Palletizer Pattern Fault

Palletizer cannot complete the current layer pattern. Product count or position mismatch detected.

Probable Causes (ranked)

• Product size changed without updating pattern recipe in HMI
• Infeed conveyor delivering product too fast — products double-stacking
• Gripper or vacuum head not picking all products in row
• Layer sheet dispenser jammed or empty
• Product counting photo-eye miscounting — dirty or misaligned

Fix Steps

1. 1 Verify product dimensions match the active pattern recipe on HMI
2. 2 Adjust infeed conveyor speed or accumulation zone timing to match palletizer cycle
3. 3 Check gripper vacuum level — inspect vacuum cups for cracks, tears, or debris
4. 4 Reload layer sheet magazine — clear any sheet jams in dispenser mechanism
5. 5 Clean and verify product counting photo-eyes — test with single product pass

Suggested Replacement Parts

Parts matched to fault category: Photoelectric Sensor

Prices are estimates. Verify part numbers match your equipment before ordering.

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