Palletizing robot

Kawasaki Robot
Palletizing robots

ROBOT DIVISION
http://www.khi.co.jp/robot/

Tokyo Head Office/Robot Division

1-14-5, Kaigan, Minato-ku, Tokyo 105-8315, Japan
Phone: +81-3-3435-6852 Fax: +81-3-3437-9880

Kawasaki Robot
Akashi Works/Robot Division
1-1, Kawasaki-cho, Akashi, Hyogo 673-8666, Japan
Phone: +81-78-921-2946 Fax: +81-78-923-6548

Global Network
Kawasaki Robotics (USA), Inc. CAUTIONS TO BE TAKEN
www.kawasakirobot.com TO ENSURE SAFETY
28140 Lakeview Drive, Wixom, MI 48393, U.S.A.
Phone: +1-248-446-4100 Fax: +1-248-446-4200 ●For those persons involved with the operation / service of
your system, including Kawasaki Robot, they must strictly
Kawasaki Robotics (UK) Ltd.
www.kawasakirobot.co.uk/ observe all safety regulations at all times. They should
Unit 4 Easter Court, Europa Boulevard, Westbrook Warrington carefully read the Manuals and other related safety
Cheshire, WA5 7ZB, United Kingdom documents.
Phone: +44-1925-71-3000 Fax: +44-1925-71-3001 ●Products described in this catalogue are general industrial
Kawasaki Robotics GmbH robots. Therefore, if a customer wishes to use the Robot
www.kawasakirobot.de for special purposes, which might endanger operators or
29 Sperberweg, 41468 Neuss, Germany if the Robot has any problems, please contact us. We will
Phone: +49-2131-34260 Fax: +49-2131-3426-22 be pleased to help you.

Kawasaki Robotics Korea, Ltd. ●Be careful as Photographs illustrated in this catalogue are
www.kawasakirobot.co.kr frequently taken after removing safety fences and other
43, Namdong-daero 215beon-gil, Namdong-gu, Incheon, 405-817, safety devices stipulated in the safety regulations from
Korea the Robot operation system.
Phone: +82-32-821-6941 Fax: +82-32-821-6947
Kawasaki Robotics (Tianjin) Co., Ltd.
www.kawasakirobot.cn
Bldg 3, No.16, Xiang'an Road, TEDA, Tianjin 300457 China
Phone: +86-22-5983-1888 Fax: +86-22-5983-1889
Kawasaki Motors Enterprise (Thailand) Co., Ltd.
(Rayong Robot Center)
www.khi.co.jp/robot/th/
ISO certified in Akashi Works.
119/10 Moo 4 T.Pluak Daeng, A.Pluak Daeng, Rayong 21140
Thailand
Phone: +66-38-955-040-58 Fax: +66-38-955-145

✽ Materials and specifications are subject to change without notice.

Cat. No. 3L0000 Jan. '15 M

 Kawasaki’s high-speed palletizing robots
can meet the demands for power and speed.

The food product, pharmaceutical, printed matter and various other industries are involved in
multi-variety small-lot production in order to be able to address the diverse needs of their
customers. In addition, there are also demands for the maintenance of product freshness and
reductions in distribution inventories while “just-in-time” delivery has also become an essential
condition.
The rationalization and automation of distribution are now a focus of attention as a means for
responding to such demands. Palletizing and depalletizing, which are especially important factors,
have given rise to demands for the development of flexible automated robot-based systems to
ensure their rapid, precise and continuous implementation.
Kawasaki Heavy Industries produces a line of three different types of palletizing robots, including
the RD80N with a maximum payload of 80 kg, model ZD130S/250S with a maximum payload of
130/250 kg and model CP180L/300L/500L with a maximum payload of 180/300/500 kg. Each
has a broad Work envelope coupled with high-speed action and demonstrates its effectiveness in
accelerating speed and reinforcing performance.

RD080N ZD130S/250S CP180L/300L CP500L

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 Features
Broad operating range and high payload capacity
Palletizing package cells
The RD80N is the most compact model, but possesses a wide range of movements. In addition, the RD80N
stacks a maximum height of 2062.3 mm on 1,100 x 1,100 mm pallets. The CP series can handle with load
capacities of up to 500kg, as well as cover multiple pallets of up to four with 1,100 x 1,100 mm. Kawasaki provides
Robot arm
system configurations
Palletizing capacity worthy of our high-speed age perfectly adapted to Palletizing hand
Safety fence
Workpiece
your needs.
Kawasaki palletizing robots deliver the high-speed operation needed for distribution. When moving a vertical acceptance
distance of 400 mm and a horizontal distance of 2,000 mm in a to-and-fro motion, the RD80N can perform 900
cycles per hour with loads of 80 Kg. In the same conditions the CP180L is capable of performing 2,050 cycles
with loads of 130 Kg,

No wasted action with the small installation space

RD80N has a turning radius of 397 mm, enabling it to cover a wide working area at high speed while occupying
less space than a person.
“Cubic-S” which is an optional function to monitor the movement of robots can be used to limit the range of
robot movements and make safety fence area smaller. Pallet (outlying)

Simple palletizing software K-SPARC (option) Robot controller

Kawasaki’s palletizing software K-SPARC allows layout planning and operations to be simulated on your Carry-in conveyor
Pallet sensors
computer. All you have to do is simply start up your computer and select the workpieces, pallets, and stacking
Pallet guide
patterns you want to use. You can also review layouts displayed on screen as well as simulate robots. With its
Robot stand
enhanced usability, K-SPARC supports more pallet stacking patterns than conventional palletizing software,
making it easier to teach robots.
Sample layout for palletizing package cells
Energy saving
Workpieces (mm)
The E03 controller used for CP series has an electricity regeneration function that reduces CO2 emission as well
Workpieces
as energy consumption.

Electricity Regeneration Function

6,100

7,850
4,050
Conventional controller

5,800
Add-on regenerative
resistor unit

1,750

1,750
Pallets Pallets
800 5,000 800 6,500

Sample of palletizing package cells System configuration example

Different
Consume electric power by resistance workpieces sent Manipulator
(with internal or external valves)
PC
(K-SPARC)
from the same
E03 Controller conveyor are
segregated and
Primary air

palletized.

Integrated electric regeneration unit

Energy
Saving Control signal
Robot-controller
USB memory
Power
cable
Different
workpieces sent Cell
controller I/O or communication
from different (CC-Link, DeviceNet, etc)
conveyors are
segregated and
Return electric power to the primary power source palletized.
Robot controller

3 4
 Depalletizing package cell Robot motion monitoring safety function (Option)

Detects the 3-D position and posture of stacked bag packages. You can build an advanced and flexible robot safety system according
A single fixed camera can monitor wide stacking areas. to the motion condition by monitoring the movements of the robot.
Able to adjust to changes in peripheral lighting environments and workpiece surface conditions.
Supervise Safety Smart Save Space by limiting the range of robot movements
No need for configuring the individual settings of each workpiece stacking pattern.
Safety function can be switched according to the state of safety
Able to handle a combination of different types of workpieces at the same time.
signal input
IEC61508 (SIL2) and ISO13849-1 (PLd/category 3) certification
LSC (Laser Slit-scan Camera)
Range : 1,600mm
Accuracy : ±10mm
Save space Transporting workpieces
You can reduce the size of the safety fence area by during robot motion
limiting the range of robot movements to the
You can limit the range of robot movements
minimum.
1,700 - according to the human work area.
3,500mm Item Specification Safety fence area
Measuring range L1,400mm×W1,400mm×L1,800mm with Cubic-S
1,400mm
Objective distance 1,700mm
1,400mm
Laser class Class 3R

Dimension L1,100mm×W125mm×H125mm

Mass About 6.5kg

System configuration example

Peripheral equipment
control panel
DC24V

Vision controller I/O or communication

(CC-Link Device Net etc

I/O
Robot controller
Ethernet Ethernet

Manipulator
(with internal or external valves)
LSC
(Laser slit-scan camera)

Robot-controller cable
Safety fence
Primary air without Cubic-S

Reduced safety fence area Reduced cycle time

Power

Control signal

Item Specification

Safety performance IEC61508 SIL2

Other applications ✽For these applications, the workpiece sizes and stacking patterns must be configured. ISO13849-1 PLd/category3
Monitoring the number of joints Maximum 9 joints

Safety function Motion area monitoring, Joint monitoring, Speed monitoring,

Stand still monitoring, Tool orientation monitoring,
Protective stop, Emergency stop, Safety status output

Safety input and output Dual channel safety input 8CH

Dual channel safety output 8CH
✽ It is possible to allocate Safety Status Output Signals and
Safety Input Signals of each Safety functions

Depalletizing carton boxes Depalletizing plastic containers

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 Motion range & dimensions

RD080N 320 210±0.1 CP180L/300L 1,192.7 1,600

JT1
380
180°
300 Rear side interference area JT1
30° 12-M12 Dp24
170 8-ø18 160° 34.2
R2,9

1,100
206
R1,1
61 0
ø18

1,800
340
300
380
400
JT1
180°

R39

210±0.1
7
619.2 1,100 JT1
160°
Motion range
VIEW A
of point "P"
370.8 2,100 2-ø13H9
26
150 1,080 ø0.06
JT5±10° 255 1,550 250
Working range
based on point P

17
244 298 474 375
ø18
JT3
40°
Base installation

240
260

100
dimensions

15°
JT3

165
Point P

158
JT2 JT6±360°
JT2
105° JT4±360° 46° JT2

450

500
750
2,079.2
870

ø50H7 60 95
P ° A

1,200
X °
Dp6
1,696.5

2,526
JT2

2,371.2
A

2,062.3
140°
ø80

100
30°

2,200

3,255.8
TSM
S/N
D.
WV

680

100 500 100 8-ø22

ø94
Y JT3 °
0
11

750
6-M8 Dp13 ø8H7 Dp8 ø42
ø0.04 X

30
ø0.3 X Y
45.8

516.2 Base installation

277 307 JT3 VIEW A dimensions

272.9
205° ø22
1,231.5 481.5 481.5
963

884.6
619.2

926.8
3,255
(mm) (mm)

ZD130S/250S CP500L 1,192.7 1,600

75 770
JT1 180° 100 500 100 2-ø25G8 Rear side interference area JT1
ø0.05
R5 30° 12-M12 Dp24
47 125 125 160° 34.2
R2,9

100
P R1,2
98
125
300

0
ø18
1,800

500
770
ø18
370

1,800
0
300

125

0 R2,87
ø15 5.3

8-ø11 91
R1,3
100

JT1
VIEW A JT1 180° 300
160°
1,130.9 1,600
VIEW A

8-ø22
998 2,257
300 1,450 255 Motion range 255 1,550 250 Working range
30

JT2 of point "P" based on point P

°
50 474 375
Base installation
dimensions
270

300

240
260

100
15
90

JT2

15°
JT3
15°

JT3
°

P JT6±360° Point P
JT4±360°
JT2
46° JT2

450

500
750
95 A
°
25

1,200
A 2,562 °

2,371.2
1,250

100
2,200

3,255.8
2,200

100 500 100 8-ø22

3,075.3

JT3
0°
11

750
JT3
0° ø42
12
670

30
Base installation

272.9
dimensions
481.5 481.5 ø22
338.2

963

884.6
810

926.8
3,255
(mm) (mm)

7 8
 Standard specifications

Arm type
RD080N ZD130S
Articulated type
ZD250S
Simple palletizing software (option)

K-SPARC
Degrees of freedom (axes) 5 4 (5 : option)
Max. payload (kg) 80 130 250
This software lets you configure the pick and place positions of the
workpieces by robots and register workpieces, pallets, and stacking
Arm rotation (JT1) ±180 ±180
patterns displayed on your computer’s screen. It also allows you to
Arm out-in (JT2) +140 - –105 +90 - –50
Max. easily create robot operation programs .
stroke Arm up-down (JT3) +40 - –205 +15 - –120
()
Wrist swivel (JT4) ±360 ±360
This optional software is one of the application programs for
✽1
Wrist compensation (JT5) ±10 –
K-ROSET (Kawasaki’s offline teaching software)
Arm rotation (JT1) 180 135 95
Max.
Arm out-in (JT2) 180 110 90
speed
( /s) Arm up-down (JT3) 175 130 95

Wrist swivel (JT4) 360 400 190 Easy setup by layout selection K-ROSET functions can be used
Width 1,100 1,800
Working Support for up to two pick positions and four place K-ROSET specify the layout by analyzing the
area Depth 1,100 1,600
positions of workpieces by robots installation positions automatically according to the
(mm) 2,062.3 2,200
Height Simply select a layout and enter a distance! robot types and place positions.
Moment of inertia (kg•m2) 13.7 50 100 You can check for interference and measure cycle
Palletizing capacity✽2 (Payload) 900 cycle/hour (80 kg) 1,700 cycle/hour (130 kg) 1,400 cycle/hour (250 kg) times by K-ROSET functions.
Positional repeatability (mm) ±0.07 ±0.5

Mass (kg) 540 1,350

Power requirements✽3 (kVA) 4.5 10

America E32 E33

Controller Europe E42 E43

Japan & Asia E22 E23

✽1: operating angle of the JT5 is ±10 degrees perpendicular to the ground.
✽2: Motion pattern (400 mm up, 2,000 mm horizontal, 400 mm down in a to-and-fro motion)
✽3: depends on the payload and motion patterns

CP180L CP300L CP500L

Arm type Articulated type

Degrees of freedom (axes) 4 (5 : option)

Max. payload (kg) 180 300 500
Arm rotation (JT1) ±160

Arm out-in (JT2) +95 - –46

Max.
stroke
()
Arm up-down (JT3) +15 - –110
Easy registration of item types Support for many kinds of
Wrist swivel (JT4) ±360

Wrist compensation (JT5) –

Item types are registered simply by entering data on stacking patterns
✽4 ✽5
your computer for workpieces, pallets, and stacking
Arm rotation (JT1) 140 115 85
patterns. Approximately 100 types of base patterns can be
Max.
Arm out-in (JT2) 125
✽4
100
✽5
80 configured for each stage .
speed
( /s) Arm up-down (JT3) 130
✽4
100
✽5
80 The place position of workpieces can be specified.
Wrist swivel (JT4) ✽4 ✽5 Gaps can also be adjusted.
400 250 180
Width 1,800
Working
area Depth 1,600
(mm)
Height 2,200
✽4 ✽5
Moment of inertia (kg•m2) 50 100 250
✽4 ✽5
Palletizing capacity✽2 (Payload) 2,050 cycle/hour 1,700 cycle/hour 1,000 cycle/hour
Positional repeatability (mm) ±0.5
Mass (kg) 1,600 1,650
Power requirements✽3 (kVA) 12

America
Controller Europe E03

Japan & Asia

✽2: Motion pattern (400 mm up, 2,000 mm horizontal, 400 mm down in a to-and-fro motion)
✽3: depends on the payload and motion patterns
✽4: in case of 130 kg payload and less
✽5: in case of 250 kg payload and less

9 10