Depalletizing

Loaded pallets arrive on a conveyor or by fork truck, and the robot picks cases off the top layer one at a time or in groups, feeding them onto an outfeed line. Once a layer is clear, the arm pauses briefly for a slip sheet if there is one, then continues on the next layer down.

Payload of 20 to 300 kg covers most case and multi-pack work, and reach in the 2000 to 3200 mm range clears a full pallet plus safety zones. A palletizing-class arm like the M-410iC/185 or IRB 460 has the reach and duty cycle for this work.

3D vision or a depth camera scans the top layer, identifies pickable cases, and sends grasp poses to the robot. Vacuum end effectors dominate, and adjustable cup arrays help when case sizes vary across incoming pallets.

Missed picks and layer-height errors are the most common runtime issues, and both usually trace back to the vision system. If cases are leaning or slipping mid-pick, check cup wear, box surface condition, and whether the pallet has settled or shifted in transit.

Mixed-SKU or damaged pallets from suppliers stress the vision system harder than a clean, uniform build, so grippers and perception need margin. Very tall or unstable pallets sometimes call for a top layer to be removed manually before the robot takes over.

A common layout pairs an IRB 460 with an infeed pallet conveyor, a 3D camera over the work area, and an outfeed line to case scanning or downstream packaging. Slip sheets get parked on a small stack beside the pallet or removed by a dedicated tool.

Lighting around the pallet has more effect on pick reliability than most integrators expect, so spend time on camera setup and reference calibration. Once vision is stable, uptime issues tend to sit on gripper wear and conveyor flow, and the robot itself rarely becomes the limit.