10 things you need to know about stacking robot system

The palletizing system is integrated with more specialized details to meet operational requirements

Robotic stacking systems are increasingly becoming an indispensable important application in industries. In this article, we will learn 10 things we may not know about this robot system.

Main specs: working zone, load capacity, speed and number of axles

After determining the applicability of the stacking robot, it is important to choose the right robot for the system. All robotic manufacturers provide a wide range of robot specifications. From there they will meet the desired performance. Some key points of the criteria include:

Reach/work zone

The distance from the center to the furthest part of the robot arm. This profile is usually spherical. The important thing to consider about the workspace is that the specifications provided by the manufacturers are usually the maximum. So we have to look closely at the 3D profiles that the company provides to build the application correctly.

Illustration of the reach of a cargo robot

Illustration of the reach of a cargo robot

Load carrying capacity

There are many different factors to choose from which robots are capable of carrying appropriate loads. Note that the load capacity must include the weight of the Gripper – gripping mechanism and the product. It is also important to understand that the load capacity of the robot. This capability is calculated from the flange center of the last shaft (End of Arm). In addition, the structure of Gripper also affects the load carrying capacity.

Stacking robot system


Speed is often difficult to classify and compare. Because the speed manufacturers provide is usually the rotation speed of each axis / joint (degrees / second). To simulate the speed of the system, people often use computer software.

Stacking robot system 2

Number of axes

Usually 4-axis robot is used in most cases. Because the products to arrange tend to be parallel to the floor. Typically in stacking applications. In other cases (when products need to be rotated or tilted), people will use 5 or 6 axis robots.

6 axis robot

6 axis robot

Integration requirements for the system

In general terms, palletizing systems are almost the same. However, to meet the different requirements of the factory, they need to be integrated with some additional equipment, mechanisms or parts.

The palletizing system is integrated with more specialized details to meet operational requirements

The palletizing system is integrated with more specialized details to meet operational requirements

Some requirements are often integrated into the system:

  • Robot vision: image processing
  • Read the dimensions directly from the product
  • Mobile robot on the slider – Rail
  • Reverse product mix
  • Advanced safety software

Flexibility in changing products

Due to the changing and customized nature of consumer goods, products classified today may not be classified the same way tomorrow. A loading robot capable of handling very flexibly different products.

Gripper can be flexibly changed to suit the needs of loading robots

Gripper can be flexibly changed to suit the needs of loading robots

If changes in specifications of the product are known, the appropriate robot can be selected. At the same time, Gripper is designed to handle such small changes. But in cases where the product is completely changed, one can flexibly change the design of the Gripper while retaining the current robot. It is in the case of a product load change within the allowance.

Reduce maintenance costs

Before robots became popular in loading operations, the loading system was heavily used in factories. These systems use conveyors, rotating mechanisms, pushers, loading tables, gaskets and lifting tables. They combine to form layers of stacked product. Such systems are highly effective. However, they often include a lot of moving parts, making maintenance more difficult.

Industrial robots exhibit advantages that are superior to stacking systems. They are originally a group of cast iron arms and servo motors. Therefore, the maintenance is very easy and fast. This feature proves robots are one of the most reliable devices in a cargo handling system.

Stacking robots are easier to maintain and repair than older systems

Stacking robots are easier to maintain and repair than older systems


Gripper is like the heart of any robot system. Because this is a direct contact with the product, the design of Gripper is always top priority.

Some types of gripper are used in many cargo loading systems:

  • Use vacuum cupping.
  • Finger gripper.
  • Clamping device

Some common types of gripper

Some common types of gripper

Handling multiple product lines

The robot has a limited working area so it can be stacked and stacked. With larger workspace requirements, robots can handle more product lines.

Typical models are 1 in 1 out, 2 in 2 out, 3 in 3 out and 4 in 4 out.

With systems like these, products need a certain consistency to reduce the complexity of Gripper.

Collaborative robot

The primary role of collaborative robots is to handle machines or production processes. Besides, they can also be used in cargo stowage. Collaborative robot models are only capable of carrying small loads. So they are suitable for light products, the shape is not too complicated. Along with that, Gripper texture is also optimized.

Stacking robot system 3

The application of collaborative robots in loading goods


Installation costs for the robot loading system are actually quite high for businesses and factories. However, many factors need to be considered. For example, labor costs are increasing these days or safety requirements are getting stricter. Considering the great advantages that the robot system brings, this system is really the best solution.

Time capability of robots

Robot can operate 24/24. However, with each specific application, it is very important to evaluate the tasks and tasks that robots must perform.

We have to calculate in detail the time to move the robot arm, the time to pick up, place products and the time for other auxiliary tasks. This calculation will help the solution maker or customer know the ability to use one or more robots for each specific object.

Attached System

Robotic solutions in the field of cargo automation have appeared in almost every industry. And applications are becoming more and more complex.

The integration of the accompanying systems will ensure complete automation, reduce labor costs for the post-packaging or transporting of finished products:

  • Conveyor system
  • Automatic Pallet Dispenser
  • Automatic wrapping system
  • Integrating multi-direction conveyor with lift table (Pop-Up Transfers)

The system comes with loading robots

Hopefully, the information of the loading robot system has helped you to have a more detailed view of this system. See you in the next posts.

Read more: Palletizing Robot System