Automated End-of-Line Corrugated Box Palletizing Cell with KUKA KR 140 R3200-2 PA 5-Axis Robotic Arm and Vacuum Gripper

KR 140 R3200-2 PA 140kg Payload 3195mm Reach IP65 Bag Palletizing Robot Arm

Overview

The KR 140 R3200-2 PA is a five-axis bag palletizing robot arm configured for bagged and sacked products, where the load is soft, dusty and never perfectly square. A rated payload of 140 kg limits gripper derating on vacuum and clamp tools, and a maximum reach of 3195 mm lets one bag palletizing robot arm span the filling spout, the bag flattener and two pallet positions without a linear track.

Soft loads punish hardware differently from cartons. Because the tool weight is high relative to the product, the ratio between gripper mass and rated capacity decides cycle time, and a 140kg payload rating gives room for a vacuum plate or clamp head without pushing the arm to its limit. Pose repeatability of plus/minus 0.07 mm to ISO 9283 then keeps layer patterns aligned so high stacks do not lean in transit.

Construction, Quality Control and Environmental Profile

Quality control follows the load path. The 754 mm x 754 mm base casting and the arm sections are machined in a single setup, gear units are matched to the measured backlash of each axis, and every unit is laser-tracked for alignment before the drivetrain is sealed. Each 140kg payload 3195mm reach arm then completes a 72-hour continuous motion test at rated payload, and the torque, temperature and repeatability curves form the test report shipped with the machine.

Dust is the environmental constant in a bagging hall, so protection is part of the specification rather than an accessory. Both the arm body and the wrist carry IP65, sealing the joints of this bag palletizing robot arm against cement, flour, resin and fertiliser dust as well as the wash-down used in food plants. Powder coating is low-VOC, gear units are sealed for life so lubricant is neither topped up nor disposed of in normal service, and energy-optimised motion profiles flatten the current peaks of layer moves.

Five-axis PA kinematics also carry an energy argument: one gear unit and one servo drive are removed compared with a six-axis arm, so standby and partial-load consumption drop on multi-shift palletizing at 3195mm reach. Stability comes from the wide cast base, which resists the reaction torque of a 140 kg load at 3195 mm, while the KR C5-2 or KR C5 controller contributes integrated safety functions, open fieldbus interfaces, remote diagnostics and ready-made palletizing packages with bag-specific pattern generators.

Key Specifications of the KR 140 R3200-2 PA

Advantages

• 140kg payload rating leaves headroom for vacuum plates and clamp grippers on bags.
• 3195mm reach serves a filling spout, bag flattener and two pallet positions from one base.
• Five-axis PA kinematics improve payload-to-tool ratio and cut standby power draw.
• Plus/minus 0.07 mm repeatability keeps bag layers aligned so high stacks stay stable.
• IP65 on arm and wrist seals joints against cement, flour and fertiliser dust.
• 754 mm x 754 mm footprint fits existing bagging hall layouts without civil work.
• Bag-specific pattern generators in the controller avoid custom programming.
• Five drives instead of six reduce maintenance points on multi-shift lines.

Typical Application Areas

• Cement, mortar and dry-mix bag stacking
• Flour, starch and grain sack palletizing
• Fertiliser and resin bag palletizing and stretch wrapping
• Chemical powder bag filling line take-away
• Bag depalletizing and layer reforming in warehouses
• Truck loading of palletised bagged goods

Frequently Asked Questions

• Why choose a 140kg payload palletizing robot arm for bags?
  Bag grippers are heavy. A vacuum plate or clamp head can weigh 40 kg or more, so a 140kg payload rating leaves enough capacity for the product itself without pushing the arm into a derated zone. Tool weight and centre of gravity are checked against the payload diagram before the cell is fixed.
• How does 3195mm reach help in a bagging hall?
  It lets one 3195mm reach arm cover the filling spout, the bag flattener and two pallet positions, so the conveyor does not need to be split and no pallet conveyor is required.
• Does dust affect operation?
  Both arm and wrist are IP65, so cement, flour, resin and fertiliser dust stay out of the joints, and the same sealing tolerates the wash-down used in food plants.
• What stacking accuracy can be expected with soft bags?
  Pose repeatability is plus/minus 0.07 mm to ISO 9283 with rated payload. Because the bag itself deforms, the controller pattern generator and gripper release height matter as much as arm accuracy, and both are tuned during commissioning.
• Which controller is supplied with the arm?
  The arm runs on a KR C5-2 or KR C5 controller with open fieldbus interfaces, integrated safety functions, remote diagnostics and bag-specific palletizing technology packages.
• What is included in delivery and support?
  Each unit ships in a wooden pallet case with shock-proof foam, desiccant and export strapping, together with axis data and test reports. Spare gear units, servo parts and commissioning guidance are available after delivery.

Share bag weight and dimensions, layer pattern, stack height and cycle target, and our engineers will confirm whether this bag palletizing robot arm fits the line, together with gripper interface, safety layout and delivery schedule.