Palletizing changeovers: what the software changes and when the gripper decides
In a palletizing changeover, operators change pallet patterns and carton data in the LUNA software without programming. The hardware limits decide whether a new format fits the cell: payload, package dimensions and gripper. Payload means the weight the robot may carry including the gripper.
Reading time approx. 5 minutes
What LUNA changes during a changeover
LUNA (LUNA Automation Operating System) is the palletizing software of the MalocherBot palletizer. According to the product page: "MalocherBot requires no coding experience to make changes to pallet pattern, box sizes, packaging parameters, carton type, and more." It also states: "Common changes and commands can be made in as little as one step."
Which limits the hardware sets during a changeover
During a changeover, the permissible package weight depends on robot and gripper. The table shows the limits of the Palletizer S, one of the sizes of the MalocherBot palletizer.
| Limit | Palletizer S (product page, datasheet) |
|---|---|
| Payload including gripper | up to 30 kg, depending on the robot |
| Package weight | approx. 20 kg, depending on gripper weight |
| Package dimensions (length × width) | up to 40 cm × 60 cm |
| Stacking height | up to 2.20 m including the pallet |
| Pallet sizes | EURO and ISO |
According to the product page, performance data depends on factors such as configuration and product specifications: "The values shown represent best-case scenarios." For pallets other than standard Euro pallets, the product page states: "different pallet standards are not a problem for MalocherBot".
The datasheet for size S names robots with a rated payload of 20 kg (UR20 from Universal Robots, Doosan H2017). It also names robots with a rated payload of 30 kg (Doosan P3020, FANUC CRX-25iA). The datasheets of sizes M and L name a payload including gripper of up to 35 kg and up to 50 kg respectively.
The datasheet for size S also lists gripper weights: PIAB piCOBOT L 1.38 kg, OnRobot 2FGP20 5 kg.
The product page lists options "from advanced suction cup and foam vacuum grippers to tactile gripping solutions". It also states: "For especially difficult workpieces custom tools are also available." The datasheet for size M gives the example of a SCHUNK finger gripper that palletizes without vacuum.
If the carton material changes, a vacuum gripper may misgrip; the post on vacuum grippers and new cartons covers causes and remedies.
A slip sheet is a separating layer between two layers of cartons. The datasheets of sizes M and L list a slip sheet magazine as an option.
In practice: changeovers at Seeberger and Meyer & Horn
At Seeberger, end-of-line palletizing of food in shipping cartons, the changeover runs directly in LUNA, per the case study. Operators "add/change carton types and pallet patterns directly in the interface", without external programming. The cell uses a MalocherBot PAL M with a KUKA KR20 R1820-2 E. A Schmalz FXCB vacuum gripper handles shipping cartons of 6 to 10 kg; the case study calls it "one tool for all sizes". The case study states: "LUNA reduces changeover time and operator workload." The case study's project FAQ states for this project: "Additional formats can be validated during project planning." The post on palletizing robot throughput covers how fast the cell palletizes.
The Meyer & Horn case study describes a Palletizer S with a Universal Robots UR20 and a PIAB piCOBOT L vacuum gripper. The cell palletizes many product variants, known as stock keeping units (SKUs). The case study names "Standard pallet patterns, fully configurable in LUNA". As maximum carton weight it states "Up to 15 kg (UR20 payload)". CEO Christian Horn says about switching between products: "Our employees can very easily switch between individual products and have had little or no problems at all in the application so far."
What your format list should include before you buy
A format list of all cartons and patterns is the basis for choosing the cell size and gripper before you buy. It should include:
- Length, width, height and weight of each carton
- Carton material and surface
- The pallet patterns you want
- Pallet type and stacking height
- Slip sheets: yes or no
- Items that are not cartons
The palletizer page shows the limits of the Palletizer S; the values of M and L are in the datasheets linked there.
Frequently asked questions
Can the MalocherBot also palletize items that are not cartons?
Yes. Per the product page: "The MalocherBot is versatile and capable of handling various stackable materials beyond cartons, such as plastic pails and other box-shaped workpieces made from different materials." The page also gives a recommendation: "For non-carton items, we recommend contacting Unchained Robotics in advance to test your specific products and provide accurate cycle time estimates".
How do operators learn the changeover?
According to the product page, training consists of "hands-on instruction for operators on pallet changes, pattern adjustments, and new carton setups". The page mentions minimal training.
Can I see LUNA before buying?
Yes. Per the product page: "Get a guided demo of our LUNA Operating System". You request the demo directly via the product page.