Layer Depalletizing Robot Tool

NūMove is proud to introduce its latest innovation in robotics: a newly designed layer depalletizing tool engineered for enhanced adaptability and performance in high-throughput logistics environments. With this improved tool, NūMove can depalletize single-SKU or rainbow pallets. This robot tool represents a significant advancement over our previous models that relied solely on suction and forks. The latest design integrates three complementary gripping mechanisms — suction, clamping, and bottom forks — enabling the robot to securely handle a broader range of packaging types and formats. These include closed cases, open cases, wrapped or unwrapped trays, and carton boxes in a tray. To avoid product damage, sensors are verifying that the layer is properly lifted before the bottom forks are extended. The combination of these mechanisms ensures reliable and secure operation across diverse product types, even at high speeds. The suction system is capable of picking partial layers and different layer arrangements that can have gaps, chimneys, etc. The clamping system is ideal for trayed items, while the bottom forks provide additional support to prevent product loss during rapid movements. To further enhance layer picking precision, the tool can be paired with a vision system that enables the robot to accurately locate the layer’s position, even if the top products have shifted during handling. In line with NūMove’s integrated approach to robotic cell development, peripheral equipment can be added to deliver a complete and optimized solution. For example, downstream conveyors can be incorporated to ensure that all products exit the cell short side leading and single filed. | RAPTOR (Robot Arm Picking to Order Release) is an advanced automation solution developed by NūMove Robotics & Vision in partnership with KPI Solutions to transform the preparation of mixed-SKU order pallets for high-volume beverage and beer distribution centers. This dual-robot system combines AI-driven vision technology, adaptive tooling, and intelligent software integration to address one of the most labor-intensive challenges in modern warehousing. RAPTOR benefits include: faster order fulfillment for mixed pallets, reduced labor dependence, increased worker safety from reduced repetitive lifting, and increased order throughput. The process begins with robotic depalletizing, where a high-speed robot equipped with proprietary 3D vision and AI algorithms identifies and localizes individual products on donor pallets, even when packaging graphics change. Products are then organized by SKU into dedicated buffer lanes within a flow rack. This temporary storage helps maximize uptime and improve overall throughput. The robot’s end-of-arm tool integrates vacuum, bottom support, and top clamping to handle diverse packaging formats such as closed cases, open-top cases, wrapped trays, and carton boxes in trays. For returnable shells containing loose bottles, detachable connectors are automatically added to ensure secure handling. This design enables high-speed operation while maintaining product integrity. On the opposite side of the buffer flow rack, a second robot performs robotic palletizing, retrieving items one at a time to build dense, stable mixed-SKU pallets. Its gripping system mirrors the depalletizer’s versatility, preventing drops even with damaged packaging. Advanced cubing software determines optimal pallet layout, applying stacking rules for product type, size, and weight to meet store requirements. The palletizing robot then retrieves items from the buffer in the precise sequence calculated by the cubing algorithm to build a dense and stable order pallet. RAPTOR also accommodates starter pallets with pre-built layers, using vision technology and AI to verify layer integrity and measure height for precise stacking. A key differentiator of RAPTOR is its seamless integration with KPI Solutions’ Opto™ Software, which acts as the link between the distribution center’s WMS and the robotic system. Opto’s Warehouse Execution System (WES) orchestrates real-time order management, SKU prioritization, and robotic task sequencing, ensuring RAPTOR operates in perfect harmony with upstream and downstream processes. This integration delivers significant benefits: dynamic order release based on demand, real-time visibility through intuitive dashboards, and scalable architecture that adapts to changing SKU profiles and multi-site deployments.