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One free scan finds every outdated or missing driver and matches the right update for your exact hardware.Free scan · exact hardware matchUse a separate, measured palletizing recipe for every case family that needs different positions, then select that recipe from the case identity before the robot starts a layer. A dependable setup combines case and pallet measurements, a planned layer sequence, platform-specific pattern software, gripper and payload checks, and a commissioning test on the real cell. One pattern should not be assumed to fit every carton: a change in length, width, height, weight, rigidity, label orientation or center of gravity can change the safe pickup and the geometry of every layer.
This guide lays out a cross-platform method for building those recipes and changeover rules. It uses the terminology and examples documented for Kawasaki neoROSET, Robotiq PE Series and a FANUC R-30iB application, but the final instructions and safety limits must come from the controller, robot, tooling and integrator documentation installed in your cell.
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What a palletizing pattern actually controls
A palletizing pattern is the set of target positions and orientations that places cases on a pallet. A complete recipe normally includes more than an X-Y grid. It defines the case orientation in each layer, the relationship between successive layers, the order in which positions are filled, the stack height, and any handling of slip sheets or top sheets. It may also include approach and retreat clearances, a pallet-change sequence and the conditions that end a layer or declare a pallet full.
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Repair Windows errors before they cause bigger problemsFix Now →Fix the driver behind crashes, sound loss and screen glitchesFind Drivers →Clear out junk files and repair common Windows errorsFree Scan →Pattern software calculates or stores positions; it does not automatically prove that the resulting load is stable. The FANUC-focused application guide for the R-30iB explicitly recommends planning the stack sequence outside the robot program because its built-in palletizing instruction does not provide stack-stability rules. Treat stability, compression, overhang and product damage as engineering decisions that must be approved by the process owner.
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Start by defining case families and measuring the cell
Group cases into a family only when they can share the same handling assumptions and a compatible placement geometry. Two cartons with similar footprints may still require different recipes if one is flexible, top-heavy, label-sensitive or difficult for the gripper to seal against.
Record every product variable
| Input | What to record | Why it changes the recipe |
|---|---|---|
| Length, width and height | Actual packed dimensions, including bulges or flaps that affect contact | Determines layer coordinates, clearances and whether cases can be rotated |
| Weight | Typical and maximum production weight | Sets gripper and robot payload requirements and affects compression of lower layers |
| Rigidity | Rigid, crushable, flexible or variable by batch | Influences clamp pressure, vacuum reliability and allowable stack load |
| Center of gravity | Location when known, especially for uneven contents | Changes pickup orientation, acceleration limits and placement stability |
| Handling surface | Porous, glossy, dusty, recessed, taped or otherwise difficult to grip | Determines whether vacuum, clamp, fork or combination tooling is suitable |
| Orientation rules | Label, barcode, opening and print-facing requirements | Limits rotations and may require different layer orientations |
| Rate and spacing | Cases per minute, infeed pitch, gaps and accumulation behavior | Sets pick timing, travel speed and whether multi-pick is practical |
Fuji Robotics identifies these product variables, along with SKU changes, pallet pattern, stack height, tooling, payload, reach and cell layout, as application variables for case palletizing. Use the same level of detail even when your robot brand is different.
Measure the pallet and surrounding equipment
- Measure pallet length and width, and document the permitted edge overhang on each side.
- Record the maximum approved stack height, including the pallet itself and any sheet material.
- Specify whether a slip sheet is required between layers, where it is picked, and how it is placed.
- Locate pallet stops, conveyors, fences, photoeyes, sensors and any obstructions that constrain the robot’s reach.
- Record the pickup point, conveyor elevation, approach direction and available clearance above the load.
- Document pallet-change timing and the signal that tells the robot an empty pallet is correctly seated.
Do not round dimensions simply to make a pattern easier to calculate. Use production measurements and state the tolerance used for cartons, pallet boards and sensor positions. If the same SKU varies materially between suppliers or lots, either widen the validated tolerance or create separate recipes.
Choose the layer geometry before teaching robot points
Decide the load architecture with the process owner before entering coordinates. A recipe should state which cases are allowed, which face points outward, how positions are filled, and how layers alternate. Common choices include all cases aligned in one direction, alternating 90-degree orientations, interlocked layers, and a mixed-case sequence that deliberately places heavier or more rigid cartons lower in the stack.
Plan for stability, not just footprint utilization
A pattern that uses nearly every square centimetre of the pallet can still fail if seams line up vertically, a flexible carton is placed under a heavy one, or the center of mass moves outside the support area. Review:
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- vertical seam alignment between layers;
- the compression strength and rigidity of each case;
- the amount and direction of overhang;
- the position of heavy, tall or unstable cases;
- the effect of slip sheets on friction and lateral movement; and
- the load’s behavior during conveyor transfer, wrapping, storage and transport.
For a mixed load, agree on the build order separately from the robot’s position-generation function. The software may generate valid coordinates while leaving the resulting stack unsafe.
Define recipe boundaries
Create a new recipe when a case family needs different target coordinates, a different orientation rule, a different tool setting, or a different layer sequence. A single recipe is reasonable only when the cases truly share those requirements and the gripper can handle the full dimensional and weight range. Keeping nominally similar cases in one recipe can create hidden collisions or poor support at the pallet edge.
Use the pattern method documented for your robot platform
Pattern configuration is not a universal pendant workflow. Menus, licensing, coordinate conventions, register types and recovery behavior vary by controller and software version. Use the following platform examples as planning models, then follow the manuals installed with your cell.
Kawasaki neoROSET: six documented setup stages
Kawasaki Robotics’ 2026 description of the neoROSET palletizing function presents a six-step sequence:
- Select the robot and material-handling setup.
- Choose a pallet layout.
- Enter workpiece and pallet dimensions.
- Generate palletizing positions.
- Load those positions to the robot.
- Execute the palletizing operation.
The same product document says the function includes more than 100 built-in patterns and requires an additional optional license. “More than 100” is a manufacturer product claim, not an independent throughput or stability benchmark. The stated capacity is a reference value that can vary with robot model, item shape and weight, transport conditions and surrounding equipment. Confirm that the selected license, robot model and controller software support the pattern you intend to use.
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Robotiq PE Series: keep configuration areas separate
The Robotiq Palletizing Solution PE Series instruction manual, dated May 31, 2023, organizes configuration into distinct SETTINGS, BOX, PALLET and PATTERN areas. It supports editable patterns and layer sequences. In practice, enter and verify product dimensions in the box area, pallet geometry in the pallet area, and the actual placement order in the pattern area rather than mixing assumptions across screens. Save a versioned recipe after each validated change so an operator can restore a known-good setup.
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These labels and actions are specific to the PE Series implementation. A different gripper, robot or software release may expose different names, units or coordinate conventions.
FANUC R-30iB example: select among taught patterns
The application guide reviewed July 21, 2026 for mixed-case palletizing on a FANUC R-30iB describes teaching a separate pattern for each case family. The robot then uses TP program logic to select the pattern from case identity delivered through the cell’s own register, digital input or host interface. This is an application example rather than a FANUC primary manual, so verify register mapping, syntax, motion instructions and recovery behavior against the installed FANUC documentation and controller software.
Build recipe selection and changeover logic
The robot must know which recipe applies before it calculates or calls the next target. The identity can come from a barcode reader, manufacturing-execution system, line PLC, operator selection or an upstream machine. Whichever source you use, make the handoff deterministic and observable.
- Assign a stable case-family identifier. Use a code that does not change when a description or marketing name changes.
- Transmit the identifier before the first pick. Allow enough time for the robot or PLC to validate it before motion begins.
- Check that the identifier is valid. Stop or divert an unknown case instead of silently using the last active recipe.
- Load the recipe and tool parameters as one transaction. A pattern change without the matching gripper setting can damage cases or cause a dropped load.
- Confirm the active recipe on the HMI or controller. Display the family name, revision and pallet count so the operator can detect a mismatch.
- Reset layer and position counters at the correct event. Decide whether a reset occurs at recipe change, new pallet, layer completion or recovery, and test each path.
- Record the changeover. Store the selected recipe, revision, operator action and any alarm or bypass for traceability.
For mixed-SKU pallets, define whether the sequence is fixed, supplied by a host system, or generated from an order. Do not let an operator improvise the order while the robot is moving unless the cell has a documented and validated control method.
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Verify gripper, payload and reach for the full range
The smallest case often determines pickup reliability, while the largest or heaviest case determines payload and reach. Check both extremes with the actual end-of-arm tool, not a CAD envelope alone.
Tool selection
Application-specific choices can include vacuum, clamp, fork, combination and custom tools. Vacuum performance depends on surface porosity, dust, tape and available flat area. Clamps must provide enough force without crushing the carton, and forks need adequate entry clearance and support. If one tool cannot handle the full family range, use interchangeable tooling or split the families into cells and recipes with explicit changeover controls.
Payload and center-of-gravity calculation
Robot payload includes the case, gripper, adapter plates, hoses, sensors and any retained product. Use the robot manufacturer’s approved payload and inertia limits, not only the carton weight. Recheck the center of gravity when the tool is extended or when a case is held off-center. A pattern that is reachable at low speed may exceed dynamic limits at production acceleration.
Reach and clearance
Verify the farthest pallet corner, highest layer, approach path and retreat path. Check adjacent cases, pallet stops, guarding and conveyor hardware at every orientation. Include clearance for a compressed or slightly misshapen carton. Programmed points should not depend on a perfect empty pallet if production pallets have board variation or damaged blocks.
Fuji notes that throughput depends on case size and weight, pick count, infeed spacing, travel, pallet pattern and height, tool design and overall line flow. A faster robot motion cannot compensate for insufficient accumulation, slow sheet handling or a downstream bottleneck.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.Understand the documented multi-pick limitation
Robotiq’s PE Series manual states that cases picked together by its multipick feature must have the same dimensions and payload and must be picked and dropped side by side. That is a limitation of the documented Robotiq implementation, not a universal rule for every robot or gripper. Do not combine different case sizes merely because the tool can physically span them; validate spacing, payload, center of gravity, release timing and the target pattern for your specific system.
Fuji describes multi-pick as conditional on the product, spacing, pattern, payload and tooling. Treat multi-pick as an engineering option that requires its own cycle-time and safety validation, not as an automatic solution for mixed cases.
Commission each recipe on the real cell
Use a controlled commissioning sequence and the approved safety procedure for your jurisdiction, robot and integrator. Keep personnel outside the safeguarded space unless the cell is placed in the documented setup mode and all required safeguards are active.
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- Dry-run without product. Confirm frame definitions, pallet origin, approach points, layer counters, end-of-arm signals and collision-free motion at reduced speed.
- Test one case family. Use representative cartons, the production pallet and the production tool. Check pickup, vacuum or clamp confirmation, orientation and release.
- Complete one layer. Inspect edge overhang, gaps, seam alignment, label direction and interference with pallet hardware.
- Build the full height. Check compression, leaning, sliding, sheet placement and reach at the highest layer.
- Test non-ideal cases. Include the allowed dimensional tolerance, realistic surface condition, a partially filled infeed and the minimum and maximum approved weights.
- Exercise recipe selection. Switch among all case families, including an invalid identifier, a late identifier, a missing signal and an interrupted changeover.
- Test recovery. Stop during pickup, transit, placement, layer completion and pallet change. Verify that restart does not duplicate a case, skip a position or reset the wrong counter.
- Run a representative mixed sequence. Use the expected production order and inspect the completed load after wrapping or transfer if those processes affect stability.
Record the validated recipe revision, product tolerances, tool settings, robot program version, pallet specification, maximum height, test conditions and approval signatures. The exact test method and safety documentation remain cell- and jurisdiction-specific.
Compare candidate patterns with a common scorecard
When two patterns both fit geometrically, compare them against the complete operating requirement rather than choosing the one with the shortest calculated path.
| Decision area | Questions to answer |
|---|---|
| Pallet utilization | How much usable area is filled, and is the permitted overhang respected on every side? |
| Layer and stack stability | Are seams interlocked, are lower cases strong enough, and does the center of mass remain supported? |
| Orientation | Do labels, barcodes, openings and prints face the required direction? |
| Tool compatibility | Can the gripper pick every size, surface and weight without a setting change that the recipe does not control? |
| Robot limits | Are payload, inertia, reach, speed and clearance within approved limits at the worst position? |
| Changeover | Can the cell receive case identity reliably and show the active recipe to the operator? |
| Sheets and pallet change | Does the pattern leave room for sheet placement and a repeatable full-pallet handoff? |
| Whole-cell throughput | Does the cycle fit infeed, accumulation, wrapping, pallet exchange and downstream flow? |
A pattern that saves one robot move but requires frequent manual correction may be slower and less reliable at line level. Measure the complete sequence, including waits and recovery, when selecting between alternatives.
Troubleshoot by symptom
Cases slip, rotate or fall during placement
- Confirm the recipe’s orientation and approach vector.
- Check vacuum seal, clamp force, fork engagement and case surface condition.
- Reduce acceleration only within approved robot and process limits, then retest the heaviest and most off-center case.
- Inspect whether a pallet edge, sheet or neighboring carton is contacting the case before release.
The first layer is correct but upper layers drift
- Verify that the layer offset and pallet frame are not being recalculated from a wrong origin.
- Check pallet squareness, board damage and sensor seating.
- Inspect whether carton compression changes the effective height or causes a case to lean.
- Confirm that the alternating-layer rule is applied exactly once per layer.
The robot uses the wrong pattern after a SKU change
- Check the timing and handshake between barcode, PLC, host and robot.
- Display the received identifier and active recipe revision.
- Ensure an invalid or missing identifier causes a controlled stop or reject, not reuse of the previous recipe.
- Test interruption during the changeover transaction and verify counter resets.
Cycle time misses the line target
- Separate robot motion time from infeed gaps, sheet handling, pallet exchange and downstream waits.
- Confirm that the selected pattern does not add unnecessary rotations or long diagonal moves.
- Evaluate whether multi-pick is allowed for that exact product and tool; do not assume mixed sizes can be grouped.
- Check payload and acceleration limits before increasing speed.
Document a recipe so another technician can reproduce it
For every case family, keep a controlled record containing:
- family identifier, product description and revision;
- measured length, width, height, weight and tolerances;
- rigidity, center-of-gravity and handling-surface notes;
- label and barcode orientation requirements;
- pallet dimensions, overhang limits, maximum stack height and sheet rules;
- layer drawings or generated pattern identifiers;
- tool model, payload data, vacuum or clamp settings and allowable substitutions;
- robot frame, program, register or input mapping and controller software version;
- recipe-selection handshake and invalid-data behavior;
- validated cycle conditions and completed-load inspection results; and
- recovery instructions, revision history and approval.
Keep the robot manufacturer’s manual, the integrator’s risk assessment and the cell’s safety procedures with that record. A cross-platform planning article cannot replace those documents or the responsible integrator’s validation.
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