Conclusion

When boxes overhang the physical pallet, defining a fictive pallet and repositioning the real one with spacers allows reliable simulation and safe operation. Sensor adjustments ensure signals remain valid even when alignment shifts.