Mixed case palletizing is one of the most complex tasks in warehouse operations. As SKU variety increases, manual palletizing becomes less efficient and more prone to errors. Fixed automation also struggles with random case feeding sequences, especially in brownfield environments.

To address these challenges, XYZ Robotics developed RockyLight, a compact and versatile Mobile Manipulation Robot. RockyLight integrates adaptive vision and intelligent pallet planning, making it ideal for mixed case palletizing at the end of the sortation line.

A leading global electrical manufacturer deployed the stationary version, RockyLight SE, in their Shanghai distribution center. The RockyLight SE retains core mechanical and software capabilities while delivering better energy efficiency, improving outbound performance and accuracy.

Seamless Brownfield Integration

RockyLight SE is designed for seamless integration into existing workflows. Unlike bulky equipment, the robot features a compact design with a pallet-sized footprint. It fits perfectly in the distribution center without major layout changes, saving valuable floor space and installation costs.

Precise Handling of Random Case Infeed

In this case, cartons arrive in an unpredictable order, with varying sizes, weights, and orientations. Previous automation struggled with this variability. RockyLight SE, equipped with a 3D vision system, detects each case’s dimensions and position in real time. This supports the following pallet planning and ensures reliable grasping.

Intelligent Mixed Case Pallet Building

RockyLight SE features an intelligent pallet planning algorithm to build dense and stable pallets. After identifying the incoming cases, the robot imagines various stacking possibilities, scores each option, and selects the optimal one from the buffer area on the fly. By maximizing pallet space usage, RockyLight SE helps reduce delivery costs.

Barcode-Out Placement for Outbound Accuracy

To streamline the outbound process, the scanning system reads the barcode and verifies its orientation as RockyLight SE picks up each case. The robot then places the case with its barcode facing outward, facilitating downstream identification before dispatch. This speeds up shipment preparation and enables error-free order fulfillment.

With its dynamic capabilities and easy implementation, RockyLight SE enables manufacturers to meet diverse palletizing requirements and enhance distribution efficiency.