Robot Models

PICK AND PLACE

Overview of FANUC, KUKA, and ABB robots commonly used for

pick-and-place applications, including their model numbers,
specifications, and relevant details.​

FANUC Robots for Pick-and-Place Applications

FANUC offers a diverse range of robots suitable for pick-and-place tasks,
characterized by their precision, speed, and adaptability.​
1. FANUC LR Mate Series
Compact and versatile, ideal for high-speed operations in confined
spaces.​QVIRO
●​ LR Mate 200iD/7H
○​ Payload: 7 kg​MTSU Pressbooks
Network+4QVIRO+4fanucamerica+4
○​ Reach: 717 mmR ​ obots+6QVIRO+6Robots+6
○​ Axes: 5​ABB Group
○​ Features: Compact design, suitable for industries like
metalworking, food processing, pharmaceuticals, and
electronics.​QVIRO
2. FANUC M-10 Series
Designed for handling applications requiring higher payloads and extended
reach.​KUKA AG+2sprutcam.com+2Robots+2
●​ M-10iD/12
○​ Payload: 12 kgR​ obots+4QVIRO+4KUKA AG+4
○​ Reach: 1441 mm​ABB Group
○​ Axes: 6​
○​ Features: Slim arm design, high-speed performance, ideal for
material handling and assembly tasks.​QVIRO
3. FANUC Delta Series
High-speed parallel robots suitable for fast pick-and-place operations.​
●​ M-2iA
 ○​ Payload: 3 kg​sprutcam.com
○​ Reach: 1130 mm​
○​ Axes: 3 or 4​
○​ Features: Ideal for food handling, packaging, and assembly
applications.​

KUKA Robots for Pick-and-Place Applications

KUKA provides a wide array of industrial robots tailored for various
applications, including pick-and-place.​
1. KUKA KR AGILUS Series
Compact robots designed for high-speed operations with precision.​QVIRO
●​ KR 4 AGILUS​
○​Payload: 4 kg​
○​Reach: 600 mmK​ UKA AG+1Robots+1
○​Axes: 6​ABB Group
○​Features: Fast cycle times, suitable for small part assembly and
handling.​ABB Group
●​ KR 6 AGILUS​
○​ Payload: 6 kg​
○​ Reach: 700 mm​
○​ Axes: 6​
○​ Features: Versatile mounting options, ideal for material
handling and packaging.​
2. KUKA KR CYBERTECH nano Series
Optimized for handling small components with high precision.​
●​ KR 10 CYBERTECH nano
○​ Payload: 10 kgQ
​ VIRO
○​ Reach: 1420 mm​
○​ Axes: 6​fanucamerica+5KUKA AG+5ABB Group+5
○​ Features: Slim design, suitable for confined spaces.​

ABB Robots for Pick-and-Place Applications

ABB offers a comprehensive range of robots designed for various industrial
tasks, including pick-and-place operations.​
1. ABB IRB 360 FlexPicker
Specifically designed for high-speed picking and packing applications.​
●​ IRB 360
○​ Payload: Up to 8 kgA ​ BB Group+1QVIRO+1
○​ Reach: 1130 to 1600 mm​ABB Group
○​ Axes: 4​
○​ Features: Ideal for food handling, packaging, and assembly
tasks.​
2. ABB IRB 460
Compact palletizing robot suitable for high-speed operations.​
●​ IRB 460
○​ Payload: 110 kg​Robots
○​ Reach: 2400 mm​
○​ Axes: 4​
○​ Features: Designed for bag palletizing and other high-speed
material handling tasks. ​Robots
3. ABB IRB 6700
Versatile robot suitable for various applications, including pick-and-place.​
●​ IRB 6700
○​ Payload: 150 to 300 kg​
○​ Reach: 2.6 to 3.2 meters​
○​ Axes: 6​Robots+1MTSU Pressbooks Network+1
○​ Features: Robust design, suitable for heavy-duty applications.
Key Parameters Influencing Robotic Pick-and-Place Operations

1. Robot Performance Parameters

Parameter Description Effect
Payload Maximum weight the Exceeding this can reduce
Capacity robot can lift accuracy or damage
hardware
Reach (Work Maximum distance the Determines coverage area in
Envelope) robot can extend your workspace
Repeatability Accuracy of returning to Crucial for precision in
a taught position repetitive tasks
Cycle Time Time taken for one Affects throughput and
complete pick-and-place productivity
loop

2. Motion and Trajectory Parameters

Parameter Description Effect
Pick/Place Speed Movement speed of Impacts cycle time but
robot joints or TCP must be balanced to avoid
dropping or shaking
objects
Approach/Retreat Vertical movement Too small = risk of
Distance height to avoid collisions; too large =
collisions slower cycle
Grip Timing Time taken to Influences smoothness and
engage/disengage efficiency
gripper
Acceleration/Decele How fast the robot Sharp changes can affect
ration speeds up or slows payload stability or part
down quality

3. Gripper/End-Effector Parameters
 Parameter Description Effect
Gripper Type Mechanical, vacuum, Must match object type,
magnetic, soft, etc. surface, and weight
Grip Force Pressure applied to hold Too much = damage; too little
the part = slippage
Sensor Feedback on successful Helps confirm part pickup
Integration grip or part presence and prevent errors
Tool Weight Affects robot’s effective Heavy tools reduce net
payload and inertia payload and increase wear

4. Part and Workspace Considerations

Parameter Description Effect
Part Size and Uniform vs. irregular Affects gripper choice and path
Shape objects planning
Part Consistent or Impacts whether vision systems
Orientation variable? or reorientation is needed
Part Stationary, Determines pickup method (fixed
Presentation tray-based, vs. tracking)
conveyor-fed
Workspace Position of infeed and Should be optimized to reduce
Layout outfeed zones robot movement time

5. Vision System (if used)

Parameter Description Effect
Camera Determines object Low resolution may cause
Resolution detection accuracy false reads
Lighting Must be consistent and Affects image quality and
Conditions glare-free object detection
Calibration Aligns camera frame Inaccurate calibration leads to
Accuracy with robot frame positioning errors
6. Control and Program Parameters
Parameter Description Effect
Wait Conditions Wait for sensors or Ensures timing
interlocks coordination with conveyors
or humans
Error Recovery What happens if no Reduces downtime and
Logic part is found or grip allows graceful recovery
fails
Multi-point Path Smart path planning Minimizes wasted
Optimization for multiple picks movement and cycle time
Loop or Batch For repetitive actions Controls how many parts
Logic are handled per run

7. Safety and Compliance

Parameter Description Effect
Safe Zones / Area or speed restrictions Protects operators and
Speed Limits based on proximity ensures compliance
sensors
Collaborative For cobots working May require force-limited
Operation alongside humans joints and slower speeds
Emergency Stop / Stop robot during hazard Must be tested and
Safety Circuits or fault validated in real
deployments

Example: Parameters for a Pick-and-Place Task in Electronics

Paramet Value
er
Robot FANUC LR Mate 200iD
Payload 7 kg
Speed 1000 mm/sec (linear), 80% joint
speed
Pick Type Vacuum gripper with part sensor
Cycle 1.5 seconds
Time
Vision 2D camera with LED ring light
Safety Light curtain + emergency stop
integration

Category Key Parameters

Robot Payload, reach, repeatability, speed
Performance
Motion Path Travel distance, approach height,
speed
Gripper Design Grip force, tool weight, sensor
feedback
Part/Environm Orientation, position, variability
ent
Vision (if used) Lighting, calibration, detection
speed
Control & Logic Waits, loops, recovery, optimization
Safety Systems Speed limits, light curtains,
emergency stops
SPRAY PAINTING
FANUC, KUKA, ABB, Yaskawa Motoman, and Kawasaki
Robotics—designed for spray painting applications in the automotive and
related industries.
FANUC Painting Robots
FANUC offers a range of paint robots suitable for various applications, from
small parts to large automotive bodies. ​Robotics Tomorrow+3Kawasaki
Robotics+3Dürr+3
1. FANUC P-40iA
●​ Axes: 6​
●​ Payload: 5 kg​howtorobot.com+5automotive.toray+5Wikipedia+5
●​ Reach: 1300 mm​Wikipedia+10fanucamerica+10Kawasaki
Robotics+10
●​ Features: Compact design ideal for general industrial painting
applications.​Yaskawa Motoman Robotics+1Dürr+1
2. FANUC P-50iB
●​ Axes: 6​
●​ Payload: 10 kg​fanucamerica
●​ Reach: 1800 mm​American Coatings
Association+10fanucamerica+10Wikipedia+10
●​ Features: Suitable for medium-sized workpieces, offering flexibility
and precision.​
3. FANUC P-250iB
●​ Axes: 6​Dürr+4Robotics Tomorrow+4Yaskawa Motoman Robotics+4
●​ Payload: 15 kg​fanucamerica
●​ Reach: 2800 mm​
●​ Features: Designed for large automotive applications with an
extended reach.​fanucamerica
4. FANUC P-700iB
●​ Axes: 7​
●​ Payload: 15 kg​Robotics Tomorrow+3fanucamerica+3Yaskawa
Motoman Robotics+3
 ●​ Reach: 3200 mm​Dürr+9fanucamerica+9ABB Library+9
●​ Features: Extra-long reach capabilities for high-volume automotive
production lines.f​ anucamerica

KUKA Painting Robots

KUKA provides explosion-proof paint robots suitable for various painting
tasks, from small parts to entire vehicle bodies. ​Kawasaki Robotics+1Dürr+1
1. KUKA KR AGILUS Series
●​ Axes: 6​American Coatings Association+3Robotics
Tomorrow+3fanucamerica+3
●​ Payload: 6 kg​
●​ Reach: 700 mma​ utomotive.toray
●​ Features: Compact and agile, ideal for intricate painting tasks.​
2. KUKA KR QUANTEC Series
●​ Axes: 6​American Coatings Association+3Wikipedia+3ABB Library+3
●​ Payload: 90–300 kg​
●​ Reach: up to 3100 mm​
●​ Features: Versatile robots suitable for large-scale painting
applications.​

ABB Painting Robots

ABB offers a range of paint robots designed for flexibility and precision in
automotive and general industrial applications. ​ABB Library
1. ABB IRB 5500
●​ Axes: 6​American Coatings Association+1Wikipedia+1
●​ Payload: 7 kg​
●​ Reach: up to 3600 mm​
●​ Features: Optimized for automotive exterior painting with a large
work envelope.​
2. ABB IRB 5400
●​ Axes: 6​
●​ Payload: 15 kg​ABB Library+8automotive.toray+8Wikipedia+8
●​ Reach: up to 3000 mm​
 ●​ Features: High acceleration and speed for increased
productivity.​Yaskawa Motoman Robotics

Yaskawa Motoman Painting Robots

Yaskawa Motoman provides high-performance paint robots that enhance
finishing quality and consistency. ​Yaskawa Motoman Robotics
1. Yaskawa Motoman MPX3500
●​ Axes: 6​Wikipedia+7American Coatings Association+7Robotics
Tomorrow+7
●​ Payload: 15 kg​Robotics Tomorrow+1Dürr+1
●​ Reach: 2700 mm​Yaskawa Motoman Robotics+1American Coatings
Association+1
●​ Features: Designed for painting large workpieces with
precision.​Wikipedia+1Wikipedia+1
2. Yaskawa Motoman MPX1150
●​ Axes: 6​American Coatings Association+2Robotics
Tomorrow+2howtorobot.com+2
●​ Payload: 5 kg​fanucamerica+2American Coatings Association+2ABB
Library+2
●​ Reach: 727 mm​
●​ Features: Compact design suitable for painting small parts.​

Kawasaki Painting Robots

Kawasaki Robotics offers explosion-proof paint robots combining high
performance with easy integration. ​Kawasaki Robotics
1. Kawasaki KJ264
●​ Axes: 6​howtorobot.com+2Wikipedia+2Robotics Tomorrow+2
●​ Payload: 15 kg​Yaskawa Motoman Robotics+2Kawasaki
Robotics+2Robotics Tomorrow+2
●​ Reach: 2655 mm​
●​ Features: Suitable for painting large vehicle bodies with
precision.​Kawasaki Robotics
2. Kawasaki KF121
 ●​ Axes: 6​American Coatings Association+2Wikipedia+2Robotics
Tomorrow+2
●​ Payload: 5 kg​Kawasaki Robotics
●​ Reach: 1240 mm​
●​ Features: Ideal for small to medium-sized workpieces.

Key Parameters Influencing Robotic Spray Painting

1. Spray Gun Parameters

Parameter Description Effect
Atomization Air pressure used to break Affects droplet size and
Pressure the paint into fine droplets finish smoothness
Paint Flow Volume of paint delivered per Too much = runs/drips;
Rate unit time too little = poor coverage
Fan Width Width of the spray pattern Affects uniformity and
overlap
Nozzle Type Shape and size of spray Controls droplet shape
& Size orifice and volume

2. Robot Motion Parameters

Parameter Description Effect
Spray Speed / Speed at which the robot Too fast = light coat; too
Travel Speed moves the spray gun slow = thick coat or
runs
Spray Distance Distance from nozzle to Too far = overspray; too
(Stand-off part surface (typically close = drips
Distance) 150–250 mm)
Spray Angle Angle between spray gun Improves coverage and
and surface (ideally 90°) minimizes reflection or
misses
Overlap Ratio % of coverage between Ensures even coat
passes (typ. 50–70%) without stripes or gaps
3. Material Parameters
Parameter Description Effect
Viscosity of Thickness or flow Affects atomization and film
Paint resistance of the paint build
Solvent Amount of solvent in the Influences drying time and finish
Content paint quality
Solid Pigments and resins in Affects coverage and film
Content paint build-up
Paint Type Solvent-based, Impacts safety, setup, and
water-based, powder, environmental requirements
etc.

4. Environmental Parameters
Parameter Description Effect
Ambient Temperature in the Affects drying time and
Temperature spray area viscosity
Humidity Moisture in the air Can cause blushing or poor
adhesion
Airflow / Air movement in the Influences overspray and
Ventilation spray booth particle settling

5. Process Control Parameters

Parameter Description Effect
Coating Thickness Target thickness in Directly affects quality,
(Film Build) microns (e.g., 30–50 µm) durability, and cost
Number of Coats Single or multiple passes Impacts appearance and
protection level
Curing Time & Required for paint to dry Critical for adhesion and
Temperature or set finish integrity
Robot Path Path planning and Prevents overlap issues,
Optimization motion smoothness saves cycle time

Consequences of Poor Parameter Control

Problem Cause
Runs and Drips Too much paint or slow movement
Dry Spray Too much distance or fast travel
Uneven Coating Inadequate overlap or incorrect
angle
Orange Peel Incorrect atomization pressure or
Texture viscosity
Overspray Loss Improper fan width or poor air
control

Best Practices
●​ Use constant speed and uniform angle during motion.
●​ Keep a consistent spray distance.
●​ Optimize overlap (50–70%) between passes.
●​ Monitor nozzle condition — worn nozzles affect spray quality.
●​ Use simulation (e.g., with FANUC PaintTool or ABB RobotStudio) for
path planning and optimization.
●​ Ensure robot and environment calibration for accuracy.
Category Key Parameters
Spray Gun Atomization pressure, flow rate,
nozzle
Robot Speed, distance, angle, overlap
Motion
Paint Viscosity, solid content, type
Properties
Environment Temperature, humidity, airflow
Process Film thickness, number of
Control coats, curing
Welding Robots

notable welding robots from leading manufacturers, along with their key
specifications.​

1. FANUC
FANUC's ARC Mate Series is renowned for its versatility in arc welding
applications.​fanucamerica
Notable Models:
●​ ARC Mate 50iD/7L:​
Axes: 6​
○​
Payload: 7 kg​Wikipedia+12fanucamerica+12FANUC+12
○​
Reach: 911 mm​FANUC+5fanucamerica+5Wikipedia+5
○​
●​ ARC Mate 100iD:​
Axes: 6​Yaskawa Motoman Robotics
○​
Payload: 12 kg​
○​
Reach: 1,441 mmK​ UKA AG
○​
●​ ARC Mate 100iD/8L:​
Axes: 6​
○​
Payload: 8 kg​Kawasaki Robotics+3FANUC+3fanucamerica+3
○​
Reach: 2,032 mm​
○​
●​ ARC Mate 100iD/10L:​
Axes: 6​
○​
Payload: 10 kgW
○​ ​ ikipedia+3KUKA AG+3FANUC+3
Reach: 1,636 mm​
○​
●​ ARC Mate 120iD:​
Axes: 6​
○​
Payload: 25 kg​
○​
Reach: 1,831 mmO
○​ ​ TC Daihen+4fanucamerica+4fanucamerica+4
●​ ARC Mate 120iD/12L:​
○​ Axes: 6​
○​ Payload: 12 kg​
○​ Reach: 2,272 mmf​ anucamerica
 ●​ M-710iC/12L for ARC:​
○​ Axes: 6​
○​ Payload: 12 kg​
○​ Reach: 3,123 mm​
These models are suitable for a wide range of industrial arc welding
applications, including MIG and TIG welding, as well as plasma and laser
cutting. ​fanucamerica

2. Yaskawa Motoman
Yaskawa's AR Series arc welding robots are designed for high-speed,
efficient welding operations.​Yaskawa Motoman Robotics
Notable Models:
●​ AR1440:​
○​Payload: 12 kgK​ awasaki Robotics+3FANUC+3KUKA AG+3
○​Horizontal Reach: 1,440 mm​
○​Vertical Reach: 2,511 mm​
○​Repeatability: ±0.02 mm​FANUC
●​ AR2010:​
○​Payload: 12 kg​
○​Horizontal Reach: 2,010 mm​
○​Vertical Reach: 3,634 mm​
○​Repeatability: ±0.03 mm​FANUC+1Wikipedia+1
●​ AR3120:​
○​ Payload: 20 kgf​ anucamerica+4KUKA AG+4Kawasaki Robotics+4
○​ Horizontal Reach: 3,120 mm​
○​ Vertical Reach: 5,622 mm​
○​ Repeatability: ±0.05 mm​
These robots offer the highest payload, fastest speed, and highest wrist
allowable moment in their class, optimizing productivity and weld quality.
​Yaskawa Motoman Robotics

3. Kawasaki Robotics
Kawasaki's BA Series is tailored for arc welding applications.​Kawasaki
Robotics
Notable Model:
●​ BA006N:
○​ Payload: 6 kg​KUKA AG
○​ Max. Reach: 1,445 mm​Kawasaki Robotics
○​ Mounting: Ceiling, Floor​Kawasaki Robotics

The BA006N features a compact arm with a long reach, making it suitable
for welding various workpieces. ​Kawasaki Robotics

4. KUKA
KUKA offers robots specifically designed for arc welding tasks.​
Notable Models:
●​ KR AGILUS:​
Payload: 6 – 10 kgK​ UKA AG+1OTC Daihen+1
○​
Reach: 700 – 1,100 mm​KUKA AG
○​
Protection Rating: IP67​Wikipedia+2KUKA AG+2fanucamerica+2
○​
●​ KR CYBERTECH ARC:​
○​ Payload: 8 kg​
○​ Reach: Up to 2,100 mm​
The KR AGILUS is ideal for confined spaces with small assemblies, while the
KR CYBERTECH ARC is suitable for welding large metallic components.
​KUKA AG

5. ABB
ABB's IRB 1520ID is a dedicated arc welding robot known for its
precision.​ABB Group
Notable Model:
●​ IRB 1520ID:
○​ Payload: 4 kg​
○​ Reach: 1,500 mm​
○​ Integrated Process Dressing: Yes​
This high-precision robotic arc welder combines continuous production
output with reduced maintenance costs. ​ABB Group
Parameters affecting Welding in Robots
several parameters directly influence the quality, strength, and
consistency of the weld. These must be carefully monitored and controlled
to produce optimal welds, reduce defects, and ensure efficiency in both
manual and automated welding systems (MIG, TIG, or spot welding).

Key Parameters Affecting Robotic Welding

1. Welding Current (Amperage)

●​ Definition: The amount of electrical current flowing through the
electrode.
●​ Effect:
○​ Higher current = deeper penetration.
○​ Too high = burn-through or excessive spatter.
○​ Too low = poor fusion or lack of penetration.

2. Welding Voltage
●​ Definition: Determines the arc length (distance between electrode and
workpiece).
●​ Effect:
○​ High voltage = wider, flatter bead, but more spatter.
○​ Low voltage = narrow bead, less penetration.

3. Travel Speed
●​ Definition: The speed at which the robot moves the welding torch
along the joint.
●​ Effect:
○​ Too fast = undercut, insufficient penetration.
○​ Too slow = excessive heat input, wide bead, potential
burn-through.
4. Wire Feed Speed (WFS) (for MIG)
●​ Definition: The rate at which filler wire is fed into the weld pool.
●​ Effect:
○​ Affects deposition rate and weld bead size.
○​ Must match the amperage setting for consistency.

5. Shielding Gas Type & Flow Rate

●​ Definition: Inert or active gas used to shield the weld pool from
contamination.
●​ Common Gases:
○​ Argon (TIG)
○​ CO₂ or Argon/CO₂ mix (MIG)
●​ Effect:
○​ Insufficient gas = porosity or oxidation.
○​ Excessive flow = turbulence and contamination.

6. Torch Angle and Position

●​ Definition: The angle at which the welding torch approaches the joint
(e.g., push or drag).
●​ Effect:
○​ Affects penetration, bead shape, and arc stability.
○​ Ideal angle: 10°–15° from vertical depending on the technique.

7. Arc Length
●​ Definition: Distance from the electrode tip to the workpiece.
●​ Effect:
○​ Too long = unstable arc, poor penetration.
○​ Too short = sticking, spatter, irregular arc.

8. Weld Joint Type & Preparation

●​ Definition: The shape, alignment, and cleanliness of the surfaces
being joined.
●​ Effect:
 ○​ Dirty or uneven joints can cause defects like lack of fusion or
inclusions.
○​ Proper edge prep ensures good fit-up and bead consistency.

9. Base Material Type & Thickness

●​ Effect:
○​ Different materials (steel, stainless, aluminum) require different
parameters.
○​ Thicker material = higher current and voltage needed.

10. Robot Path Accuracy

●​ Definition: How precisely the robot follows the programmed weld
path.
●​ Effect:
○​ Deviations can result in off-target welds, poor fusion, or rework.
○​ Calibration and proper fixture setup are critical.

11. Preheat and Interpass Temperature

●​ Definition: Heat applied before or between weld passes.
●​ Effect:
○​ Reduces thermal shock, improves fusion.
○​ Required especially in high-carbon or alloy steels.

12. Weld Sequence and Heat Control

●​ Definition: Order and direction of welds.
●​ Effect:
○​ Helps reduce warping and residual stress.
○​ Symmetrical welding can balance distortion.

Consequences of Poor Parameter Control

Defect Caused By
Porosity Poor shielding gas, contaminated
surfaces
Cracking Improper preheat, high heat input
Undercut High speed, excessive voltage
Incomplete Low current, improper joint prep
Fusion
Spatter High voltage or incorrect gas flow
Burn-Through Excessive heat on thin materials

Optimizing Welding Parameters

To get the best weld quality in robotic welding:
●​ Calibrate the robot and tool center point (TCP) precisely.
●​ Use welding data tables (WPS – Welding Procedure Specifications) to
select correct settings.
●​ Continuously monitor parameters using sensors or weld quality
monitoring systems.
●​ Implement adaptive welding control (available in advanced robots).

Category Parameters
Electrical Current, Voltage, Wire Feed
Speed
Motion Travel Speed, Torch Angle,
Path
Material Joint Type, Base Material,
Prep
Shielding Gas Type, Flow Rate
Environment Temperature, Humidity
Robotic TCP Setup, Path Accuracy,
Accuracy Speed
Palletization
Palletization is the automated process of stacking products or boxes onto
pallets in a defined pattern. Robots are widely used in manufacturing,
packaging, logistics, and warehousing to perform this task with speed and
precision.

Parameters Affecting Robotic Palletization

Category Parameter Description & Effect
Robot Payload Capacity Must support the weight of
Performance individual items, end-effector, and
any vacuum pressure system
Reach/Work Determines how many layers or
Envelope pallet positions the robot can
access
Speed/Acceleration Influences cycle time; faster robots
can increase throughput
Repeatability Critical for consistent placement
accuracy over long shifts
End Effector Gripper Type Vacuum, mechanical, magnetic, or
clamp grippers depending on the
item type (boxes, bags, bottles,
etc.)
Gripper Size & Affects robot payload and center of
Weight gravity
Grip Pressure & Should handle item weight and
Adaptability fragility without damage
Pallet Stack Pattern Interlocked or column pattern
Layout based on load stability
Layer Configuration Items per layer, number of layers,
offset logic
 Interlayer Sheets Whether robot places
cardboard/plastic sheets between
layers
Product Infeed Orientation Orientation of incoming items
Flow must match placement
requirement
Item Dimensions & Must be known for calculating
Weight pick and place paths
Conveyor Speed / Affects pickup timing and robot
Item Spacing motion planning
Programmin Pick & Place Path Robot path and joint movement
g Logic Optimization need to be optimized for shortest
cycle time
Vision / Sensor To correct misaligned parts or
Feedback variable pallet positions
Error Recovery In case of dropped item, missing
Logic pallet, jammed conveyor, etc.
Safety & Safety Sensors, Needed in high-speed or industrial
Compliance Fencing, or Light environments
Curtains
Common Problems from Poor Parameter Setup
Problem Likely Cause
Misaligned Inaccurate path or TCP
stacks calibration
Product Poor grip, too fast acceleration
dropping
Robot Improper pallet zone setup or
collisions layout
Pallet tipping Bad stack pattern or unstable
base
Long cycle Inefficient motion path or
time programming
Palletizing Robots by Major Manufacturers

FANUC
FANUC specializes in high-speed and heavy-duty palletizing robots.
Model Payloa Reach Notes
d
M-410iB/14 140 kg 2850 High-speed palletizer for
0H mm medium loads
M-410iC/18 185 kg 3143 Versatile heavy-duty palletizing
5 mm
M-410iC/31 315 kg 3143 Long reach, high-payload robot
5 mm
M-410iC/50 500 kg 3143 Ideal for heavy bags, drums,
0 mm etc.
FANUC Palletizing Robots
ABB
ABB offers purpose-built palletizers in their IRB series.
Model Payload Reach Notes
IRB 110 kg 2400 High-speed compact
460 mm palletizing robot
IRB 180/250 3200 Flexible, long-reach palletizer
660 kg mm
IRB 450 kg 3150 Heavy-duty, 4-axis high
760 mm throughput
ABB Palletizing Robots

KUKA
KUKA robots are known for reach and payload flexibility in palletizing.
 Model Payload Reach Notes
KR QUANTEC 240–500 3195 Powerful palletizing-specific
PA kg mm version
KR 40 PA 40 kg 2091 For fast and lightweight
mm palletizing tasks
KR 700 PA 700 kg 3320 Ultra-heavy-duty palletizing
mm
KUKA Palletizing Robots

Yaskawa Motoman
Motoman robots for palletizing include specialized and multi-role units.
Mode Payloa Reach Notes
l d
PL80 80 kg 2061 Compact and high-speed
mm palletizing robot
PL19 190 kg 3159 Long-reach and heavy-duty
0 mm capability
PL50 500 kg 3159 Designed for heavy material
0 mm palletizing
Motoman Palletizing Robots

Universal Robots (Collaborative Palletizing)

Ideal for low-speed, collaborative palletizing (no cage required).
Mode Payloa Reach Notes
l d
UR10 12.5 1300 Suitable for light carton stacking
e kg mm
UR20 20 kg 1750 New cobot with extended reach for
mm higher stacks
Universal Robots for Palletizing

Summary Table – Parameters vs Robot Features

Parameter Affects Choose Robot Based On
Payload per Gripper size, robot Robot's payload & wrist
item/layer model strength
Pallet height & Reach, programming Robot reach and floor layout
pattern logic
Throughput Speed, acceleration Robot cycle time and path
requirements control
Product fragility End-effector type Soft vacuum or mechanical
gripper
Mixed-size Vision, smart path Adaptive path and sensor
packaging planning integration

Special Robotic Applications

Special applications go beyond general handling, welding, or palletizing —
they require custom tooling, special motion patterns, or intelligent
interaction. Common categories include:
1.​ Painting & Coating
2.​ Machine Tending
3.​ Polishing / Grinding / Deburring
4.​ Bin Picking (with vision)
5.​ Medical / Pharma Handling
6.​ Additive Manufacturing (3D printing)
7.​ Cleanroom / Semiconductor Handling
8.​ Inspection / Quality Control
Key Parameters Affecting Special Applications
Category Parameter Description & Impact
Robot Dynamics Payload, Reach, Must match task precision &
Repeatability part size
Surface Interaction Force control / Needed for polishing,
compliance deburring, and
force-sensitive tasks
Vision/Scanning 2D/3D vision, AI For inspection, bin picking,
classification object ID
Cleanroom/Contami ISO class Essential for medical,
nation compliance pharma, or semiconductor
use
Tooling Special Brushes, sanders,
end-effectors dispensers, pipettes, etc.
Integration IO, feedback loops, Close-loop control enhances
sensors precision and safety
Software Specialized Required for non-linear,
motion/path smooth or force-controlled
planning paths

1. Painting & Coating Robots

🔹 Common Tasks:
●​ Automotive body painting
●​ Spray coating (metal, wood, ceramic)
●​ Powder coating
●​ Protective film application
Top Robot Models:
Brand Model Payloa Reach Notes
d
FANUC P-250iB 15 kg 2800 Automotive spray painting
mm
ABB IRB 5500 7 kg 3600 Paint optimization, large
mm envelopes
KUKA KR AGILUS 6 kg 900 Compact, IP-rated for paint
CR mm cells
Yaska MPX3500 15 kg 2700 Flexible 6-axis paint robot
wa mm
Requires explosion-proof design, solvent-safe coatings, and smooth motion
paths.

2. Machine Tending
🔹 Common Tasks:
●​ Loading/unloading CNC machines
●​ Press brake automation
●​ Injection molding handling
Top Robot Models:
Brand Model Paylo Notes
ad
FANU M-20iD/25 25 kg Compact arm for tight CNC
C enclosures
KUKA KR CYBERTECH 6–12 Designed for fast CNC loading
nano kg
ABB IRB 2600 20 kg Ideal for compact cell layouts
Yaska GP12 12 kg High-speed and IP-rated for harsh
wa environments
Needs reliable communication with machine via I/O or industrial bus
(Ethernet/IP, PROFINET).
3. Polishing / Grinding / Deburring
🔹 Common Tasks:
●​ Die polishing
●​ Edge deburring
●​ Surface finishing (metal, plastic)
Top Robot Models:
Brand Model Features
KUKA LBR iiwa Force control (7 DOF), ideal for
contact-sensitive tasks
Universal UR10e + Force Adaptive force + collaborative mode
Robots Sensor
ABB IRB 1600 High precision & rigidity
Yaskawa HC10 Cobot with force compliance for
sanding/polishing
Requires force-torque sensors and compliance logic (either hardware or
software).

Bin Picking (Random Object Pick)

🔹 Common Tasks:
●​ Picking randomly oriented parts from bins
●​ Vision-guided sorting
Top Robot Models:
Brand Model Features
FANUC M-10iD/12 + iRVision Built-in 3D vision bin picking
package
ABB IRB 1200 + PickMaster Ideal for high-speed vision-guided
picking
KUKA KR AGILUS + Fast 3D recognition integration
KUKA.VisionTech
Yaska GP8 + MotoSight Compact for cluttered bin picking
wa setups
Key components: 3D vision system, AI model (for detection), and anti-collision
path planning.

5. Medical / Pharma Handling

🔹 Common Tasks:
●​ Sample dispensing
●​ Test tube handling
●​ Sterile product loading/unloading
Top Robot Models:
Brand Model Cleanroom Notes
Class
ABB IRB 1100 ISO 4 Compact, for tight lab spaces
Cleanroom
Yaska HC20CR ISO 5 Collaborative
wa cleanroom-certified
FANUC LR Mate ISO 5 Clean version with white epoxy
200iD/7C coating
Staubl TX2-60 ISO 2 High-end cleanroom
i Cleanroom automation
📌 Meets FDA/GMP and ISO cleanroom standards; often needs UV-resistant
surfaces, washdown protection, and anti-static design.

6. Additive Manufacturing (Robotic 3D Printing)

🔹 Common Tasks:
 ●​ Robotic 3D printing of metals, composites, polymers
●​ WAAM (Wire Arc Additive Manufacturing)
Top Robot Models:
Brand Model Payload Notes
KUKA KR 90–300 6+ axis additive builds
QUANTEC kg
ABB IRB 6700 150–300 Used for robotic WAAM
kg
FANUC M-20iA 20 kg Ideal for robotic extrusion
arms
Universal UR10e 12.5 kg Small-scale composite
Robots printing
Requires G-code interpreter, special slicing software (like RoboDK or
KUKA|prc).

Application Key Parameters Typical Robot

Features
Painting & Coating Smooth motion, Long reach, sealed arm
ATEX/Explosion Proof
Machine Tending I/O control, precision Mid-payload, fast wrist
gripping
Polishing / Force control, path FT sensors, 7 DOF
Grinding smoothness arms
Bin Picking 3D vision, path planning, Vision + agile robot
cycle time
Medical/Pharma ISO cleanroom class, FDA/GMP compliant
Handling compact design arms
Additive Precision layering, path 6- or 7-axis with G-code
Manufacturing following integration