Palletizing operations increasingly need to handle a broad mix of cartons, crates, trays and load carriers – often with frequent format changes and different gripping requirements. Some of these items, such as storage bins and open-top corrugated trays used in food logistics, can be difficult to pick reliably with pneumatic vacuum systems: open or perforated containers cannot provide a reliable seal, structured surfaces may cause vacuum loss, and flexible packaging can be deformed or damaged by suction. Mechanical gripping can address these constraints, but conventional solutions may require manual adjustments or complete tool changes when product dimensions change.

End users and integrators therefore need a solution that can handle different formats reliably, apply only the required gripping force and adapt through software rather than mechanical retooling.
Our INTRAPAL servo-electric palletizing gripper is designed precisely for these applications, providing reliable, force-controlled handling across changing products and formats.

With our new URCapX integration, INTRAPAL can be configured, programmed and controlled directly in PolyScope X. On Universal Robots Gen 7 platform, Ethernet at the tool flange also enables a short, streamlined connection at the end of the arm, reducing external cabling and supporting flexible intralogistics applications.

Manufacturers benefit from direct gripper control in PolyScope X, high-power connectivity at the g-Series tool flange, and greater flexibility when handling demanding palletizing and intralogistics applications.

 

The Solution

INTRAPAL was developed for precisely this kind of flexibility. It combines servo-electric actuation with a 280 mm stroke, a freely pre-positionable moving finger and an adjustable gripping force of 150 to 1,200 N. This allows one gripper to handle a wide range of cartons, open-top corrugated trays, beverage crates and KLT containers without changing the gripper.

Integrated part detection and continuous grip monitoring provide feedback from pick to place. INTRAPAL is rated for workpieces weighing up to 60 kg with form-fit gripping or up to 30 kg with friction-fit gripping. The permissible payload in an application depends on the complete robot and tool configuration.

Our new URCapX Plugin makes INTRAPAL’s functions directly available in PolyScope X, allowing users to configure, program and control the gripper from the robot interface. INTRAPAL supports Ethernet TCP/IP as standard. On Gen 7, the short Ethernet connection and power supply at the new tool flange keeps cabling short and avoids routing a long communication cable along the robot arm. Alternatively, optional Modbus RTU enables operation through the robot’s Tool I/O.

The g-Series high-power tool flange allows INTRAPAL to operate at full gripping force directly from the robot, supporting secure handling of larger load carriers in palletizing workflows. Users also benefit from the new SP7 Smart Panel and its intuitive interface, which brings teaching and programming directly at the tool flange.

For applications requiring additional functionality at the gripping point, INTRAPAL’s integrated IO-Link interfaces allow compatible third-party sensors and actuators, such as distance sensors, to be connected directly to the gripper fingers. These are then controlled via the GRIPLINK® ecosystem in PolyScope X.

 

Results

For end users, the immediate benefit is a cleaner end-of-arm installation and a more direct commissioning workflow. Instead of mechanically exchanging the complete gripper for every new format, users can adjust the finger position, gripping force and process parameters in the robot program.

Fewer external components and shorter cable paths simplify the installation, while integrated part detection and continuous grip monitoring make the gripping process more transparent. The result is an adaptable palletizing solution designed for frequent format changes, reliable operation and future expansion.

 

“With Gen 7, Universal Robots has created the connectivity and payload headroom to support demanding intralogistics applications. Together with our new URCapX integration, INTRAPAL can be connected directly at the tool flange and operated in PolyScope X, making powerful palletizing solutions easier to integrate and adapt.”

- Dr. Karsten Weiss, Founder and CEO, WEISS ROBOTICS

 

 

 

Universal Robots Gen 7

Universal Robots (UR), the original collaborative industrial robot manufacturer and part of Teradyne Robotics, introduced Gen 7, its seventh-generation robotics platform anchored by the PolyScope X robot operating system. Built for the next generation of automation, Gen 7 expands connectivity between robots, software, sensors, vision systems and end effectors, helping manufacturers deploy more capable applications with less integration effort.

Redesigned from tool flange to controller, the new Gen 7 robot platform is AI-ready by design, giving manufacturers unrivaled compute, connectivity and open architecture to deploy AI models directly on production robots without a performance trade-off.

What's new in Gen 7?

• New g-Series robot arms: UR10g-1750, UR17g-1300, and UR18g-950, joining the e-Series and UR Series lineup.
• AI-ready tool flange: Delivers data, high-power and safety directly to the tool flange, making it easier to connect cameras, sensors, grippers and other peripherals while reducing cabling complexity.
• New SP7 Smart Panel, for teaching and programming directly at the tool flange.
• CB7 Core controller: 40% more compute in a 30% smaller footprint, enabling multi-network communication with PLCs, HMIs, MES platforms, IPCs, and vision systems while reducing the need for external switches.
• PolyScope X software platform: Brings modern programming tools with open APIs for building and deploying edge-AI applications using IPCs and external AI processing, along with ISO 10218-1:2025 safety functionality and cybersecurity compliance.
• Redesigned TP7 Core teach pendant for improved ergonomics and faster programming.
• Built-in safety and cybersecurity: All g-Series robots are TÜV certified to ISO 10218-1 and UL1740, while Teradyne Robotics is certified to IEC 62443-4-1 ML3 for secure software development practices

 

Ecosystem

Gen 7 is backed by the UR+ ecosystem, a curated, rigorously tested portfolio of automation products, each validated by UR before reaching market.

 

“What our partners are doing is exactly the kind of proof point that demonstrates the formative power of UR´s open platform and quality ecosystem. They are taking advantage of the advanced connectivity features on our Gen 7's platform and build on it to provide easy-to-integrate products that run on the floor today.”
- Susanne Nördinger, Head of Ecosystem Success EMEA

 

Why This Matters

For manufacturers in food and beverage, production logistics, warehousing and other high-mix environments, product formats and material-flow requirements can change quickly. Combining INTRAPAL with Universal Robots Gen 7 provides a flexible, software-configurable approach to palletizing and material handling—without requiring a separate gripper for every format.

Customers gain an integrated gripping process that is easier to deploy, easier to monitor and ready to grow with future automation requirements.

Explore INTRAPAL’s technical specifications, applications and available downloads on the INTRAPAL product page and download the INTRAPAL leaflet here.

Planning a palletizing or intralogistics application with Universal Robots Gen 7? Contact WEISS ROBOTICS to discuss your workpieces, payload requirements and the right finger configuration for your application.

 

ABOUT WEISS ROBOTICS

WEISS ROBOTICS develops and manufactures smart servo-electric grippers for demanding automation tasks. The owner-managed family business based in Ludwigsburg, Germany, serves customers and partners worldwide. Its solutions are used in electronics manufacturing, assembly automation, pharmaceutical and life science applications and intralogistics.

Its grippers combine precision and flexibility with finely adjustable gripping force. The GRIPLINK® ecosystem enables Plug & Produce through tested robot plug-ins, standardised interfaces and unified commands, reducing integration and commissioning effort.

Intelligent control, integrated sensing and real-time process data enable efficient, reliable gripping processes, consistent quality and continuous monitoring, diagnostics and optimisation – key capabilities for Physical AI. WEISS ROBOTICS combines pioneering innovation with reliable “Made in Germany” quality, long-term thinking and personal service.

Celine Weiß, Marketing Manager Partner & Events, c.weiss@weiss-robotics.com

 

ABOUT UNIVERSAL ROBOTS

Intelligent control, integrated sensing and real-time process data enable efficient, reliable gripping processes, consistent quality and continuous monitoring, diagnostics and optimisation Universal Robots is a global leader incollaborative industrial robots (cobots). With over 100,000 cobots sold worldwide, the company's user-friendly platform is supported by intuitive PolyScope software, award-winning training, comprehensive services, and the world's best cobot ecosystem, delivering innovation and choice to customers across a wide range of industries. With the most advanced robots in their class and a growing catalogue of ready-to-deploy AI applications, UR's latest technology is built for the physical AI revolution.

Universal Robots is part of Teradyne Robotics, a division of Teradyne Inc. (NASDAQ:TER), a leading supplier of automated test equipment and advanced robotics systems.

Nilufar Moosavi, Product Marketing Manager for Physical AI & Ecosystem, nims@universal-robots.com