Yaskawa PalletSolver: Your First Step to Perfect Pallets with Robots

Palletising may seem straightforward, but when you’re dealing with varying product types, sizes, and configurations, efficiency can quickly become a challenge.

Our PalletSolver takes the complexity out of robotic palletising, offering a flexible and easy-to-use solution for Motoman® robots.

Whether you're managing one work cell or multiple, this software allows for precise, reliable, and quick palletising with minimal downtime.

What Is PalletSolver?

At its core, PalletSolver is a software package designed to optimise the use of Motoman® robots for palletising. It integrates directly with the robot’s controller, providing an intuitive system for creating and managing palletising routines.

Whether you’re working with a single production line or a complex multi-line system, PalletSolver simplifies the process of moving products onto pallets with precision and flexibility.

Key Features That Make PalletSolver Stand Out

1. Handles a Variety of Products
   PalletSolver is adaptable enough to handle a wide range of product types, from small boxes to oddly shaped items. This flexibility means you won’t have to reconfigure your system each time you switch products, making it a more efficient solution for any operation.
    

2. Compatibility with All Gripper Types
   Whether you're using vacuum, clamp, fork, or bag grippers, PalletSolver works with them all. This ensures you don’t need to replace or modify your existing equipment, helping to reduce initial costs and avoid downtime.
    

3. Dynamic Gripper Zone Adjustments
   The software allows the gripper zones to be adjusted based on the size of the product being picked up. This dynamic adjustment ensures that the gripper can handle varying product sizes and configurations, optimising both speed and accuracy.
    

4. User-Friendly Setup
   Setting up your palletising system with PalletSolver is quick and straightforward. The drag-and-drop interface makes it easy to configure routines, from simple tasks to more complex multi-line operations. This simplicity reduces the time and effort typically spent on programming and training.

How PalletSolver Works

PalletSolver is built around two main components:

• PalletSolver-PC: This is an offline tool that runs on a Windows® PC. It generates palletising patterns that are then saved and can be transferred to the robot controller. Once the patterns are uploaded, they’re ready for use in production.
   

• PalletSolver-Engine: This portion of the software runs on the robot’s DX200 controller. It handles the execution of the palletising tasks, from controlling robot movements to managing I/O signals. The engine ensures the robot performs each action with precision and speed.

The Advantages of Using PalletSolver

• Quick Pattern Changes
  With PalletSolver, changing the palletising pattern doesn’t require stopping production. Operators can simply select and upload a new pattern, ensuring that the system keeps running without disruption. This is particularly useful when dealing with different product sizes or types in the same line.
   

• System Integration
  PalletSolver integrates smoothly with your existing systems, including PLCs and other equipment. This means you can keep your current setup and still take advantage of the automation benefits the software offers.
   

• Optimised for Efficiency
  The software adjusts parameters like motion paths and pick-and-place depth to optimise the speed of the palletising process without sacrificing accuracy. This leads to higher throughput and less wasted time.
   

• Error Handling and Recovery
  Even in automated systems, errors can happen. If a product is dropped or if something goes wrong, PalletSolver provides various recovery options. You can re-pick the product, continue the cycle, or abort the process entirely, depending on what works best for your operation.

Customisation for Your Needs

PalletSolver is designed to be flexible and customisable. The software’s modular structure means you can tailor it to your specific needs:

• Adjustable Motion Settings
  PalletSolver automatically adjusts pick-and-place depths depending on the product size or environmental conditions, so you don’t have to worry about frequent reconfiguration.
   

• Pattern Optimisation Tools
  The software includes tools like Label Positioning, Snap, and Placement Spread to ensure that items are placed efficiently on the pallet. These features help maximise space and reduce the chance of errors in placement.
   

• Sequencing Flexibility
  PalletSolver offers multiple sequencing options for your infeed cycle, including round robin, priority, ratio balancing, and override. These options give you full control over how products are handled and placed.

Simple Setup, Effective Monitoring

PalletSolver’s interface makes both setup and ongoing monitoring straightforward:

• Step-by-Step Setup
  The software guides operators through each step of the setup, including configuring infeed, build, and dispenser stations. The only thing that needs to be manually taught is the user frame for each station, simplifying the process and saving time.
   

• Real-Time Status Updates
  Operators can monitor the status of each build station during production. If there’s an issue, the system provides immediate alerts, allowing for quick intervention and minimal disruption to the workflow.

Why Choose PalletSolver?

PalletSolver offers a simple yet effective solution for automating the palletising process. Its compatibility with a wide range of products and gripper types, along with its flexible and easy-to-use interface, makes it an ideal choice for businesses looking to streamline their operations.

With PalletSolver, you get a customisable, efficient system that adapts to your needs and grows with your business.

In short, if you're looking to improve your palletising system, increase throughput, and reduce downtime, PalletSolver is the right tool for the job. It's the first step toward efficient, automated palletising that adapts to any product or environment.