Breaking Down the Maths Behind Decide Charges, Patterns, and Productiveness
When contemplating the funding in a robotic palletising system, one of many first questions producers ask is: “What number of bins per hour can it really deal with?”
The reply isn’t a obscure estimate—it’s an easy calculation based mostly on choose charges and the way merchandise are grouped throughout every choose. Whereas actual efficiency depends upon the product, pallet sample, and gripper configuration, a couple of easy examples may give you a transparent image of what’s realistically achievable.
Let’s stroll by way of the maths.
A Conservative Baseline: 330 Picks Per Hour
Though many robotic palletisers are able to larger speeds, we’ll use 330 picks per hour as a conservative benchmark. That is slower than the everyday charge, however gives a stable baseline for planning.
At this choose charge, you solely want a mean of two.4 bins per choose to succeed in over 790 bins per hour. Right here’s how completely different stacking patterns have an effect on that final result:
Instance 1: 10 Bins Per Layer
Picked in 3 rows (approx. 3–4 bins per row)
Calculation:
10 bins ÷ 3 picks = 3.33 bins per choose on common
At 330 cycles per hours = 3.33 bins x 250 picks/hour = 1099 bins per hour
It is a widespread, environment friendly sample the place grouped picks ship sturdy output whereas sustaining stack stability.
Instance 2: 5 Bins Per Layer
Picked in 2 rows (e.g. 3 + 2 bins)
Calculation:
5 bins ÷ 2 picks = 2.5 bins per choose on common
At 330 cycles per hour = 2.5 bins x 330 picks/hour = 825 bins per hour
Even with smaller layers, environment friendly choose grouping can ship properly over 800 bins per hour.
Instance 3: 7 Bins Per Layer
Two choices right here relying in your tolerance for gaps within the stack:
Possibility A: Protect Gaps
Picked in 5 rows
Calculation:
7 bins ÷ 5 picks = 1.4 bins per choose on common
At 330 cycles per hour = 1.4 bins x 330 picks/hour = 462 bins per hour
Possibility B: Take away The Gaps
Picked in 3 rows
Calculation:
7 bins ÷ 3 picks = 2.33 bins per choose on averageAt 330 cycles per hour = 2.33 bins x 330 picks/hour = 768 bins per hour
This instance reveals how adjusting the sample can considerably have an effect on throughput—even when the variety of bins stays the identical.
Instance 4: 20 Bins Per Layer
Picked in 4 rows (5 bins per row)
Calculation:
20 bins ÷ 4 picks = 5 bins per choose on common
At 330 cycles per hour = 5 bins x 330 picks/hour = 1650 bins per hour
Excessive-volume row picks like this present the ability of multi-pick grippers and well-optimised stacking logic.
What If the Robotic Runs Quicker?
In some circumstances—significantly the place bins are light-weight, uniform, and the gripper is properly optimised—robotic palletisers can run at 400 picks per hour or extra.
Right here’s what which means for every instance:
As you’ll be able to see, the choose grouping and stacking sample have a a lot greater impression on throughput than the robotic pace alone.
Key Takeaways
- Decide charge is simply a part of the story—the variety of bins per choose has a dramatic impact on whole output.
- Even with conservative cycle speeds, it’s attainable to exceed 800 bins/hour with primary field grouping.
- Sensible gripper design and optimised pallet patterns can greater than double throughput in some circumstances.
- When you’re stacking lighter merchandise with good field high quality, larger choose charges (350–400/hr) are sometimes achievable.
- Designing your palletising answer round the precise stacking technique can unlock main effectivity positive aspects.
Considering About Automating?
At Granta Automation, we design clever, totally built-in palletising techniques tailor-made to your merchandise, your house, and your output targets. We assist you mannequin your throughput with real looking, data-driven expectations—so precisely what to anticipate earlier than the robotic is even put in.
- Palletiser Feasibility Research
- Gripper Design for Multi-Field Picks
- Full System Integration & Controls
- Clever Stack Sample Software program
Name us on 01223 499488 or helpline@granta-automation.co.uk, to request a free system session.
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