The layer pattern fits, but some cartons sit over gaps

ThomasAdams0103 · 2 Sept 2026, 05:12 UTC

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TH
ThomasAdams0103
Our plan for planning alternating carton layers on a pallet with Universal Robots UR5e in a workshop packing department has a very neat alternating layer drawing. But a packed rectangular product box has a preferred support direction, and some rotated cartons sit over gaps. I want packaging support and tool access reviewed together before I accept the pattern. Where should I start?

16 replies

JO
JoAllen0331
Replying to ThomasAdams0103

Does your layer drawing show the load-bearing carton edges and pallet deck beneath them? Add those, then overlay the complete gripper outline.

5 points
TH
ThomasAdams0103
Replying to JoAllen0331

My current layer drawing shows carton footprints and a tool centre point only. It hasn't incorporated the support direction specified in the carton documentation.

14 points
JO
JoAllen0331
Replying to ThomasAdams0103

@ThomasAdams0103 Give packaging and the integrator a drawing combining those details. A repeated unrotated layer is worth assessing alongside the alternating one because it may better suit the specified support direction.

20 points
GA
GabrielBarnes0540
Replying to JoAllen0331

Don't let simpler sound like approved. An unrotated layer still needs its load and stability assessed with the actual contents.

2 points
JO
JoAllen0331
Replying to GabrielBarnes0540

@GabrielBarnes0540 Agreed; I meant a comparison option. Packaging must assess both arrangements with the specified cartons and contents, including support and stability.

8 points
SO
SofiaBell0630
Replying to JoAllen0331

I thought alternating layers always made a stronger stack. Is that too simple?

17 points
JO
JoAllen0331
Replying to SofiaBell0630

@SofiaBell0630 Too general. The arrangement changes where loads pass through the cartons. Your packaging reviewer needs the actual construction and support geometry to judge it.

22 points
TH
ThomasAdams0103
Replying to JoAllen0331

I've overlaid the layers and can identify carton edges positioned above gaps. I can now show packaging the actual support condition that concerned me.

6 points
FA
FarahArcher0417
Replying to ThomasAdams0103

I had a separate dispatch setup where the carton top view omitted the pallet's deck gaps. Including the deck geometry exposed additional positions for packaging assessment.

14 points
TH
ThomasAdams0103
Replying to FarahArcher0417

@FarahArcher0417 Was your accepted pattern linked to a particular pallet specification? My drawing currently names only the overall pallet size.

13 points
FA
FarahArcher0417
Replying to ThomasAdams0103

Include the deck geometry in the pattern's pallet reference. Matching overall dimensions don't establish identical support beneath the carton arrangement.

22 points
JO
JoAllen0331
Replying to ThomasAdams0103

@ThomasAdams0103 For access, show the whole tool beside neighbouring cartons at the corner placements. The centre mark won't reveal body or finger overlap.

19 points
TH
ThomasAdams0103
Replying to JoAllen0331

@JoAllen0331 With the complete outline added, my offline layout shows a tool overlap with a neighbouring carton at one corner. I'll identify that specific position for the integrator's assessment.

17 points
GA
GabrielBarnes0540
Replying to ThomasAdams0103

Include approach and release, not just the final pose. Clearing the outline at the destination wouldn't establish access to it.

12 points
TH
ThomasAdams0103
Replying to GabrielBarnes0540

@GabrielBarnes0540 My next step is defined: combine support geometry and the complete tool in the layer drawings for packaging and integration assessment. The planning question is answered, with pattern acceptance still dependent on that review.

23 points
JO
JoAllen0331
Replying to ThomasAdams0103

You've settled the review basis, with the actual pattern decision still tied to the packaging and integration assessments.

10 points

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