Application setup
Handling Mixed-Case Palletizing with the Palletizing Instruction
For integrators building a pallet from more than one case size using the standard palletizing instruction, by teaching a separate pattern per case family and selecting among them with TP program logic.
- Step 1.
Understand what the palletizing instruction does and doesn't do
The built-in palletizing instruction is register-driven with rows, columns, and layers, and supports up to 16 layer patterns and 16 path patterns for BX/EX. It doesn't include a case-type table, manifest input, or built-in stack stability rules. Mixed-case handling is not a native feature. You'll build it by combining several taught patterns with your own TP program logic.
- Step 2.
Group cases into families with a common pattern
Break the mix down into groups where each group can be palletized by one repeatable rows/columns/layers pattern. Each family becomes its own palletizing instruction.
- Step 3.
Plan the build order outside the robot
Stack stability, layer sequencing, and whether heavy cases go down first is process design, not something the palletizing instruction enforces. Work the sequence out with the process owner and write it down before teaching.
- Step 4.
Teach one palletizing pattern per family
For each case family, teach a palletizing instruction with its own PL[i] register, rows/columns/layers, and stack and path points. See the teaching-a-palletizing-pattern guide for the per-pattern procedure.
- Step 5.
Add TP program logic to select the active pattern
Write TP program logic that reads the incoming case type (from a register, DI, or host message you provide) and branches to the palletizing instruction for that family. Each family runs its own PL[i] and advances independently.
- Step 6.
Handle pattern completion and pallet change
Add logic that detects when each PL[i] has completed its last position, and coordinates pallet-full signaling and pallet change with the cell as required by the process.
- Step 7.
Dry-run each pattern on its own
Before mixing, run each family's palletizing instruction end-to-end with sample cases and confirm the pattern completes correctly.
- Step 8.
Run a representative mixed sequence
With the selection logic in place, run a realistic mix of case types and confirm the robot picks the correct pattern for each case and places without collision.
- Step 9.
Document the setup
Record which case types map to which palletizing instruction and PL[i] register, the selection logic, and any build-order constraints, so the next technician can extend it.
Common questions
- How long does Handling Mixed-Case Palletizing with the Palletizing Instruction take?
- Handling Mixed-Case Palletizing with the Palletizing Instruction is rated Advanced and takes about 120 minutes across 9 steps.
- What tools do I need?
- You will need Teach pendant, Sample cases in each size used.
- What should I do before starting?
- Case dimensions and build order defined by the process. Gripper capable of handling the range of case sizes. Comfort with the standard palletizing instruction (rows, columns, layers, path patterns).
- What is the first step?
- Understand what the palletizing instruction does and doesn't do. The built-in palletizing instruction is register-driven with rows, columns, and layers, and supports up to 16 layer patterns and 16 path patterns for BX/EX. It doesn't include a case-type table, manifest input, or built-in stack stability rules. Mixed-case handling is not a native feature. You'll build it by combining several taught patterns with your own TP program logic.