A Look at Festo’s “Gantry Palletizer in a Box” for Cost-Effective Automation

Today, our world relies on logistics companies to ship goods worldwide. To do this efficiently, many warehouses palletize their shipments, meaning they place boxes of different shapes and sizes onto a skid. There are many ways to execute this job. One way is to use human workers, which requires repetitive lifting of heavy objects. Another option is to use robots with built-in safety features to work alongside humans. These robots, however, have limited payloads and reach.

A third option is to use a gantry system, which typically consists of three servo motors that control the x-, y-, and z-axis. These systems can reach large areas and feature high payload capacities. Festo, a major pneumatic and motion supplier, currently offers a turnkey gantry system specifically designed for palletizing.

Festo’s FPaKit is an all-in-one, out-of-the-box gantry palletizing solution. Image used courtesy of Festo

The FPaKit Gantry Palletizer

Festo’s FPaKit gantry palletizer solution offers three different-sized turnkey gantries with the ability to lift up to 50 kg (for the MW4x customized kit) at a speed ranging from four to 10 boxes per minute. The three available kits include everything needed to assemble the gantry, and the components come from the Festo catalog, so replacement parts are simple to acquire. Each kit has been designed and engineered to stack boxes as efficiently as possible, a need that is becoming increasingly popular as products are shipped around the country more frequently.

The FPaKit can handle loads up to 50 kg (for the MW4x customized kit) with speeds capable of handling four to 10 boxes per minute. Image used courtesy of Festo

Configuring Instead of Designing

Instead of spending time calculating axis speeds and sizing servo motors, the FPaKits offer two standard-sized systems and one that can be custom-sized for applications. The two standard versions have a payload capacity of 20 kg (for the LW2x kit) and 30 kg (for the LW3x kit) and a serviceable area of 1,200 mm².

Both systems operate on AC voltage, with the LW2x kit utilizing single-phase and the LW3x kit utilizing three-phase power. The motors used in both gantry systems operate at a speed of 1 to 1.5 m/s with an acceleration of 2 m/s². The z-axis includes a break, while the other motors do not have a break.

Configuring Instead of Programming

All of the axes, motors, and drives used in the FPaKit come from the Festo catalog, which means they all interface into the same software and can be easily configured. To support the FPaKit, Festo’s software features a web-based interface that enables end users to configure their palletizing system instead of having to create complex programs.

The software comes pre-installed in the controller and has a one-click optimization feature that calculates the most efficient pick patterns based on the incoming objects. Packaged goods can be repositioned via a 3D image and a simple click of the mouse.

The FPaKit relies on Festo’s gantry robots to move pallets across the x, y, and z axes. Image used courtesy of Festo

Along with palletizing software, Festo includes subscription-based predictive and data collection softwares AX Motion Insights and AX Data. These software packages allow end users to order parts instead of storing them. The software has access to predictive failure data and can suggest when to order or replace parts within the system. The AX Data software gives IT services access to machine data for production analytics.

Advancing Palletizing Applications

Festo has built the FPaKit solution for companies looking to palletize their goods faster, cheaper, and more efficiently. The kit serves as a pre-engineered, all-in-one solution offering advantages over manual and robotic solutions. Additionally, the kit’s user-friendly software and predictive analytics further the FPaKit’s goal of advancing palletizing in logistics applications.