1. Project Background

A palletizer is an automated system widely used in warehousing, logistics, and production lines. Its primary function is to efficiently stack, unload, and transport goods to or from conveyors or storage areas. By integrating electric drive units, lifting mechanisms, and support modules, modern palletizers enable fast, accurate, and stable material handling.

With increasing demand for automated logistics and reduced manual labor, palletizers play a key role in modern warehouse operations. They help enterprises improve space utilization, enhance operational safety, and lower overall operating costs.

This project focuses on delivering a highly automated palletizing control solution for a logistics application in Suzhou.

2. Solution Overview

• Main Controller: Siemens PLC

• Applicable Process: Material Handling

• I/O Configuration:

  • 2 × RS-PN2

  • 5 × 16DI

  • 4 × 16DO

  • 1 × 8AI

• Annual Deployment: 30,000 units

3. Project Implementation

The solution uses a Siemens S7-1200 PLC combined with the customer’s I/O modules to form a complete, high-efficiency palletizer control system.

1. Intelligent Sensor Integration

The system supports access to various industrial sensors, including:

• Position sensors

• Weight sensors

• Photoelectric sensors

• Safety detection modules

These inputs allow real-time monitoring of cargo status, loading conditions, and operational safety.

2. Precise Control of Machinery

Based on sensor feedback, the PLC precisely controls key components such as:

• Electric drive units

• Lifting mechanisms

• Palletizing arms

• Loading and unloading actuators

This ensures smooth, repeatable operation and highly efficient material stacking and retrieval.

3. Improved Efficiency & Safety

The automated control scheme significantly reduces manual intervention. The palletizer achieves higher operational efficiency, stable handling accuracy, and improved safety standards—essential for modern warehouse management.

4. Solution Advantages

Multiple Installation and Expansion Options

The modular design supports various installation layouts, making it suitable for different warehouse sizes and floor plans.

Flexible and Easy to Assemble

The plug-and-play structure and simplified wiring allow faster on-site assembly and maintenance, enhancing system adaptability.

5. Results & Customer Value

Through Siemens PLC-based automation, the palletizer achieves:

• Higher stacking efficiency and process consistency

• Reduced labor cost and improved safety

• Better cargo accuracy during loading/unloading operations

• Stronger support for modern, intelligent warehouse management

This solution has been successfully adopted by the Suzhou Bujiaer team, contributing to more efficient warehouse logistics and greater overall operational reliability.